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FIELD OF THE INVENTION
[0001] The present invention relates to the collection of a sample of biological material and particularly to devices to collect and transport samples in a form suitable for testing.
BACKGROUND ART
[0002] Analysis of human or veterinary conditions by way of laboratory assay of DNA or other biochemical testing is well known. The collection of specific samples of biological material (blood, saliva, hair, semen and other secretions) by way of self-collection tools and methods is also known.
[0003] The provision of these samples to appropriate laboratory facilities by various methods of transport, including postal services, is also known.
[0004] For example, a Method of self-sampling and analysing a semen sample is described in United States Patent Application No. US2003148365, which also provides a description of two prior art methods as follows:
[0005] “Methods for transporting medical samples, such as semen, blood, bone marrow, skin tissue and the like by conventional overnight delivery/mail services have been disclosed in the prior art. For example, U.S. Pat. No. 5,983,661 to Wiesman discloses a container arrangement and method for transporting equine semen. This container allows for transporting samples of equine semen over long distance while at the same time maintaining the motility and fertility of the transported spermatozoa for at least 48 hours without the sperm being inactivated.
[0006] Devices for collection, packaging, transport and return of devices are available. Improvements in technology to extract and identify biological material, particularly Nucleic Acid fragments, has allowed precise qualitative identification of components of virtually any biological material, with suitable test chemistry.
[0007] These methods of analysis may be applied to identification of biological material, from the origin of plant matter, to identification of viral/bacterial/fungal presence in humans or animals, to identification of genetic traits in any organisms. In this instance, the primary focus remains on diagnosis of human infection, however the application should not be limited.
[0008] The sensitivity and specificity of test chemistry and extraction or amplification techniques allow specimens to be both very small and contain only trace amounts of the target material within the total sample load. Thus, non-invasive collection of material where the probability of target material being present is suitable for positive assessment is possible.
[0009] Consequently, the “patient” or user is capable of self-collecting specimens without overbearing anti-contamination measures. This enables self-collection of samples in a normal home environment, relieving the need to visit clinical facilities and involve professional healthcare workers, providing an alternative to users, offering comfort, flexibility and privacy.
[0010] One key limitation of self-collection technologies has been the provision of the specimen to the laboratory in a fit condition for testing. As the specificity and sensitivity of test chemistry has improved, however, the condition of the sample has become less important (that is, the biological material is not required in pristine “live” condition), and the need to transport material that may be considered potentially infectious is removed. The need to maintain live material, using refrigeration or other methods, is also removed. Thus, the restrictions to access of the postal system, with its associated limitations on transport of biological material, may be eased, provided the sample may be prepared appropriately.
[0011] It will be clearly understood that, if a prior art publication is referred to herein, this reference does not constitute an admission that the publication forms part of the common general knowledge in the art in Australia or in any other country.
SUMMARY OF THE INVENTION
[0012] The present invention is directed to a device for collection and transport of a biological sample, which may at least partially overcome at least one of the abovementioned disadvantages or provide the consumer with a useful or commercial choice.
[0013] In a first form, the invention resides in a device for the collection and transport of biological material, the device including a container having at least two parts temporarily attached together and adapted for storage of biological collection indicia on an outbound leg of the transport and the safe transport of a biological sample on an inbound leg wherein the biological sample is rendered benign during transport and transported in one of the container parts.
[0014] The container having two parts may be termed a primary package when the two parts are attached together. This primary package is suitably adapted to be used in a postal system, be it local, national or international.
[0015] The primary package will typically be ordered by or provided to a user and may be dispatched to the user (once tailored or selected according to the user's specific requirements) by containing it in a casing, such as a pouch or envelope.
[0016] For the purposes of the following discussion, the following nomenclature is used:
[0000] “Kit”=the entire set of manufactured items comprising all components sent to users, including envelopes or similar
“Collection device”=the item used to physically collect the sample
“Primary package”=the two part container that the collection device arrives in and includes the return package, sample carrier and sample receiver
“Return package”=the container for the elements to be returned to the laboratory
“Sample Carrier”=the portion of the collection device to which the target biological material is collected or concentrated
“Sample Receiver”=the component within the return package into which the sample carrier is placed
[0017] Upon determination of test requirement, the user is provided, preferably using postal services, a kit adapted to the particular test. The kit will preferably contain all components for safe transport to and from the user, appropriate devices for collecting the biological sample, instructions for use and components for effective treatment of the biological sample in order to render it benign but in a form suitable for presentation to the testing laboratory and useable by the laboratory. Elements to assure the privacy, authority and sample chain of custody are also incorporated.
[0018] The kit is typically sized to suit preferred postal dimensions, such that postal volume, weight and associated costs may be reduced. For example, in Australia, suitable preferred dimensions are either a maximum of 130×240×5 mm thickness and 250 g, or 260×360×20 mm thickness and 500 g.
[0019] When dispatched by postal means, the primary package is preferably enclosed in a pouch or envelope of suitable plastics or paper material to avoid damage. The pouch or envelope is suitably pre-printed with the information appropriate to indicate paid postage and indications of contents and sender, if required. The name and address of the user will generally be added to the postal packaging by application of a printed adhesive label. In order to maintain the privacy of the user ordering and receiving the kit, the packaging may be minimally marked or identified.
[0020] The kit also typically includes a pre-printed return postal pouch or envelope of similar type, sized to fit the return package and similarly marked with identification, addressee (laboratory) and postage details. The return postal pouch or envelope may be placed in a recess or other enclosure provided in the primary package casing.
[0021] The primary package casing will suitably include top and bottom halves and a sealing means for releasably opening and resealing the container. The most preferred form of sealing means includes a perimeter seal fin and trench, typically provided with finger tabs placed to allow easy opening of the casing. The casing may be resealed by closing and pressing the top and bottom halves together. The closure should be constructed to avoid unintended opening of the case when crushed, pressurised or impacted.
[0022] The casing may be provided with openings, preferably breathable membrane or one way type openings to allow pressure and moisture balancing and further avoid inadvertent opening.
[0023] The casing will generally be manufactured from an impermeable plastic material, chosen for properties such as stability, strength, antimicrobial formulation and the like, and should not adversely affect the contents of the container during storage or transport. The casing will normally be closed in its unused state, further protecting the contents from environmental factors and contaminants.
[0024] The kit materials and component constructions are preferably be such that the kit retains a usable lifespan of several years in clean and dry storage conditions out of direct sunlight. The properties of the chemicals included in the package components are typically such that they are also not affected by temperature, humidity or atmospheric pressure in normal conditions during this period.
[0025] The kit construction should be such that damage or degradation of performance is avoided in normal foreseeable handling or storage.
[0026] Kits will usually be marked clearly with an expiry date and any storage or handling conditions, applied at the time of manufacture according to applicable regulations.
[0027] The unused kit will also preferably be sealed with tape or other tamper-evident mechanism, such as a break-away portion of the casing seal, to assure the integrity of the contents as they arrive at the user. The tamper-evident mechanism may be designed in such a way that gross attempts to open the casing or access the contents, or damage in transit, may be visually obvious. The requirement for the user to assess the integrity of the package may be noted on external instructions printed on or integral to the casing.
[0028] The kit will typically include printed or integral identification of the contents specific to the test type.
[0029] According to its functions, the kit will include sample collection devices and other components appropriate to the required test. The casing of the kit may be generic, with the contents interchangeable at the time of assembly.
[0030] The kit typically contains several key elements, namely:
[0031] 1. Instructions
[0032] 2. sample collection device
[0033] 3. sample enclosure and treatment component
[0034] 4. waste collection and disposal elements
[0035] 5. return seal and user/kit identification
[0036] Upon opening, the kit may clearly display instructions for use and appropriate directions for reduction in contamination and the like. The instructions will normally be prominently displayed or accessible in a manner that remains visible throughout the use process, without the requirement for excessive handling by the user. It is intended that the instructions may be displayed on a panel attached to the lid portion of the casing, such that the lid portion of the casing remains in an open position and the user is minimally required to turn pages or otherwise handle kit materials. The instructions may be provided in a manner such that when the casing is opened, the instructions are deployed, attached to the casing and visually accessible to the user.
[0037] The instructions shall be provided in a suitable language, in text or graphic format appropriate for the task.
[0038] All sample collection devices and other components are preferably sized to fit within one or more cavities provided in one of the parts of the casing of the primary package.
[0039] The sample collection devices should be specifically designed to meet the ergonomic aspects of their intended procedure.
[0040] The design of the collection devices should preclude, by way of ergonomic shaping or other features, the incorrect taking of samples, by site or action. It is known, for example, that users may attempt to get greater value for money from a sampler by retrieving samples from multiple body sites. This potentially increases the likelihood of false negatives by swamping the sample carrier with inappropriate material.
[0041] Kits are preferably provided to the user in a sterile condition, such that contamination may be minimised or reasonably identified. The kit casing shall be suitably constructed and sealed to enable maintenance of the internal sterile conditions during storage and transport, and promote non-contamination during use.
[0042] In general, the collection devices shall include a “sample carrier” in various forms, all of which typically are or include a removable portion of minimal size which carries the target material, for return to the laboratory. As described above, only very small amounts of target material are generally required for analysis, and the laboratory has no use for the entire collection device. In order to reduce the volume of waste material returned to the laboratory (and thus postal bulk and cost), the target material is preferably concentrated onto only the sample carrier for return. Each of the preferred sample collection types described shortly employs a form of sample carrier configured in this manner.
[0043] As the collection devices generally pose negligible biological safety risk, and materials are selected to be disposable and benign, all components unnecessary for return of the sample carrier itself may be discarded by the user.
[0044] In each instance, the sample carrier should be sized and configured such that it may be easily handled and manipulated without contact with the collected material, thus avoiding contamination, and should be removable from the body of the collector by means of a handling portion configured such that the user is not subject to contact with the sample area itself, which may be objectionable. This may entail an elongate tail or flap integral with the material, a string or other non-integral “handle” means. A specific handling area may be printed, marked or otherwise indicated on the carrier component.
[0045] The sample carrier should carry the target material in a manner that it may be released into fluid upon immersion and agitation of the sample carrier. As such, the sample carrier will not require inversion (if formed into a bag configuration) nor create traps or corners where particles may become trapped and thus lost to the test.
[0046] Following collection of the sample and isolation of the sample carrier, the sample carrier is then preferably treated to render the material benign to enable postal carriage. Postal acceptance rules, particularly in the absence of special-purpose packaging, commonly require the sample to be non-viable and non-infectious. This “stabilisation” may be achieved by physical or chemical destruction or bonding of the sample material or by removal of any medium which may sustain or allow dispersal of biological material. In this way, nucleic acid material may be denatured or cleaved and cellular or other molecular material may be chemically altered and/or the sample may be dried or deprived of a suitable growth media. The degree of denaturing and molecular alteration dictates the nature of remnant material that may be recognised by the subsequent analysis chemistry.
[0047] The shorter the remnant nucleic acid fragments, or the more random/severe the chemical alteration, the more specific the test chemistry must be (greater “specificity”), and the less likelihood of a positive match or reaction and successful test. The probability of the test providing a correct positive result is the “sensitivity” of the test. Thus, high specificity and sensitivity is the goal of the test chemistry.
[0048] With the objective of maximising sensitivity and specificity in testing, the amount of molecular alteration or denaturing of the sample should be minimised, thus, the chemical action of the sample receiver must be relatively mild. The sample receiver will preferably also remove moisture from the sample, such that no free fluid is present in the package which may present a sustaining medium.
[0049] The sample receiver may preferably incorporate two features, namely desiccation and chemical treatment of the sample.
[0050] Desiccation may be largely achieved by use of a highly absorbent substrate, such as thick blotting paper. Desiccation may also be assisted by inclusion in the kit of an absorbent material such as silica gel.
[0051] The chemical treatment may be achieved by addition to, or impregnation of the substrate with a substance activated when in contact with the sample. One embodiment is the addition of a crystalline salt, which may be impregnated into the substrate by wetting in solution followed by drying. When the sample carrier is placed upon the sample receiver, the moist sample typically dissolves some of the salt, creating an appropriate chemical environment to stabilise the sample. Being crystalline, the salt also generally assists in dispersal of moisture and desiccation of the sample. For example, a salt which creates a mildly alkaline solution known to disrupt biological molecules, and which is readily available and suitable for impregnation into an absorbent substrate is Sodium Hydroxide (Caustic Soda or NaOH). A gentler and preferred solution is Sodium Chloride (NaCl), with the extent of disruption controlled by the volume of impregnated salt and the subsequent concentration of the solution surrounding the wet sample.
[0052] The continued contact with the sample receiver chemicals, particularly when dry, will typically prevent any recombination or sustained viability of the biological material. The sample receiver is suitably required to completely enclose the sample carrier, and provide maximum contact for the chemical and drying action.
[0053] The sample receiver shall be suitably sized to enclose the various sample carriers, and shall remain in a predominantly flat shape when encapsulating the carrier.
[0054] The sample receiver may be a folded sleeve of absorbent material, for example blotting paper. The sleeve may simply be a pair of leaves with a single fold line, or a more complex envelope structure to retain the sample carrier. The sample receiver may be separable from the kit casing, or retained by the structure.
[0055] Dependent on the type of sample associated with the kit, the sample receiver or other element of the return package may include a deodorizing agent to mask or remove any odour that may emanate from the sample.
[0056] The nature of the chemicals may require that the sample receiver is configured to avoid direct user contact with the impregnated portion, by means of a laminated plastic construction or non-absorbent backing.
[0057] The sample receiver may also be configured to reduce the handling required to enclose the sample carrier. The sample receiver may include a folded corner or other shaped section to allow easy opening of the folded sleeve. The sleeve may be automatically opened by the opening of the kit casing, such that the receiving surface is presented immediately, with no handling required.
[0058] The sample carrier may be placed within the receiver in any orientation, however, in order to maximise the treatment action, the carrier may be placed such that it is substantially spread flat onto the receiver surface. It is not intended that the carrier is manipulated by the user to maintain a flat shape, rather adopting a natural position suitable for enclosure. A printed outline indicating position or orientation may be placed on the receiver surface to act as a placement guide to the user.
[0059] To achieve a spread position, the sample carrier membrane (which may be inherently prone to crumpling) may be reinforced at its perimeter or other areas to maintain a substantially flat or extended structure when removed from the collection device body.
[0060] To further reduce the risk of contamination, the sample receiver may be marked with alignment marks indicating the position of the sample carrier with the elongated tail or handling portion external to the receiver sleeve, such that potentially contaminated handling portions are physically separated from the target material.
[0061] Depending on the nature of the sample (e.g. a hair sample), the chemical treatment of the material may not be required, or may be very mild. For particularly robust samples, treatment may be customised at a more aggressive level. The chemical action may be modified by concentration or composition to achieve the desired level of sample stabilisation.
[0062] Certain kits not requiring sample treatment may exclude the impregnated sample receiver in favour of a non-impregnated sleeve. In order to simplify the manufacturing or assembly process, it is likely that all kits will retain the full complement of components, but with variants of materials or chemical applications.
[0063] Upon closure of the casing, the sample receiver sleeve is slightly compressed by the walls of the casing, thus retaining the sample carrier and ensuring maximum contact of the sample carrier to the receiver chemicals.
[0064] The material and surface treatment of the sample receiver is selected such that minimal target sample material is removed from the sample carrier upon removal of the sample carrier at the laboratory. The sample carrier is preferably removed from the receiver either by simply tipping out, or removing with tweezers.
[0065] The user is preferably required to identify themselves and provide a signature which indicates agreement to the terms and conditions of the testing process (provided with the kit, or in external literature); authority to use the sample provided; and verification that the sample is indeed provided by them, according to the instructions provided. This signature may be applied to a panel affixed to the kit, preferably on an outer side of the casing. The signature panel should be affixed to the returnable portion of the kit and may be incorporated into the tamper-evident return seal, whereby the application of the seal is also verified by the signature.
[0066] The signature may be accompanied by a date, from which the natural degradation of the specimen over time and the likelihood of a successful test may be judged.
[0067] The return seal may comprise a self-adhesive label, which, with the backing layer removed, may be affixed over the casing closure and permanently adhered to the opposing side. The label adhesion may be sufficiently strong to destroy the label on attempted opening, or the label may incorporate weakened or perforated sections to enable rapid verification of casing integrity. The correct positioning of the label may be indicated on the casing, such that incomplete closure may be rectified by the user prior to attachment. Identification indicia may be provided on the return seal.
[0068] For the purposes of verifying the identity of the user when collecting test results, a unique identifier matched to the kit may be retained by the user. This identifier may be printed on the rear backing layer of the adhesive tamper label or another removable portion of the labelling. Should results be collected by phone or online, the user may quote this identifier to verify their identity.
[0069] The user signature label may be positioned to enable scanning, complete removal or other recording of the application of the signature by the laboratory, as this label constitutes a legal document and record of chain of custody. To protect user privacy, the identification and authority label may be removable prior to provision of the kit to the testing laboratory. Thus, personal identification is removed, and the kit is thereafter identified by a unique numerical or other code.
[0070] To reduce the volume of material returned to the laboratory, the primary package casing or container is typically divided into two segments or parts which are designated for enclosure of the sample, and for the collection devices. The parts of the casing are attached to one another until the user forcibly separates the two parts. The segment of the kit casing which contained the collection device may be attached to the other by means of a thin neck, line of weakness or other means, such that it may be broken away or otherwise removed for return of the sample. The integrity of the perimeter seal should not be affected by this broken portion.
[0071] The removed portion of the casing may be used to enclose the used collection device, for discrete disposal by the user.
[0072] The return package will typically provide the same level of protection to the contents as the primary package.
[0073] Opening of the casing at the laboratory is preferably easy, quickly accomplished and safe, in terms of operator health and contamination/damage to the sample. The tamper evident labels or mechanisms should allow for rapid assessment of integrity, followed by simple removal or deactivation for kit opening. The position of tamper-evident elements and the shaping of the casing should enable safe opening of the casing by lab staff, by for example, providing a guide slot or similar in which to run a sharp knife to slit the seal label.
[0074] For identification of the sample through the laboratory analysis, a series of pre-prepared identification labels or markers may be incorporated into the kit, such that as the sample is removed from the carrier, the receptacles or testing vials may be provided with matching labels taken directly from the test kit, to minimise mistakes in identification of the sample. The tamper seal may incorporate a suitable number of removable labels incorporating barcodes or other identifiers readable by the laboratory. The number of labels provided will match the common process of laboratory test steps.
[0075] An alternative method of sample identification may be the use of single or multiple Radio Frequency Identification (RFID) devices, placed on the sample carrier or other component of the kit. Due to the small size and robustness of these chips, and their unique identification characteristics, the chip may be suitably protected and incorporated into the volume of test fluid and, as such, follow the sample to the conclusion of the test without the need for further labelling.
[0076] An advantage of the use of RFID identity tags is that a database of test progress and completion may be automatically generated and the risk of human-error in mislabeling or incorrect entry are reduced.
[0077] The sample carrier is also typically designed at minimal size such that separation of the target material in the laboratory uses minimal fluid volume. Commonly the sample carrier is placed in a container of fluid suitable to remove biological material from the substrate and agitated to assist removal. The smallest possible sample carrier requires a smaller fluid volume and thus less wastage and cost for the laboratory.
[0078] The preferred collection devices used according to the present invention preferably fall into the following categories:
1. Blood sampling—Requiring skin-prick or other sharps penetration 2. Fluid sampling—Includes any free flowing fluid of low viscosity, from which material is filtered, particularly urine 3. Internal (wet) swab—Includes cervico/vaginal swab or tampon 4. External (dry) swab—Includes abrasive pads or wettable sponge wipe 5. Adhesive panel—For hair or other large dry fragments 6. Probe—For faecal sample or other semi-solid
Category 1—Blood Sampling Devices:
[0000]
A lancet device or other skin-penetrating mechanism is required to draw the required blood sample
The drop/s of blood is/are placed in a position marked on an absorbent substrate. This sample carrier may be placed within the sample receiver.
Sharps selected for this purpose shall typically be proprietary items, selected for appropriate performance and fit to the kit.
Any sharps device in a used condition must be stored and disposed of in a regulated manner, preferably stored in an approved sharps container or other protective mechanism and incinerated as medical waste. Thus, the user commonly cannot dispose of the used lancet.
The lancet device may therefore be returned to the laboratory with the return package for correct disposal, according to the enclosed instructions.
The kit casing typically includes provision of a recess or position within the return package for placement of the used sharp
The sharp should be retained by the casing or otherwise removable from the casing for disposal by the laboratory in a safe manner. A recess incorporated in the casing with intruding “fingers” may be sufficient to retain the lancet device.
The kit casing or the sharps device itself shall meet the requirements of standards for the transport of used sharps, by way of puncture resistance and exposure of the sharp. Many devices are commercially available which incorporate integral safety features suitable for this application.
Category 2—Fluid Sampling Device:
[0000]
The most common application of this category is sampling of urine, although a similar device may be adapted for sampling of toilet water (fluid in contact and carrying faecal matter) or other fluid.
Fluid sampling may be undertaken in three ways:
Direct absorption of fluid onto an absorbent panel; or Gravity-assisted coarse filtration through a membrane; or Pressure assisted filtration through a fine membrane.
A direct absorption fluid collector may simply carry an exposed end for plunging into a fluid volume, shaped to suit a particular application and suitably absorbent or textured to retain a minimal sample volume.
A direct absorption collector may be attached to the non-return portion of the kit casing, such that kit casing (being supplied sterile) itself may be used as a cup to catch a small volume of urine with the user holding the lid portion and allowing the base portion to fill sufficiently to wet the absorbent panel removeably affixed therein.
A gravity assisted fluid collection device usually incorporates a cup element sized to gather a suitable volume of fluid (approximately 20 to 30 mL)
The gravity assisted fluid collector suitably contains a highly absorbent material comprised of either compacted fibres relying on capillary absorption, or other chemical means.
The absorbent material is preferably separated from the collection volume by a hydrophilic membrane (sample carrier) with pore size suitable to act as a coarse filter for the target particles as fluid is drawn through.
The absorbent material is in contact with the membrane and pore size is selected to ensure penetration and drawing-through of the fluid is rapid and consistent.
The surface of the membrane may be textured or otherwise treated to promote adherence of target particles to the membrane.
The filter membrane/sample carrier is typically attached removeably to the collection device housing, such that it may be removed from the housing following absorption of the target fluid, loaded with the collected material.
The collection device may be packaged in a flat form, with fold-out or otherwise expandable members, to allow enclosure within the restricted volume of the kit.
The absorbent material may be allowed to expand during its action, and expansion members may be provided in the collector housing to accommodate or control this.
A pressure assisted fluid collection device usually incorporates a vessel of suitable volume (20 to 30 mL), provided with an opening to facilitate urination into the vessel. The opening may preferably be in the form of a cap or end with funnel-shaped aperture, affixed to the vessel which is preferably configured to be collapsible from a position of greater volume (filled with fluid) to a position of lesser volume (fluid expelled).
The pressure assisted fluid collection vessel will typically be provided in the collapsed (minimal volume) position such that it occupies minimal kit space.
A secondary cap carrying a filter element is provided to be sealably affixed to the aperture of the vessel, such that fluid may be expelled from the vessel upon compression by finger pressure, via the filter element.
Filter pore size may typically be in the range 0.5 to 5 micron
The vessel and cap/s are preferably shaped or incorporate overhangs or lips to shield the user from contact with fluid and to reduce sample contamination.
The filter element is removeably affixed by way of a thermal weld, mechanical or adhesive bond, such that it will remain in position and leak-free under finger pressure collapsing the collection vessel, but which may be easily peeled away or released by means of an elongate tail portion without risking contamination by contact with other items.
In each collection instance, the sample collection panel or membrane is removed and presented in a substantially flat format suitable for the next step of stabilisation and transport.
Category 3—Internal (Wet) Swab Sampling Devices:
[0000]
This category of devices are provided in the form of padded or absorbent-ended swabs. The collectors may be used in any instance where a target material is removed by wiping or absorbing from a surface. This includes buccal cells (inner cheek), vaginal swabs, rectal swabs, external swabs etc.
The sample collection device may incorporate an absorbent substrate enclosed by a removable membrane sample carrier, or may incorporate a non-absorbent padded substrate enclosed by the sample carrier. In either case, the target material is drawn into or wiped onto the sample carrier, with the resilient substrate providing sufficient contact to the target surface that the sample collection is maximised.
The action of collecting the target material may be a process of fluid or moisture absorption, leaving material on the membrane surface, as described in the fluid sampler above, or it may be simply sweeping or gently abrading particles from the surface.
Again, the sample carrier material should be sufficiently retentive to the target material to enable maximum collection.
The sample collection device may include a rigid substrate surrounded or covered by the sample carrier, with no padding or absorbent substrate. The device body may be shaped to suit the contours of the collection site.
The sample collection device preferably incorporates an elongated handle, to enable control and orientation of the device. The handle may be shaped in any way to improve the ability to hold and control the device in a self-collection scenario.
The sample carrier may be attached removeably to the collection device body by means of adhesive material, mechanical connection or other means. A preferred embodiment incorporates attachment by means of slits in the body of the device, into which a small portion of the carrier material is pressed, providing a cheap and effective assembly solution with minimal risk of complication at the point of removal.
The sample carrier also suitably incorporates a tail or handling portion as described above, such that the portion of the carrier that must be touched by the user is remote from the sampling area.
For use in cervico-vaginal cell collection, the device may incorporate an expanding absorbent mass, similar to a tampon that may be inserted into the vagina for a longer period, such that the increase in size and additional absorption may increase the sample yield from all areas of the vagina. This mass may be sheathed in a removable sample carrier, to reduce transit and laboratory volume.
The sample carrier may also be configured integrally to the form of a finger sheath, thus collecting target material on the sheath surface with digital application. The formation of the sheath and the use of longitudinal stiffening elements may avoid the tendency for the sheath to invert and trap target material. The inner layers of the sheath in contact with the user may be impermeable to avoid contact with the target material. The entire sheath may then form the sample carrier, to be processed in its entirety.
Alternately, a swab which requires expansion to fill or extend into a cavity may employ mechanical or other means to maximise the sample collection area in contact with the target surface.
Category 4—External Swab Sampling Devices:
[0000]
This device category differs from internal (wet) swab devices in that these are adapted to remove dry material from a dry surface.
The sample carrier may be adapted to carry an external surface that is textured, abrasive, adhesive or moistened at the time of application to remove dry material from a surface and capture it on the carrier surface.
The device may incorporate a substrate that is deformable, padded or otherwise conforming to the target surface, to enable maximal sample carrier contact with the surface.
The device may be used in conjunction with the adhesive panel collection devices described below.
Category 5—Adhesive Panel/Dry Material Collection Devices:
[0000]
Incorporates an adhesive panel suitable for the collection of skin cells or free dry material, by placing the panel over the target surface and applying a compressive force or by simply placing the target material onto the adhesive panel.
The adhesive panel may be provided with a repositionable cover to maintain adhesive properties prior to use.
The adhesive panel may be used as a location panel for large scale free samples, such as hair strands.
Collection of dry biological material may require the wetting of the sample receiver in order to activate the chemicals which stabilise the material. For example, fungal fragments or spores may survive contact with sample receiver chemicals in the dry state, but may be unlikely to survive contact with the more active solution if a drop of water is added to the receiver.
The device may include the ability of the adhesive used in the panel construction to be water soluble, such that the adhesive and the material captured by it may be washed into suspension for concentration and analysis.
The adhesive panel device may be used in conjunction with or without the sample receiver or treatment action.
Category 6—Probe Devices—Consider the Following:
[0000]
A probe device may incorporate a sponge, scoop, punch or blade “head” to dislodge and capture particles of larger semi-solid samples.
A probe device may also incorporate an extended handling body attached to the head
The head may be adapted to be squeezed, retracted or otherwise eject the material collected without the need for the user to contact the sample directly. An embodiment may include a punch tube with a mating internal rod slidably engaged within such that forward motion of the inner rod will eject material collected in the tube end by the action of punching the tube into a sample.
The target material may be collected onto a sample carrier sheath or cover, equipped with an elongated handling area as described above for remote removal of the carrier from the collector body and placement within the sample receiver.
The collected material may alternately be deposited directly into the sample receiver.
[0141] In a second form, wherein individual transport and thus the robust casing of the kit is not required, such as may be the case when in use at a collection centre or supervised collections, the sample collection device itself may incorporate elements of the sample carrier, receiver and labelling requirements into one component.
[0142] In this instance, the collection devices, including, for example, the swab sticks or the collapsible urine vessels are provided to the user without the kit, and the sample carriers, when collections are complete, are transported to the laboratory in bulk.
[0143] In this form, the sample carrier may allow for additional space on the handling “tail” portion of the carrier to enable recording of user identification, plus a fold-over or other enclosing portion into which the sample collection end of the carrier may be placed.
[0144] In this way, the bulk and waste materials associated with testing of a number of users is reduced, and patient details securely accompany the sample to a testing facility.
[0145] The sample collection end of the integrated carrier performs the filtering, swabbing or other function as described above, as does the enclosing and stabilising segment of the carrier. By linking these elements together and allowing written information to be applied, the versatility of the system is enhanced.
[0146] The sample receiver portion of the integrated carrier may require non-absorbent backing or a similar barrier to handling, or may carry a removable cover to maintain cleanliness until the sample carrier portion is ready to be received. In this instance, the enclosure of the sample carrier may be undertaken by a practitioner rather than by the user themselves.
BRIEF DESCRIPTION OF THE DRAWINGS
[0147] Various embodiments of the invention will be described with reference to the following drawings, in which:
[0148] FIG. 1 is a perspective view of a primary postal package according to a preferred embodiment of the invention.
[0149] FIG. 2 is a top view of the primary postal package illustrated in FIG. 1 .
[0150] FIG. 3 is an underside view of the primary postal package illustrated in FIG. 1 .
[0151] FIG. 4 is a perspective view of the primary postal package illustrated in FIG. 1 when open.
[0152] FIG. 5 is a perspective view of the primary postal package illustrated in FIG. 1 receiving a sample.
[0153] FIG. 6 is a perspective view of the postal package illustrated in FIG. 1 separated to form the return package.
[0154] FIG. 7 is a perspective view of a blood sampling collection device according to a preferred embodiment of the present invention.
[0155] FIG. 8 is a perspective view of a direct absorption fluid collection device according to a preferred embodiment of the present invention.
[0156] FIG. 9 is a perspective view of a gravity assisted fluid collection device according to a preferred embodiment of the present invention.
[0157] FIG. 10 is a perspective view of a pressure assisted fluid collection device according to a preferred embodiment of the present invention.
[0158] FIG. 11 is a perspective view of a pressure assisted fluid collection device in the process of compression and fluid filtering.
[0159] FIG. 12 is a perspective of a cervico-vaginal sampling collection device according to a preferred embodiment of the present invention, including wet swab and tampon-type device.
[0160] FIG. 13 is a perspective view of a dry swab collection device according to a preferred embodiment of the present invention.
[0161] FIG. 14 is a perspective view of an adhesive panel collection device according to a preferred embodiment of the present invention.
[0162] FIG. 15 is a perspective view of a probe punch collection device according to a preferred embodiment of the present invention, including a detail cutaway view.
[0163] FIG. 16 is a perspective view of an integrated sample carrier device according to an alternate embodiment, showing a generic sample carrier and integrated receiver enclosure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0164] According to a preferred embodiment, various forms of a device adapted for the delivery of a sample collection kit, collection of a sample and return of the sample to an analysis facility are provided.
[0165] For the purposes of the following discussion, the nomenclature used is as above.
[0166] Upon determination of test requirement, the user is provided, preferably via postal services, a kit adapted to the particular test.
[0167] The kit contains all components for safe transport to and from the user, appropriate devices for collecting the sample, instructions for use and components for effective treatment of the specimen for presentation to the testing laboratory.
[0168] The kit is sized to suit preferred postal dimensions, such that postal volume, weight and associated costs may be reduced. In Australia, suitable preferred dimensions are either a maximum of 130×240×5 mm thickness and 250 g, or 260×360×20 mm thickness and 500 g.
[0169] The primary package ( 1 ) is enclosed in a pouch or envelope ( 2 ) of suitable plastics or paper material to avoid damage, pre-printed with the information appropriate to indicate paid postage and indications of contents and sender, if required. The name and address of the user will be added to the postal packaging by application of a printed adhesive label. In the interests of privacy, the packaging may be minimally marked or identified.
[0170] The kit includes a pre-printed return postal package ( 3 ) of similar type, sized to fit the return package and similarly marked with identification, addressee (laboratory) and postage details. The primary package may be placed in a recess or other enclosure ( 4 ) incorporated into the primary package casing.
[0171] The primary package casing includes a means for releasably opening and resealing the container. A perimeter fin and trench seal ( 5 ) may be used, with finger tabs ( 6 ) placed to allow easy opening of the case. The casing may be resealed by closing and pressing the top and bottom halves together. The closure seal should be constructed to avoid unintended opening of the case when crushed, pressurised or impacted.
[0172] The casing may be breached at some point to avoid internal pressure imbalance that may contribute to inadvertent opening, and to enable evaporative escape of any residual internal moisture.
[0173] The casing shall be constructed from an impermeable plastic material which, by its properties, shall not adversely affect the contents. The casing shall be closed in its unused state, further protecting the contents from environmental factors and contaminants.
[0174] The kit materials and component constructions should be such that the kit retains a usable lifespan of several years in clean and dry storage conditions out of direct sunlight. The properties of the chemicals included in the package components shall also not be affected by temperature, humidity or pressure in normal conditions during this period.
[0175] The kit construction should be such that damage or degradation of performance is avoided in normal foreseeable handling or storage.
[0176] Kits shall be marked clearly with an expiry date and any storage or handling conditions, applied at the time of manufacture.
[0177] The unused kit shall be sealed with tape or other tamper-evident mechanism ( 7 ), such as a break-away portion of the casing seal, to ensure the integrity of the contents as they arrive at the user. The tamper-evident mechanism shall be designed in such a way that gross attempts to open the casing or access the contents, or damage in transit, may be visually obvious. The requirement for the user to assess the integrity of the package may be noted on external instructions printed on or integral to the casing.
[0178] The kit will include printed or integral identification of the contents specific to the test type.
[0179] The kit will include sample collection devices and other components appropriate to the required test. The casing of the kit may be generic, with the contents interchangeable at the time of assembly.
[0180] The kit contains several key elements, namely:
[0181] 6. Instructions
[0182] 7. sample collection device
[0183] 8. sample enclosure and treatment component
[0184] 9. waste collection and disposal elements
[0185] 10. return seal and user/kit identification means
[0186] Upon opening, the kit shall clearly display instructions for use and appropriate directions for reduction in contamination or the like ( 8 ). The instructions shall be prominently displayed in a manner that remains visible throughout the use process, without the requirement for excessive contact with the kit interior by the user.
[0187] Instructions shall be provided in a suitable language, in text or graphic format appropriate for the task.
[0188] All sample collection devices and other components will be sized to fit within the cavities provided in the casing ( 9 ).
[0189] The sample collection devices should be specifically designed to meet the ergonomic aspects of their intended procedure.
[0190] The design of the collection devices should preclude, by way of ergonomic shaping or other features, the incorrect taking of samples, by site or action.
[0191] In general, the collection devices shall include a “sample carrier” ( 10 ) in various forms—a removable portion of minimal size which carries the target material, for return to the laboratory. As described, only very small amounts of target material are required for analysis, and the laboratory typically has no use for the entire collection device. In order to reduce the volume of waste material returned to the laboratory (and thus postal bulk and cost), the target material is concentrated onto only the sample carrier for return. Each of the specific sample collection types described in detail below employ a form of sample carrier configured in this manner.
[0192] As the collection devices pose negligible biological safety risk, and materials are selected to be disposable and benign, all components unnecessary for return of the sample carrier itself may be discarded by the user.
[0193] The sample carrier should be sized and configured such that it may be easily handled and manipulated without contact with the collected material, thus avoiding contamination, and should be removable from the body of the collector by means of a handling portion ( 11 ) configured such that the user is not subject to contact with the sample area itself which may be objectionable. This may entail an elongate tail or flap integral with the material, a string or other non-integral “handle” means. A specific handling area may be printed, marked or otherwise indicated on the carrier component.
[0194] The sample carrier should carry the target material in a manner that it may be released from the sample carrier into a fluid upon immersion and agitation.
[0195] As such, the sample carrier cannot be turned inside out (if formed into a bag configuration) nor create traps or corners where particles may become trapped and thus lost to the test.
[0196] The collection devices fall into the following categories:
[0197] 7. Blood sampling ( FIG. 7 )
Requiring skin-prick or other sharps penetration
[0199] 8. Fluid sampling ( FIGS. 8 , 9 , 10 and 11 )
Includes any free flowing fluid of low viscosity, from which material is filtered
[0201] 9. Internal (wet) swab ( FIG. 12 )
Includes cervico/vaginal swab or tampon
[0203] 10. External (dry) swab ( FIG. 13 )
Includes abrasive pads or wettable sponge wipe
[0205] 11. Adhesive panel ( FIG. 14 )
[0206] For hair or other large dry fragments
[0207] 12. Probe ( FIG. 15 )
For faecal sample or other semi-solid
Category 1—Blood Sampling Devices:
[0000]
A lancet device or other skin-penetrating mechanism is required to draw the required blood sample
The drop/s of blood is/are placed in a position marked on an absorbent substrate ( 12 ). This sample carrier may be placed within the sample receiver ( 13 ) as detailed below.
Sharps selected for this purpose shall be proprietary items, selected for appropriate performance and size to fit the kit.
Any sharps device in a used condition must be stored and disposed of in a regulated manner, that is, stored in an approved sharps container or other protective mechanism and incinerated as medical waste. Thus, the user cannot commonly dispose of the used lancet.
The lancet device may therefore be returned to the laboratory with the return package for correct disposal according to the enclosed instructions.
The kit casing includes provision of a recess or position ( 14 ) within the return package for placement of the used sharp
The sharp should be retained by the casing or otherwise removable from the casing for disposal by the laboratory in a safe manner. A recess incorporated in the casing with intruding “fingers” ( 15 ) may be sufficient to retain the lancet device.
The kit casing or the sharps device itself shall meet the requirements of standards for the transport of used sharps, by way of puncture resistance and exposure of the sharp. Many devices are commercially available which incorporate integral safety features suitable for this application.
Category 2—Fluid Sampling Devices:
[0000]
The most common application of this category is sampling of urine, although a similar device may be adapted for sampling of toilet water (fluid in contact and carrying faecal matter) or other fluid.
Fluid sampling may be undertaken in three ways:
Direct absorption of fluid onto an absorbent panel Gravity-assisted coarse filtration through a membrane Pressure assisted filtration through a fine membrane
A direct absorption fluid collector may simply carry an exposed end for plunging into a fluid volume, shaped to suit a particular application and suitably absorbent or textured to retain a minimal sample volume.
A direct absorption collector may be attached to the non-return portion of the kit casing, such that the kit casing itself (being supplied sterile) may be used as a cup ( 16 ) to catch a small volume of urine with the user holding the lid portion and allowing the base portion to fill sufficiently to wet the absorbent panel ( 43 ) removeably affixed therein.
A gravity assisted fluid collection device usually incorporates a cup element ( 16 ) sized to gather a suitable volume of fluid (approximately 20 to 30 mL)
The gravity assisted fluid collector suitably contains a highly absorbent material ( 17 ) comprised of either compacted fibres relying on capillary absorption, or other chemical means.
The absorbent material is preferably separated from the collection volume by a hydrophilic membrane (sample carrier) with pore size suitable to act as a coarse filter ( 10 ) for the target particles as fluid is drawn through.
The absorbent material is in contact with the membrane and pore size is selected to ensure penetration and drawing-through of the fluid is rapid and consistent.
The surface of the membrane may be textured or otherwise treated to promote adherence of target particles to the membrane.
The filter membrane/sample carrier is typically attached removeably to the collection device housing, such that it may be removed from the housing following absorption of the target fluid, loaded with the collected material.
The collection device may be packaged in a flat form, with fold-out or otherwise expandable members ( 18 ), to allow enclosure within the restricted volume of the kit.
The absorbent material may be allowed to expand during its action, and expansion members ( 19 ) may be provided in the collector housing to accommodate or control this.
A pressure assisted fluid collection device usually incorporates a vessel of suitable volume (20 to 30 mL) ( 44 ), provided with an opening to facilitate urination into the vessel. The opening may preferably be in the form of a cap or end with funnel-shaped aperture ( 45 ), affixed to the vessel which is preferably configured to be collapsible from a position of greater volume (filled with fluid) to a position of lesser volume (fluid expelled).
The pressure assisted fluid collection vessel will typically be provided in the collapsed (minimal volume) position such that it occupies minimal kit space.
A secondary cap ( 46 ) carrying a filter element ( 10 ) is provided to be sealably affixed to the aperture of the vessel, such that fluid may be expelled from the vessel upon compression by finger pressure, via the filter element.
Filter pore size for use in the pressure assisted condition may typically be in the range 0.5 to 5 micron
The vessel and cap/s are preferably shaped or incorporate overhangs or lips ( 47 ) to shield the user from contact with fluid and to reduce sample contamination.
The filter element ( 10 ) is removeably affixed by way of a thermal weld, mechanical or adhesive bond, such that it will remain in position and leak-free under finger pressure collapsing the collection vessel, but which may be easily peeled away or released by means of an elongate tail portion ( 11 ) without risking contamination by contact with other items.
In each collection instance, the sample collection panel or membrane is removed and presented in a substantially flat format suitable for the next step of stabilisation and transport.
Category 3—Internal (Wet) swab Sampling Devices:
This category includes devices in the form of padded or absorbent-ended swabs. The collectors may be used in any instance where a target material is removed by wiping or absorbing from a surface. This includes buccal cells (inner cheek), vaginal swabs, rectal swabs, external swabs etc.
The sample collection device may incorporate an absorbent substrate ( 20 ) enclosed by a removable membrane sample carrier ( 10 ), or may incorporate a non-absorbent padded substrate enclosed by the sample carrier. In either case, the target material is drawn into or wiped onto the sample carrier, with the resilient substrate providing sufficient contact to the target surface that the sample collection is maximised.
The action of collecting the target material may be a process of fluid or moisture absorption, leaving material on the membrane surface, as described in the fluid sampler above, or it may be simply sweeping or gently abrading particles from the surface.
Again, the sample carrier material must be sufficiently retentive to the target material to enable maximum collection.
The sample collection device may include a rigid substrate surrounded or covered by the sample carrier, with no padding or absorbent substrate. The device body may be shaped to suit the contours of the collection site.
The sample collection device incorporates an elongated handle ( 21 ), to enable control and orientation of the device. The handle may be shaped in any way to improve the ability to hold and control the device in a self-collection scenario.
The sample carrier may be attached removeably to the collection device body by means of adhesive material, mechanical connection or other means. A preferred embodiment incorporates attachment by means of slits in the body of the device ( 22 ), into which a small portion of the carrier material is pressed, providing a cheap and effective assembly solution with minimal risk of complication at the point of removal.
The sample carrier incorporates a tail or handling portion ( 11 ) as described above, such that the portion of the carrier that must be touched by the user is remote from the sampling area.
For use in cervico-vaginal cell collection, the device may incorporate a larger absorbent mass ( 23 ), similar to a tampon, that may be inserted into the vagina for a longer period, such that the increase in size and additional absorption may increase the sample yield from all areas of the vagina. This mass may be sheathed in a removable sample carrier, to reduce transit and laboratory volume.
Alternately, a swab which requires expansion to fill or extend into a cavity may employ mechanical or other means to maximise the sample collection area in contact with the target surface.
Category 4—External Swab Sampling Devices:
[0000]
This device category differs from internal (wet) swab devices in that these are adapted to remove dry material from a dry surface.
The sample carrier may be adapted to carry an external surface that is textured, abrasive, adhesive or moistened at the time of application to remove dry material from a surface and capture it on the carrier surface ( 28 ).
May incorporate a substrate ( 29 ) that is deformable, padded or otherwise conforming to the target surface, to enable maximal sample carrier contact with the surface.
May be used in conjunction with the adhesive panel collection devices described below.
Category 5—Adhesive Panel/Dry Material Collection Devices:
[0000]
Incorporates an adhesive panel ( 24 ) suitable for the collection of skin cells or free dry material, by placing over the target surface and applying a compressive force.
The adhesive panel may be provided with a repositionable cover ( 42 ) to maintain adhesive properties prior to use.
May be used as a location panel for large scale free samples, such as hair strands.
Collection of dry biological material may require the wetting of the sample receiver in order to activate the chemicals which destroy the material. For example, fungal fragments or spores may survive contact with sample receiver chemicals in the dry state, but are unlikely to survive contact with the more active solution if a drop of water is added to the receiver.
May include the ability of the adhesive used in the panel construction to be water soluble, such that the adhesive and the material captured by it may be washed into suspension for concentration and analysis.
May be used in conjunction with or without the sample receiver or treatment action.
Category 6—Probe Devices:
[0000]
Incorporation of a sponge, scoop, punch or blade “head” ( 25 ) to dislodge and capture particles of larger semisolid samples.
Incorporation of an extended handling body attached to the head
Adaptation of the head to be squeezed retracted or otherwise manipulated to eject the material collected without the need for the user to contact the sample directly. An embodiment may include a punch tube ( 26 ) with a mating internal rod ( 27 ) slidably engaged within such that forward motion of the inner rod will eject material collected in the tube end by the action of punching the tube into a sample.
The target material may be collected onto a sample carrier sheath or cover, equipped with an elongated handling area as described above for remote removal of the carrier from the collector body and placement within the sample receiver.
The collected material may alternately be deposited directly into the sample receiver.
[0264] Following collection of the sample and isolation of the sample carrier, the sample carrier is then preferably treated to render the material benign to enable postal carriage. Postal acceptance rules, particularly in the absence of special-purpose packaging, commonly require the sample to be non-viable and non-infectious. This “stabilisation” may be achieved by physical or chemical destruction or bonding of the sample material or by removal of any medium which may sustain or allow dispersal of biological material. In this way, nucleic acid material may be denatured or cleaved and cellular or other molecular material may be chemically altered and/or the sample may be dried or deprived of a suitable growth media. The degree of denaturing and molecular alteration dictates the nature of remnant material that may be recognised by the subsequent analysis chemistry.
[0265] The shorter the remnant nucleic acid fragments, or the more random/severe the chemical alteration, the more specific the test chemistry must be (greater “specificity”), and the less likelihood of a positive match or reaction and successful test.
[0266] With the objective of maximising sensitivity and specificity in testing, the amount of molecular alteration or denaturing of the sample should be minimised, thus, the chemical action of the sample receiver must be relatively mild. The sample receiver must also remove moisture from the sample, such that no free fluid is present in the package.
[0267] The sample receiver ( 13 ) may incorporate two features—desiccation and chemical treatment of the sample. Desiccation may be largely achieved by use of a highly absorbent substrate, such as thick blotting paper. Desiccation may also be assisted by inclusion in the kit of an absorbent material such as silica gel. The chemical treatment may be achieved by addition to, or impregnation of the substrate with a substance activated when in contact with the sample. One embodiment is the addition of a crystalline salt, which may be impregnated into the substrate by wetting in solution followed by drying. When the sample carrier is placed upon the sample receiver, the moist sample dissolves some of the salt, creating an appropriate chemical environment to stabilise the sample. Being crystalline, the salt also assists in dispersal of moisture and desiccation of the sample. A salt which creates a mildly alkaline solution known to disrupt biological molecules, and which is readily available and suitable for impregnation into an absorbent substrate is Sodium Hydroxide (Caustic Soda or NaOH). A gentler and preferred solution is Sodium Chloride (NaCl), with the extent of disruption controlled by the volume of impregnated salt and the subsequent concentration of the solution surrounding the wet sample.
[0268] The continued contact with the sample receiver chemicals, particularly when dry, will typically prevent any recombination or sustained viability of the biological material.
[0269] The sample receiver is required to completely enclose the sample carrier, and provide maximum contact for the chemical and drying action.
[0270] The sample receiver shall be suitably sized to enclose the various sample carriers, and shall remain in a predominantly flat shape when encapsulating the carrier.
[0271] The sample receiver may be a folded sleeve of absorbent material, for example blotting paper. The sleeve may simply be a pair of leaves with a single fold ( 30 ), or a more complex envelope structure to fully retain the sample carrier. The sample receiver may be separable from the kit casing, or retained by the structure.
[0272] Dependent on the type of sample associated with the kit, the sample receiver or other element of the return package may include a deodorizing agent to mask or remove any odour that may emanate from the sample.
[0273] The sample receiver construction may incorporate an impermeable layer such that the impregnated chemical may not come into direct contact with the user during alignment and placement of the sample carrier within.
[0274] The sample receiver may also be configured to reduce the handling required to enclose the sample carrier. The sample receiver may include a folded corner ( 31 ) or other shaped section to allow easy opening of the folded sleeve. The sleeve may be automatically opened by the opening of the kit casing, such that the receiving surface is presented immediately, with no handling required.
[0275] The sample carrier may be placed within the receiver in any orientation, however, in order to maximise the treatment action, the carrier may be placed such that it is substantially spread flat onto the receiver surface. It is not intended that the carrier is handled to maintain this shape, but a printed outline ( 32 ) indicating position or orientation may be placed on the receiver surface to act as a guide to the user.
[0276] To achieve a spread position, the sample carrier membrane (which may be inherently prone to crumpling) may be reinforced at its perimeter ( 33 ) or other areas to maintain a substantially flat or extended structure when removed from the collection device body.
[0277] To further reduce the risk of contamination, the sample receiver may be marked with alignment marks indicating the position of the sample carrier with the elongated tail or handling portion external to the receiver sleeve ( 34 ).
[0278] Depending on the nature of the sample (eg a hair sample), the chemical treatment of the material may not be required, or may be very mild. For particularly robust samples, treatment may be customised at a more aggressive level. The chemical action may be modified by concentration or composition to achieve the desired level of sample stabilisation.
[0279] Certain kits not requiring sample treatment may exclude the impregnated sample receiver in favour of a non-impregnated sleeve. In the interests of production rationalization, it is likely that all kits will retain the full complement of components, but with variants of materials or chemical applications.
[0280] Upon closure of the casing, the sample receiver sleeve is slightly compressed by the walls of the casing, thus retaining the sample carrier and ensuring maximum contact of the sample carrier to the receiver chemicals.
[0281] The material of the sample receiver is selected such that minimal target sample material is removed from the sample carrier upon removal of the sample carrier at the laboratory. The sample carrier is removed from the receiver either by simply tipping out, or removing with tweezers.
[0282] The user is required to identify themselves and provide a signature which indicates agreement to the terms and conditions of the testing process (provide with the kit, or in external literature); authority to use the sample provided; and verification that the sample is indeed provided by them according to the instructions provided. This signature may be applied to a writable panel ( 35 ) affixed to the kit. The signature panel must be affixed permanently to the returnable portion ( 36 ) of the kit and may be incorporated into the tamper-evident return seal ( 37 ), whereby the application of the seal is also verified by the signature.
[0283] The signature may be accompanied by a date, from which the natural degradation of the specimen over time may be judged.
[0284] The return seal may comprise a self-adhesive label, which, with the backing layer ( 38 ) removed, may be affixed over the casing closure and permanently adhered to the opposing side. The label adhesion may be sufficiently strong to destroy the label on attempted opening, or the label may incorporate weakened or perforated sections to enable rapid verification of casing integrity. The correct positioning of the label may be indicated on the casing, such that incomplete closure may be rectified by the user prior to attachment.
[0285] For the purposes of verifying the identity of the user when collecting test results, a unique identifier matched to the kit may be retained by the user. This identifier may be printed on the rear backing layer of the adhesive tamper label or another removable portion of the labelling. Should results be collected by phone or online, the user may quote this identifier to verify their identity.
[0286] The user signature label may be positioned to enable scanning, complete removal or other recording of the application of the signature by the laboratory, as this label constitutes a legal document and record of chain of custody.
[0287] To reduce the volume of material returned to the laboratory, the kit casing may be divided into two segments which are designated for enclosure of the sample, and for the collection devices. The segment of the kit casing which contained the collection device may be attached to the other by means of a thin neck ( 39 ) or other means, such that it may be broken away or otherwise removed for return of the sample. The integrity of the perimeter seal must not be affected by this break portion.
[0288] The removed portion of the casing may be used to enclose the used collection device, for discrete disposal by the user.
[0289] The return package must provide the same level of protection to the contents as the primary package.
[0290] Opening of the casing at the laboratory shall be fast and safe, in terms of operator health and contamination/damage to the sample. The tamper evident labels or mechanisms must allow for rapid assessment of integrity, followed by simple removal or deactivation for kit opening. The position of tamper-evident elements and the shaping of the casing should enable safe opening of the casing by lab staff, by for example, providing a guide slot ( 40 ) in which to run a sharp knife to slit the seal label.
[0291] For identification of the sample through the laboratory analysis, a series of pre-prepared identification labels ( 41 ) or markers may be incorporated into the kit, such that as the sample is removed from the carrier, the receptacles or testing vials may be provided with matching labels taken directly from the test kit, thus avoiding mix-ups. The tamper seal may incorporate a suitable number of removable labels incorporating barcodes or other identifiers readable by the laboratory. The number of labels provided will match the common process of laboratory test steps.
[0292] An alternative method of sample identification may be the use of single or multiple RFID chips, placed on the sample carrier or other component of the kit. Due to the small size and robustness of these chips, and their unique identification characteristics, the chip may be suitably protected and incorporated into the volume of test fluid and, as such, follow the sample to the conclusion of the test without the need for further labelling.
[0293] An advantage of the use of RFID identity tags is that the database of test progress and completion does not include a human-error risk of mislabeling or incorrect entry, and the manual processes included in the testing are reduced.
[0294] In a second form, wherein individual transport and thus the robust casing of the kit is not required, such as may be the case when in use at a collection centre or supervised collections, the sample collection device may incorporate elements of the sample carrier, receiver and labelling requirements into one component.
[0295] In this instance, the collection devices, including, for example, the swab sticks or the collapsible urine vessels are provided to the user without the kit, and the sample carriers, when collections are complete, are transported to the laboratory in bulk.
[0296] The sample carrier ( 10 ) may allow for additional space on the handling “tail” portion ( 11 ) of the carrier to enable recording of user identification, plus a fold-over or other enclosing portion (sample receiver) ( 13 ) into which the sample collection end of the carrier may be placed.
[0297] In this way, the bulk and waste materials associated with testing of a number of users is reduced, and patient details securely accompany the sample to a testing facility.
[0298] The sample receiver portion of the integrated carrier may require non-absorbent backing or a similar barrier to handling, or may carry a removable cover to maintain cleanliness until the sample carrier portion is ready to be received. In this instance, the enclosure of the sample carrier may be undertaken by a practitioner rather than by the user themselves.
[0299] In all cases, the sample carrier is designed at minimal size such that separation of the target material in the laboratory uses minimal fluid volume. The sample carrier is placed in a container of fluid suitable to remove biological material from the substrate and agitated to assist removal. The smallest possible sample carrier requires a smaller fluid volume and thus less wastage and cost for the laboratory.
[0300] In the present specification and claims (if any), the word “comprising” and its derivatives including “comprises” and “comprise” include each of the stated integers but does not exclude the inclusion of one or more further integers.
[0301] Reference throughout this specification to “one embodiment” or “an embodiment” means that a particular feature, structure, or characteristic described in connection with the embodiment is included in at least one embodiment of the present invention. Thus, the appearance of the phrases “in one embodiment” or “in an embodiment” in various places throughout this specification are not necessarily all referring to the same embodiment. Furthermore, the particular features, structures, or characteristics may be combined in any suitable manner in one or more combinations.
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A device for the collection and transport of biological material, the device including a container having at least two parts temporarily attached together and adapted for storage of biological collection indicia on an outbound leg of the transport and the safe transport of a biological sample on an inbound leg wherein the biological sample is rendered benign during transport and transported in one of the container parts.
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BACKGROUND OF INVENTION
Field of Invention
[0001] Hinge chains, flat belts, circular profile cords or the like are known for transport of bottles from DE 35 15 353 A1, which engage beneath the annular collar and thus produce transport. The annular collar in EP 0 842 875 A1 is engaged at the top and bottom by a pair of endless cords. According to the present technique the preforms produced in the injection molding die are arranged in complicated installations that require considerable space and transported to the blow molding machine. It is new to separate these preforms in a centrifuge-like separator, as is described, for example, in PCT/EP2006/050682.
[0002] The task of the present invention is to provide an appropriate device of the aforementioned type with which the objects, especially preforms can be arranged and reliably transported from one to the next station.
SUMMARY OF INVENTION
[0003] The fact that the part of the transport device lying frictionally against the object is flexible or mounted flexibly leads to the solution to the task.
[0004] The most important advantage of this flexible mounting of the objects is that both the possibility of transport and holdup exists. This is of great importance for practical application of the device. The possibility of producing a dynamic pressure also exists.
[0005] The containers that are transported preferably have a body, an annular collar and an opening and they are preferably PET bottles and PET preforms. Support devices and transport devices are provided to support the transport containers, the support devices being arranged fixed. The support devices can be formed from plastic or metal strips. The support devices, however, cannot only be designed as a strip, but any configuration is instead possible, like a band with a circular cross section.
[0006] The at least one transport device is preferably capable of main power introduction into the container for forward movement in the transport direction. The support device and the transport device preferably engage beneath or above the annular collar. Engagement of the support device or transport device touching the annular collar is just as conceivable as engagement carried out with a slight spacing to the annular collar.
[0007] The at least one transport device is preferably designed as a revolving strand side on which spring elements are mounted. By cooperation of the spring elements with a support device or with spring elements of other transport devices, clamping of the containers in the area of the annular collar is obtained.
[0008] According a preferred modification of the invention, the support devices are mounted fixed and the transport device movable in the transport direction, two support devices and two support devices also preferably being present. The containers are preferably transported suspended so that the support devices engage parallel tangentially beneath the annular collar, whereas the two transport devices are mounted tangentially parallel above the annular collar. However, it is also within the scope of the invention for three support devices to be present which hold the container in a certain position, whereas a transport device ensures forward movement in the transport direction.
[0009] It is also possible to provide a total of only three support and transport devices. In this case either two support devices and one transport device or two transport devices and one support device can be provided. With four engagement possibilities available above and below the annular collar in the preform to its left and right, one engagement site remains free during use of three support devices or transport devices in which it is completely irrelevant whether the free site is on the left, right, top or bottom.
[0010] According to a particularly preferred modification of the invention, part of the transport device is designed as an endlessly revolving chain, the chain consisting at least of a chain strand, mounting elements and spring elements. Return of the chain preferably occurs parallel to the plane of the annular collar. The chain has mounting elements at regular intervals to which spring elements can be fastened. The spring elements can then be designed so that one spring element per mounting element or several mounting elements per spring element are necessary. The mounting elements are preferably rolls with grooves made in them in which the spring elements can be guided. The spring elements are therefore preferably made from wire, which is guided or secured in the grooves of the mounting elements. The mounting elements, however, can also be pins or other spring fastening possibilities. In addition, it is conceivable that the spring elements are fastened directly to the revolving chain. Two mounting elements are preferably used to fasten one spring element, in which the spacings of the mounting element that accommodate the spring elements can be greater, smaller or equal to the spacings of the next mounting elements.
[0011] In the variant in the which the spring element is made from wire and is fastened to two mounting element, a preferred fastening appears so that the beginning and end of the wire are situated on a mounting element, whereas the other mounting element is wrapped around by the wire, preferably one and a half times. The one mounting element is preferably enclosed by the wire so that it forms a C shape, the spacing of the arms in the C shape being greater than the diameter of a mounting element. In this way it is possible for the spring element to move relative to the mounting element in order to be able to clamp the container.
[0012] According to a preferred modification of the invention two transport devices designed as endlessly revolving chains are situated to the left and right parallel to the transport direction, which clamp the containers above the annular collar. In this arrangement the chain strands with their mounting elements and spring elements are arranged in mirror fashion on the plane passing through the center point of the containers transported in a row in a transport device. The mirror arrangement has the advantage that the spring elements can optimally grasp the containers. In their unclamping state two opposite C-shaped areas of the spring elements are spaced from each other so that the annular collar diameter is greater than the spacing of these two spring element areas. This has the advantage that optimal clamping of the containers can be achieved. If the containers are clamped between two C-shaped areas of the spring elements, the arms of the C-shaped elements in contact with the containers on the annular collars move in the direction of the center point of the mounting elements. Owing to the fact that the spring elements enclose a mounting element, another type of fastening is not necessary.
[0013] During transport of the containers through the device, the annular collar is situated in an annular collar plane that preferably is perpendicular to the plane through the center point of the containers transported in a row. According to a preferred modification of the invention the spring elements and the support devices are arranged so that they are parallel to the plane of the annular collar. An angled arrangement of the support devices and/or transport devices, however, is also conceivable so that an arrangement of the spring element with reference to the annular collar plane at an angle between 0 and 90 degrees is conceivable.
[0014] In order to optimally guide the chain to which the mounting elements and spring elements are fastened, according to a preferred modification of the invention guides are provided in which the chain strands can run. Exact guiding of the revolving transport devices has the advantage that the mounting elements and the spring elements are also exactly guided, which again means that the holding force between two spring elements can be exactly defined. The spring elements are preferably designed so that they can be adjusted so that the holding force with which the containers can be grasped on the annular collar is adjustable. The spring force is best adjusted so that the spring elements continue to move at the occurring dynamic pressure of the containers and therefore “slip through” the containers.
[0015] The guides preferably have grooves in which the chain strand can be guided. The guides are preferably situated parallel to the transport direction.
[0016] In another practical example of the invention at least one part of the transport device that lies frictionally against the object is supported against pressure rolls and these pressure rolls are mounted flexibly. Because of this reliable transport of the preforms is guaranteed. In one practical example of the invention the pressure rolls are mounted on spring tabs, leaf springs, spring brackets or the like, which are biased. In another variant of the invention the pressure rolls can be arranged on a support block which is supported against a wall via a spring. In order for the springs not to break off laterally, it preferably wraps around a pin through which the support block is inserted into the wall.
[0017] In a practical example of the invention endless belts, preferably endless round belts can be allocated to the object being transported on both sides, between which the object being transported is unclamped. By the choice of endless belts with round cross section, no change in engagement points on the objects occurs, regardless of the position in which the preforms are transported.
[0018] These endless belts wrap around deflection rolls arranged at a spacing, which are preferably tiltable so that by changing the position of the deflection rolls the preforms can be transported not only suspended, but also horizontally or event vertically upright, depending on the desire. A hold-down against which the preforms stop or lie is an additional aid here. This means the preforms can be transported in any position and untimed, which was not possible in the devices known thus far. For example, no transport and back pressure generation from the bottom up of the preforms was thus far possible. This is feasible with the device according to the invention.
[0019] The sliding planes and support devices naturally must be adapted to the desired transport path. In this way any type of guiding of the preforms is possible. This means that the spatial alignment of the preforms can be adjusted to an inlet on a blow molding machine of different manufacturers.
[0020] Especially during transport of preforms, but also bottles, there is a necessity that the transport path extend in one plane. If the transport path, however, is rising or falling and passes through different slopes, there are positive and negative slope areas in which the spacing of the center axes of the consecutive objects is reduced or widened. If the spacing is reduced, the consecutive objects deflect, require more space and can jam. They also rub against each other.
[0021] To prevent this drawback, according to the present invention in one practical example, the possibility is offered that a deflection element is inserted in the area of the negative slope in the transport path of the object so that they slide along a sliding surface and are deflected outward. Because of this the diminishing spacing between the said axes of the consecutive preforms is increased again.
[0022] It is also conceivable that the sliding planes on which the annular collars of the preform slide along run in different planes in individual areas. Because of this, tilting of the preforms occurs so that they are also deflected laterally and the spacing of their center axes is increased again.
[0023] Arrangement of the differently sloped sliding planes is also conceivable, which can also be offset at different heights. Many possibilities are conceivable here and are to be included by the present invention.
[0024] Precisely the possibility that the present invention offers by different arrangement of the sliding planes does not allow the problem of a negative arc to develop at all. The preforms can be transported in any position of their center axes so that the desired spacing of the center axes can be taken into account by changing the positions of the preforms in space.
[0025] Another idea of the present invention pertains mostly to the fact that the spacing of the sliding planes is variable relative to each other. For this purpose the sliding planes are part of the housing that preferably consists of two housing shells. The two housing shells form a slit in the area of the sliding planes, in which the edges maintain a desired spacing from each other. The edges take up the preforms between them in the use position.
[0026] In order to be able to change this spacing, the two housing shells must be movable one into the other for which purpose two arm strips of the housing shells overlap and can be joined to each other overlapping.
BRIEF DESCRIPTION OF DRAWINGS
[0027] Additional advantages, features and details of the invention are apparent from the following description and preferred practical examples as well as with reference to the drawing; in the drawing
[0028] FIG. 1 shows a perspective view of a device according to the invention for transport of preforms;
[0029] FIG. 2 shows a bottom view of such a device;
[0030] FIG. 3 shows a section through a device;
[0031] FIG. 4 shows another embodiment of a device according to FIG. 1 ;
[0032] FIG. 5 shows a sectional depiction in a perspective view of another practical example of a device according to the invention for transport of preforms;
[0033] FIG. 6 shows an enlarged side view from a partial area of the device according to FIG. 5 ;
[0034] FIG. 7 shows a cross section through FIG. 6 along line VII-VII;
[0035] FIG. 8 shows a cross section through FIG. 6 along line VIII-VIII;
[0036] FIG. 9 shows a schematic side view of parts of the device according to FIG. 7 in different arrangements of endless belts;
[0037] FIG. 10 shows a side view of a partial cutout from a device according to the invention for transport position change of objects;
[0038] FIG. 11 shows a top view of the partial cutout according to FIG. 10 ;
[0039] FIG. 12 shows a schematic view of different transport positions of the preforms;
[0040] FIG. 13 shows a sectional view of parts of an additional practical example of the device for transport of free forms;
[0041] FIG. 14 shows a top view of the parts of the device according to FIG. 13 ;
[0042] FIG. 15 shows a side view of a part of transport zone according to the prior art;
[0043] FIG. 16 shows a view of the transport device of the preforms with additional parts of the device for transport of these preforms;
[0044] FIG. 17 shows a bottom view of partial area of the device according to FIG. 16 ;
[0045] FIG. 18 shows a side view of another cutout from another practical example of a device according to the invention for transport of objects;
[0046] FIG. 19 shows a perspective view of the partial area according to FIG. 18 ;
[0047] FIG. 20 shows another perspective view of another partial area of the device according to the invention for transport of objects.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0048] FIG. 1 shows a device 1 for transport of preforms 2 for production of plastic bottles. The preforms 2 are brought for this purpose from a preform sorting not shown here in a row and introduced to device 1 and transported to a stretch blow molding machine (not shown here). The device 1 has two support devices 4 , which support the preforms 2 beneath the annular collar 3 . Device 1 also has transport devices 5 , which support the preforms 2 or, as shown in FIG. 12 , bottles 2 . 1 on the left and right above the annular collar 3 . The transport devices 5 each consist of a chain strand 21 , several mounting elements 7 , 7 ′ and several spring elements 6 . The chain strand 21 is designed as a link chain similar to a bicycle chain. At some connection site of the chain links of the chain strand 21 mounting element 7 , 7 ′ are mounted on the bottom on connection pins. Two mounting element 7 and 7 ′ are wrapped around by a spring element 6 . The spring elements 6 are mounted so that an elastic effect inward in the direction of preforms 2 occurs.
[0049] FIG. 2 shows a device 1 in a bottom view, in which it is apparent that the preforms 2 are transported in a row that is defined by lying through the center points 8 of preforms 2 . Transport occurs in transport direction T. The design of the device 1 is in mirror symmetry with a plane that passes through the center point 8 and through the longitudinal axes of the preforms 2 . Here again the two guides 9 can be seen in which the chain strands 21 are guided. The chains are then constructed as link chains in the form of bicycle chains. The mounting element 7 and 7 ′ are fastened to the chain strands 21 . The spring elements 6 are again mounted on them. How a spring element 6 winds around two mounting elements 7 , 7 ′ is best shown in FIG. 2 on the right top by the dashed spring element 6 . The chain beginning 6 ′ is then bent C-shaped around the mounting element 7 , the diameter of the mounting element 7 being smaller than the distance between the two arms of the C shape. This means that the lower arm of the C shape of the spring element 6 stands in the transport path of preforms 2 . Spring element 6 is continued to the mounting element 7 ′, wrapping around it one and a half times in order to then return in the direction of mounting element 7 . The end of the spring element 6 ″ is situated on the side of the mounting element 7 facing the preforms 2 . Because of installation at the beginning of the spring element 6 ′ and the end of the spring element 6 ″ on the mounting element 7 and by wrapping around the mounting element 7 ′ a spring force is generated that elastically clamps the preforms 2 with a perpendicular component to the transport direction T. If no preforms 2 are situated between two opposite spring elements 6 , they have a spacing A between each other, which is less than the diameter of the opening area of preform 2 . If preforms 2 are situated between opposite spring 6 , the C-shaped part of the element 6 moves in the direction X toward the center point 17 of mounting element 7 .
[0050] FIG. 3 shows a section for a device 1 . Here again a device 2 can be seen, which is supported beneath its annular collar 3 on the left and right by a support device 4 . One spring element 6 each engages above annular collar 3 to the left and right. The spring elements 6 that are in turn situated parallel to the plane of the annular collar N are fastened to mounting element 7 ′. Wrapping around of spring element 6 around mounting element 7 ′ is readily apparent here. The mounting element 7 ′ is fastened to the chain strand 21 . The endlessly revolving chain strain 21 is guided in the groove 10 situated in guide 9 . In this way stabilization of the transport device 5 occurs.
[0051] FIG. 4 the same device 1 as in FIG. 3 is shown in principle, but with the difference that a support device 4 and a transport device 5 have an angle γ to the plane of the annular collar N that is greater than zero degrees. However, the angle γ can also be present only in the transport device 5 or only in the support device 4 . Another practical example of a device according to the invention for transport of preforms according to FIGS. 6 and 7 has a housing 22 formed from two housing shells 23 . 1 and 23 . 2 . The housing shells 23 . 1 and 23 . 2 can be moved one into the other so that a spacing a from the edges 24 . 1 and 24 . 2 , which form a slit 25 between them, can be changed. For this purpose the two housing shells 23 . 1 and 23 . 2 overlap with their upper arms 26 . 1 and 26 . 2 and are connected in this overlapping area by fastening elements (not further shown) which pass through elongated holes 27 shown in FIG. 5 . The preforms 2 slide in slit 25 , in which they lie with annular collar 3 against edges 24 . 1 and 24 . 2 connected to the side to sliding planes 32 . 1 , 32 . 2 . Two endless belts 29 . 1 and 29 . 2 arranged on both sides serve for transport of the preforms 2 along slit 25 in housing 22 , which wrap around deflection rolls 30 . 1 and 30 . 2 and run in plastic rails 42 . The endless belts 29 . 1 and 29 . 2 are nestled above annular collar 3 closely to the neck of preforms 2 and frictionally entrain the preforms 2 . In order for the preforms 2 not to be able to expand upward, a rail 31 additionally serves as hold-down. The two sliding plane 32 . 1 and 32 . 2 are indicated in FIG. 9 , in which the annular collars 3 slide along. However, additional different use positions of the deflection rolls 30 . 1 and 30 . 2 are indicated by the dash-dot line so that it is apparent that the corresponding endless belts 29 . 1 and 29 . 2 engage the preform 2 in any desired position and can further transport it, depending on which position is preferred by design. This mostly depends on whether suspended transport of the preforms, horizontal or even vertical transport is desired. The last two mentioned transport possibilities are show in FIG. 12 . It is also shown in FIGS. 10 and 11 that by corresponding guiding of sliding planes 32 . 1 and 32 . 2 alignment of the preforms from the horizontal position to a suspended position is possible without difficulty. The same actually applies for alignment of the preforms from a suspended to a horizontal position and from there even into a vertical position. All this is possible by the transport devices according to the invention.
[0052] According to FIGS. 7 and 8 the two endless belts 29 . 1 and 29 . 2 engage the preforms 2 from one side each so that the preforms 2 are moved through slit 25 during transport. In order for the endless belts 29 . 1 and 29 . 2 to enter into close, i.e., frictional contact with preforms 2 , lateral pressure rolls 33 . 1 and 33 . 2 are provided, which force the endless belts 29 . 1 and 29 . 2 elastically against the neck of the preform 2 above the annular collar 3 . These pressure rolls 33 . 1 and 33 . 2 run with the endless belts 29 . 1 and 29 . 2 . They then rotate around a pivot axis 34 . 1 and 34 . 2 , being each suspended on a spring tab 35 . 1 and 35 . 2 , which is biased and forces the pressure rolls 33 . 1 and 33 . 2 against the endless belts 29 . 1 and 29 . 2 .
[0053] In another variant of the device according to the invention for transport of preforms according to FIGS. 13 and 14 the pressure rolls 33 . 1 and 33 . 2 are each arranged in a support block 36 . 1 and 36 . 2 , each support block 36 . 1 and 36 . 2 being held by a pin 37 . 1 and 37 . 2 against a wall 38 . 1 and 38 . 2 . Each support block 36 . 1 and 36 . 2 is supported against this wall 38 . 1 and 38 . 2 by a coil spring 39 , which wraps around pins 37 . 1 and 37 . 2 . This coil spring 39 is also biased so that the pressure rolls 33 . 1 and 33 . 2 force the endless belts 29 . 1 and 29 . 2 against preform 2 .
[0054] According to the invention in the device for transport of preforms 2 it is also supposed to be possible for the preforms to travel along a curve transport path. For example, if the preforms are arranged suspended, as shown in FIG. 15 and pass through different slopes of the transport path, positive and negative slope areas are passed through, which means the center axes of adjacent preforms become more spaced in the positive slope areas, whereas adjacent preforms are forced against each other in the negative slope areas in the area following the annular collar 28 and mutually expand so that the preforms are no longer guided in a plane and clamped. This can be avoided according to FIGS. 16 and 17 by the fact that a deflection element 40 with a rounded sliding surface 41 is used in the area of slit 25 . In the region of this sliding surface 41 , the preforms 2 are deflected so that more room is available to them in the negative arc area and the drawback of negative slope is eliminated.
[0055] Another possibility according to FIGS. 18 and 19 consists of the fact that the sliding planes 32 . 1 and 32 . 2 run at different heights in sections so that the preforms 2 in this area are tilted outward.
[0056] There is also the possibility according to FIG. 20 to arrange sliding planes 32 . 1 and 32 . 2 sloped at different heights so that the preforms 2 are also tilted outward.
LIST OF REFERENCE NUMBERS
[0057]
[0000]
1
Device
2/2.1
Preform/bottle
3
Annular collar
4
Support device
5
Transport devices
6
Spring element
7
Mounting element
8
Center point
9
Guides
10
Grooves
11
12
13
14
15
16
17
Center point of 7
18
19
20
21
Chain strand
22
Housing
23
Housing shell
24
Edge
25
Slit
26
Arm
27
Elongated hole
28
Annular collar
29
Endless belt
30
Deflection roll
31
Hold-down
32
Sliding plane
33
Pressure roll
34
Pivot axis
35
Spring tab
36
Support block
37
Pin
38
Wall
39
Coil spring
40
Deflection element
41
Sliding surface
42
Plastic rail
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
A
Spacing
a
Spacing
N
Annular collar plane
T
Transport direction
X
Direction
γ
Angle
|
Disclosed is a device for conveying profiled objects, particularly bottles or parisons comprising an annular collar between two sliding planes with the aid of at least one conveying apparatus, at least one part of which rests against the object in a frictionally engaging manner and is supported on receiving elements or pressure rollers.
| 1
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is directed to providing new and improved direct positive radiation recording photosensitive photographic elements.
2. Description of the Prior Art
As is known in the prior art, photographic silver halide elements may be constituted which are adapted to provide, upon photoexposure and processing, direct positive image formation, that is, image formation in terms of the unexposed areas of the element as a function of the point-to-point degree of the elements' exposure to incident electromagnetic radiation actinic to the silver halide crystals constituting such elements. Specifically, the constitution of direct positive silver halide elements adapted to provide the requisite reversal image formation, as a function of photoexposure and chemical processing, is disclosed in substantial detail in a plurality of United States and foreign patents including among others U.S. Pat. Nos. 2,592,250; 3,206,313; 3,317,322; 3,364,026; 3,367,778; 3,501,305; 3,501,306; 3,501,307; 3,501,309; 3,501,310; 3,501,311; 3,501,312; 3,505,070; 3,537,858; and the like.
In general, the aforementioned direct positive silver halide elements comprise a particulate dispersion of substantially uniformly fogged silver halide crystals or grains which in particularly preferred situations may comprise uniformly fogged silver halide grains comprising a central core of silver halide containing centers which promote deposition of photolytic silver and an outer shell covering the core comprising fogged silver halide that is adapted to be rapidly reduced to silver absent photoexposure; the latter structures being described in further detail in U.S. patents such as aforementioned U.S. Pat. Nos. 3,206,313; 3,317,322; 3,367,778; 3,537,858; and the like.
SUMMARY OF THE INVENTION
The present invention is directed to a new and improved radiation recording photographic element which comprises a direct positive photosensitive element which includes, in combination, a particulate dispersion of fogged silver halide photosensitive crystals and, specifically, silver halide crystals adapted to discharge their latent fog image upon exposure to electromagnetic radiation actinic thereto, and adapted to be reduced to silver upon contact with a silver halide reducing agent, having associated therewith in electron accepting relationship a semiconductor adapted to accept electrons from the silver halide crystals as a function of the exposure of the crystals to the incident actinic radiation to spectrally sensitize the crystals to incident actinic radiation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graphical representation of the action spectra, as determined on a wedge spectrograph, of a direct positive photosensitive silver chloride emulsion; and
FIG. 2 is a graphical representation of the action spectra of a direct positive silver chloride emulsion formulation to which has been added a particulate dispersion of a semiconductor in accordance with the present invention.
DETAILED DESCRIPTION OF THE INVENTION
Commensurate with the present invention, enhancement of the photographic action of a direct positive photoresponsive silver halide material may be achieved by electron transfer from said photoresponsive material to an associated electron sink which comprises an inorganic semiconductor adapted to receive electron flow in response to incident electromagnetic radiation.
In general, the absorption of photon excitation derived activating energy, e.g., a photon, by a photoresponsive silver halide crystalline material retaining prefogged silver results in the imagewise discharge of the prefogged silver.
Silver halide, which itself is a semiconductor can be uniformly fogged by overall exposure or by chemical agents known to the art.
The thus-formed uniformly fogged silver halide accordingly is adapted to be developed, or reduced, by conventional direct positive procedures known to the art to provide a visible species by contact with reagents which will react differentially between exposed and unexposed pre-fogged photoresponsive material.
Excitation of the fogged photoresponsive silver halide materials, however, by incident electromagnetic radiation possessing frequencies to which the crystals are responsive in net effect acts to discharge the fog [(Ag 0 ) n → nAg +] , thus treating the capacity of discharged silver halide to be itself converted to a visible photographic signal.
A variety of photoresponsive silver halides are suitable for use in the present invention such as, for example, silver chloride, silver bromide, and mixed halides such as silver iodobromide and silver iodochlorobromide and the like.
The term "photoresponsive" as employed throughout the present specification is thus intended to refer to a material adapted to receive activating energy of selected wavelengths incident thereon which, as a result of the incident radiation, is adapted to undergo modification to provide a photographic signal, either not obtainable in exposed material or not obtainable at an effective differential rate.
The semiconductor to be employed is adapted to accept electrons directly or indirectly from the silver halide component of the system in response to activating energy impinging on said system. Thus, assuming photons are absorbed directly by the silver halide, the free electrons generated by reason of the incident photon energy, are transferred to the semiconductor electron sink as a function of the photosensitive elements' photoexposure, thus discharging fog carried by photoexposed silver halide. Assuming photons are absorbed directly by the semiconductor, positive holes are generated in the semiconductor by reason of the incident photon energy, discharging fog carried by the prefogged silver halide in contact with the semiconductor. Fog discharge by removing electrons from the photoresponsive component and/or injection of positive holes into the photoresponsive component thus promotes direct positive image formation as a function of the impingement of radiation on fogged silver halide.
Specifically with reference to the electron transfer mechanism, sensitization of the photographic process is understood to occur by the removal of electrons from the prefogged silver halide crystals by the semiconductor material as a result of incident actinic radiation. Positive holes are formed which can react with prefogged silver from the silver halide grains making it unavailable for surface development.
Silver halide dispersions employed for the fabrication of preferred photographic film units comprising sensitized photoresponsive silver halide crystals, as specifically detailed immediately above, may be prepared by reacting a water-soluble silver salt, such as silver nitrate, with at least one water soluble halide, such as ammonium, potassium or sodium chloride, in an aqueous solution of a peptizing agent such as a colloidal gelatin solution by methods known to the art and detailed in the above-indicated U.S. Patents.
The direct positive emulsions employed in the present invention may be fogged by chemical or physical methods known to the art, for example, as described by Antoine Hautet and Henri Saubenier in Science et Industries Photographiques, Vol. XXVIII, January 1957, pages 57-65; U.S. Pat. Nos. 3,062,651; 2,487,850; 2,519,698; 2,521,925; 2,521,926; 2,399,083; and 2,642,361.
The semiconductor may be provided to the formulation by suspension in particulate form in a liquid medium in which it is insoluble and which is nondeleterious to photographic emulsions, such as water, methanol or other lower molecular weight alcohol, or a mixture of water and alcohol; the suspension so formed is then added to and mixed throughout the above-described formulation. Preferably, an inorganic semiconductor is employed.
Alternatively, the silver halide may be formed in the presence of the semiconductor in such a way that a core-shell configuration is obtained, with either material, i.e., the silver halide crystal or a GaS particle, comprising either the core or the shell.
With respect to semiconductor/silver halide ratio, silver halides have been effectively sensitized according to the present inventive concept, by utilizing a molar ratio of one silver halide:one semiconductor, although higher or lower ratios may be suitable, depending upon emulsion and sensitization characteristics desired and relative silver halide/semiconductor contact area.
The particle size of the semiconductor particles has been found not to be critical, except that is will be obvious to those familiar with semiconductor theory that the particle size and configuration must be such as to provide for adequate interfacial contact between the silver halide crystals, sensitizing dye and semiconductor particles. In practice, sonified suspensions of semiconductor have been found to give particularly good results, since the submicroscopic particles may then in part layer on silver halide crystal. However, it will be appreciated from the foregoing discussion of theoretical considerations that the sensitizing activity of the semiconductor is not dependent upon the formation of an actual semiconductor layer as such; rather, electron transfer can take place readily provided there is at least minimum effective electronic contact between respective reactants. Insofar as silver halide sensitization is concerned, there is no theoretical maximum particle size for the semiconductor. However, the particles should be of sufficiently small size, as well as concentration, so as not to interfere with the photographic characteristics of the silver halide emulsion, as by reflecting and/or scattering incident actinic radiation to any significant extent. It will be appreciated that absolute numbers as applied to a specific semiconductor particle size and ratio to a silver halide are only meaningful with respect to a single specified silver halide system and that one of ordinary skill in the art possessing the present invention would readily be able to determine empirically the specific parameters which must be utilized to give optimum sensitizing results in the practice of the invention.
It will be recognized that semiconductor particles for use within the scope of the present invention may be readily prepared by any of the conventional techniques, for example, ball mill, sand grinding, ultrasonic, and the like, for the production of particulate solid materials. In general, a wet paste comprising solid semiconductor particles, and optionally, one or more dispersing agents, surfactants, antifoamers, antioxidants, or the like, and water may be processed according to the identified techniques to provide particles of the size desired and the output of the process selected, where desired, may be appropriately filtered to effect removal of any particles which may be present exceeding that of a diameter within the particle size range desired.
Conventional sand grinding techniques adapted to mill solid particles such as to provide the requisite particle size distribution generally comprise agitating an aqueous semiconductor slurry with a sand, which, for example, may possess a size range of 20 to 40 mesh, until the desired particle size distribution is obtained and then separating the semiconductor from contact with the abrasive sand. Commercial mills, of various capacities, adapted to perform sand grinding, may be procured from the Chicago Boiler Company, Chicago, Ill., U.S.A.
For the preparation of semiconductor material possessing the desired particle size distribution by ultrasonic techniques, an aqueous semiconductor slurry may be treated employing commercial sonifiers such as those procured from Bronson Instruments, Incorporated, Stamford, Conn., U.S.A.
Subsequent to sensitization, any further desired additives, such as coating aids and the like, may be incorporated in the emulsion and the mixture coated and processed according to the conventional procedures known in the photographic emulsion manufacturing art.
The sensitized formulation may then be coated on an appropriate support as, for example, cellulose triacetate film base and the film units thus prepared exposed in a conventional wedge spectrograph to detail wavelength specific sensitivity of the formulation to incident electromagnetic radiation.
Upon processing with a photographic developing composition as, for example, a conventional processing composition of the type commerically distributed by Eastman Kodak Company, Rochester, N.Y., U.S.A., under the trade name of "KODAK D-19 Developer" and comprising an aqueous alkaline solution of p-methylamino phenol sulfate and hydroquinone, and a conventional acid stop bath, the resultant spectrograms will detail the sensitivity characteristics of the sensitized formulation of the present invention which may be directly compared with a control formulation which does not contain the described semiconductor.
As previously detailed, the photoresponsive crystals of the present invention may be employed as the photosensitive component of a photographic emulsion by incorporated within a suitable binder and the coating and processing of the thus prepared emulsion according to conventional procedures known in the photographic manufacturing art.
The photoresponsive crystal material of the photographic emulsion will, as previously described, preferably comprise a crystal of a silver compound, for example, one or more of the silver halides such as silver chloride, silver bromides, or mixed silver halides such as silver chlorobromide, silver iodobromide or silver iodochlorobromide or varying halide ratios and varying silver concentrations.
The extended range of spectral sensitivity is determined by the long wavelength absorption edge of the selected semiconductor.
A particularly preferred semiconductor contemplated for employment in the practice of the present invention comprises GaS.
The fabricated emulsion may be coated onto various types of rigid or flexible supports, for example, glass, paper, metal, polymeric films of both the synthetic types and those derived from naturally occurring products, etc. Especially suitable materials include paper; aluminum; polymethacrylic acid, methyl and ethyl esters; vinyl chloride polymers; polyvinyl acetals; polyamides such as nylon; polyesters such as the polymeric films derived from ethylene glycol terephthalic acid; polymeric cellulose derivatives such as cellulose acetate, triacetate, nitrate, propionate, butyrate, acetate-butyrate, or acetate-propionate; polycarbonates; polystyrenes, etc.
The emulsion may also contain one or more innocuous coating aids such as saponin; a polyethyleneglycol of U.S. Pat. No. 2,831,766; a polyethyleneglycol ether of U.S. Pat. No. 2,719,087; a taurine of U.S. Pat. No. 2,739,891; a maleopimarate of U.S. Pat. No. 2,823,123; an amino acid of U.S. Pat. No. 3,038,804; a sulfosuccinamate of U.S. Pat. No. 2,992,108; or a polyether of U.S. Pat. No. 2,600,831; or a gelatin plasticizer such as glycerin; a dihydroxyalkane of U.S. Pat. No. 2,960,404; a bisglycolic acid ester of U.S. Pat. No. 2,904,434; a succinate of U.S. Pat. No. 2,940,854; or a polymeric hydrosol of U.S. Pat. No. 2,852,386.
As the binder for photosensitive crystals, the aforementioned gelatin may be, in whole or in part, replaced with some other colloidal material such as albumin, casein; or zein; or resins such as cellulose derivatives and vinyl polymers such as described in an extensive multiplicity of readily available U.S. and foreign patents.
The photographic emulsions may be employed in black-and-white or color photographic systems, of both the additive and subtractive types, including diffusion transfer systems, for example, those described in Photography, Its Materials and Processes, supra, wherein direct positive emulsions are conventionall employed.
The photoresponsive crystals of the present invention may also be employed as the photosensitive component of information recording elements which employ the distribution of a dispersion of relatively discrete photoresponsive crystal, substantially free from interstitial binding agents, on a supporting member such as those previously designated, to provide image recording elements, for example, as described in U.S. Pat. Nos. 2,945,771; 3,142,566; 3,142,567; Newman, Comment on Non-Gelatin Film, B.J.O.P., 534, Sept. 15, 1961; and Belgian Pat. Nos. 642,557 and 642,558.
As taught in the art, the concentration of silver halide crystals forming a photographic emulsion and the relative structural parameters of the emulsion layer, for example, the relative thickness, and the like, may be varied extensively and drastically, depending upon the specific photographic system desired and the ultimate employment of the selective photographic system.
In conventional direct positive photographic processes, for the formation of silver images, a latent image carried by a fogged silver halide system is formed by selective exposure of a photosensitive photographic system, generally containing the aforementioned photoresponsive silver halide crystals or the like. The residual latent image is developed, to provide a visible silver image, by a suitable contact with any of the photographic developing solutions set forth in the art. For the purpose of enhancing the resultant visible image's stability, the image may be suitably fixed, according to the procedures also well known to those skilled in the art. The resultant image-containing element may be then directed employed or, optionally, may be employed, where applicable, as a positive image, for example, to provide a reversed or negative image by conventional contact or projection printing processes employing suitable photosensitive printing papers.
The present invention will be illustrated in greater detail in conjunction with the following specific example which sets forth a representative fabrication of the film units of the present invention, which, however, is not limited to the detailed description herein set forth but is intended to be illustrative only.
EXAMPLE
A direct positive silver chloride emulsion was prepared according to the teachings of U.S. Pat. No. 3,537,858. One portion was retained as a control.
To 10 g. of the emulsion was added 14 g. of a 10:1 gelatin solution and 2.4 ml. of water. The mixture was melted for 15 minutes and then 4 g. of methanol were added. After mixing for 10 minutes a sonified mixture of 0.9465 g. of gallium sulfide (to give a 1:1 Ag:Gas mole ratio) and 10 ml. of water were added, mixed for 30 seconds after which 1 ml. of a 1% solution of the sodium salt of dioctyl sulfosuccinate was added. The emulsions were coated with a No. 30 Meyer rod and air dried. Exposure was carried out with a wedge spectrograph and development with KODAK D-19 developer.
Kodak Developer D-19 is commercially available from Eastman Kodak Company, Rochester, N.Y., and has the following composition:
______________________________________Water (125° C) 500.0 mlKodak Elon 2.0 gms.Kodak Sodium Sulfite, dessiccated 90.0 gms.Kodak Hydroquinone 8.0 gms.Kodak Sodium Carbonate, monohydrated 52.5 gms.Kodak Potassium Bromide 5.0 gms.Add cold water to make 1.0 liter______________________________________
A comparison of the figures shows an extended range of spectral sensitization with the emulsion of the present invention (FIG. 2) as compared with a control (FIG. 1) which is the same emulsion without the gallium sulfide additive.
Since certain changes may be made in the above product without departing from the scope of the invention herein involved, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
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The present invention relates to photography and, more particularly, to a novel radiation recording photographic element which comprises a direct positive photosensitive element which includes, in combination, a particulate dispersion of fogged silver halide crystals, adapted to discharge the fogged silver halide upon exposure to electromagnetic radiation actinic thereto, having associated therewith in electron accepting relationship a semiconductor adapted to accept electrons from said silver halide crystals as a function of the exposure of the crystals to incident electromagnetic radiation actinic thereto.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an automatic focusing camera one particularly, having a photographic lens with variable focal length.
2. Description of the Prior Art
Until now, the so-called active type automatic focusing camera has been designed so that photographic lens focusing is adjusted by projecting the light beam from the light emitting elements toward the object and detecting the light beam reflected from the object by the light sensing element. However, in the conventional automatic focusing camera, the range in which the distance is measured (hereinafter called the focus target) is limited to a remarkably narrow range in the middle of the photographic picture plane so that the object to be photographed is not well focused unless the object to be photographed is located in a predetermined position in the middle of the photographic picture plane. Generally, the object to be photographed should be located within the distance measuring mark provided in the view finder.
Consequently, quite recently, an automatic focusing camera has been proposed, in which a plurality of focus targets are set in the photographic picture plane to obtain a well focused picture regardless of the position of the object in the photographic picture plane. FIG. 1 shows an example of the distance measuring system of such an automatic focusing camera. In the drawing, a light emitting element array 1 has a plurality of light emitting elements 1a-1e, a light projecting lens 2 projects the light beams produced by the light emitting elements 1a-1e towards respective focus targets 6a-6e provided in the horizontal direction of the photographic picture plane, and a light sensing element 3 whose signal output changes based on the incident position of the light beam, for example, a PSD (position sensitive device). A light receiving lens 4 serves to lead the projected light beam reflected from the object in the respective focus targets 6a-6e to the light sensing element 3. In this example, the projected light beams of the respective light emitting elements 1a-1e are reflected by the objects existing along the respective direction of the focus targets 6a-6e and the respective reflected light beams are sensed by the light sensing element 3 at the light sensing positions according to object distances based upon the principles of trigonometry. The output of the light sensing element 3 changes based on the light sensing position so that information regarding the distance to the focus target 6a-6e from the illuminant light emitting element 1a-1e can be obtained from the output. By obtaining the distance information for the respective targets 6a-6e a well focused picture can always be obtained regardless of the position of the object in the photographic plane.
When the focal length of the photographic lens of such an automatic focusing camera is variable, the following problems occur. The so-called variable focus camera having a photographic lens with variable focal length is disclosed in Japanese Laid-Open Patent Application No. Sho 57-141084.
In the variable focus camera, the photographic picture angle changes based on the change over of the focal length of the photographic lens so that there is a possibility that the object distance of the photographic picture plane is also measured if the above automatic focusing camera is provided with a plurality of focus targets. Namely, as is shown in FIG. 1, the photographic picture angle β at the side of the long focal length of the photographic lens is smaller than that α at the side of the short focal length, so that when a plurality of focus targets 6a-6e are provided corresponding to the photographic range 5a at the side of the short focal length, the object distance outside the photographic range 5a, namely the object in the focus targets 6a and 6e are also measured. In such a case there is a danger that the result of the distance measurement would be wrong due to unnecessary distance information, while the light emitting elements 1a and 1e are also wastefully lit.
It is, accordingly, an object of the present invention to provide an automatic focusing camera capable of measuring a wide range of distances by setting a plurality of focus targets in the photographic picture plane, so designed that when the photographic picture angle changes due to the changing of the focal length of the photographic lens the distance is measured by the focus targets provided in a number corresponding to the pnotographic picture angle, in order to avoid mismeasurement of the distance.
Further objects and features of the present invention will become apparent from the following description of the preferred embodiment with reference to the accompanying drawings.
SUMMARY OF THE INVENTION
An automatic focusing camera includes distance measuring means capable of automatically measuring an object distance and change over means for changing over a distance measuring range of the distance measuring means to a range appropriate to a photographic picture angle according to the change in focal length of a photographic optical system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an example of a distance measuring system capable of measuring the distance for a plurality of focus targets.
FIG. 2 shows an example of the principle of the distance measurement of the automatic focusing camera of the present invention.
FIG. 3 shows a diagram for explaining the incident position of the light beam on the light sensing element of FIG. 2.
FIG. 4 shows the circuit of the distance measuring system of the automatic focusing camera of the present invention.
FIG. 5 shows the incident position detecting circuit of FIG. 4.
FIG. 6 shows the outputs of the incident position detecting circuit of FIG. 5.
FIG. 7 shows the light emitting element driving circuit of FIG. 4.
FIG. 8 shows the signal converting circuit of FIG. 4.
FIG. 9 shows the output of the signal converting circuit of FIG. 8.
FIG. 10 shows the signal evaluating circuit of FIG. 4.
FIG. 11 shows the control circuit of FIG. 4.
FIG. 12 shows the timing chart of the control circuit signals of FIG. 11.
FIG. 13 shows the timing chart of the signal evaluating circuit signals of FIG. 10.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The embodiment of the present invention will be described with reference to the accompanying drawings.
FIG. 2 shows the principle of the distance measurement of the automatic focusing camera of the present invention. In the drawing, the light emitting array is composed of the five light emitting elements 1a-1e arranged on the same chip in the horizontal direction of the photographic picture plane, the projection lens 2 projects a light beam a-e from each of the light emitting elements 1a-1e toward the focusing targets 6a-6e, the light sensing emement 3 (hereinafter called PSD) is designed so that the rate of the outputs from terminals 3a and 3b change based on the incident position of the light beam, and the light receiving lens for 4 leads the projected light beam reflected by the object toward the PSD 3, in the same manner as shown in FIG. 1. Hereby, for the sake of a simplified explanation, the light receiving range of the PSD 3 is divided into 8 portions, namely light receiving portions A-H arranged in the horizontal direction. Hereby, the relation between each light emitting element 1a-1e and each light recieving portion A-H of the PSD 3 via the projected light beams a-e is as shown in FIG. 3 when the object is at D1, D2, D3 and D4. For example, when the object is at D1, the light beam "a" from the element 1a is incident on the portion A, the light beam "b" from the element 1b on the portion B, the light beam "c" from the element 1c on the portion C, the light beam "d" from the element 1d on the portion D and the light beam "e" from the element 1e on the portion E. As the object position changes to D2, D3 and D4, the incident position changes in the order of the light receiving portions B-F, C-G and D-H, as shown in FIG. 3
FIG. 4 shows the outline of the control system of the present embodiment. In the drawing, an incident position detecting circuit 13 detects the incident position of the light beam in the PSD 3, reference numeral 27 identifies a light emitting element driving circuit for time serially illuminating the light emitting elements 1a-1e in sequence, a signal converting circuit 47 converts the incident position signal obtained by the incident position detecting circuit 13 into the distance signal, a signal evaluating signal 107 selects the most proper distance signal from a plurality of distance signals obtained from the illumination of each light emitting element 1a-1e, and a control circuit 109 controls the operation of each circuit. Furthermore, each circuit is connected to each other via signal lines 23-25, 41-45 and 73-75.
Below, the operation of each circuit will be described.
FIG. 5 shows the incident position detecting circuit 13. A bias voltage Vc is delivered to the PSD 3. From each of the output terminals 3a and 3b photoelectric currents Ia and Ib are charged in a ratio based on the incident position of the light beam which is delivered. Reference numeral 15 identifies a conventional signal processing circuit to which the photoelectric currents Ia and Ib are input and which calculates (Va-Vb)/(Va+Vb) using voltages Va and Vb based upon the photoelectric current and delivers the corresponding voltage, namely the voltage proportional to the change of the incident position of the light beam on the PSD 3 to a signal line 21. The signal processing circuit 15 includes a MOS amplifier, a high pass filter, a preamplifier, an adder, a subtractor, a sample and hold circuit, a low pass filter and so on. A A/D converter 17 converts the information of the incident position of the light beam into digital data based upon the voltage produced in the signal line 21 so as to deliver the incident position information converted into digital data to the signal lines 23-25. The outputs of the signal lines 23-25, when the light beam is incident on each light receiving portion A-H of the PSD 3, are set as shown in FIG. 6
FIG. 7 shows a light emitting element driving circuit 27. The circuit 27 has drive circuits 31-35 each connected to the signal lines 41-45 from a control circuit 109. Each drive circuit 31-35 includes a transistor, a constant current circuit and so on. A long as a high level signal is produced in the connected signal line the corresponding drive circuit 31-35 makes the individual connected light emitting element 1a-1e flicker based on the clock pulse from the oscillator circuit (not shown).
FIG. 8 shows a signal converting circuit 47. Reference numeral 49 identifies a binary-to-octonal converting circuit. Input terminals B0-B2 are respectively connected to the signal lines 23-25. By converting the incident position signal input from the incident position detecting circuit 13 via the signal lines 23-25 according to the relation shown in FIG. 6, the level of one of the outputs at output terminals A'-H' corresponding to the respective light receiving portions A-H of the PSD 3 is made high. Namely, when each output of the signal lines 23-25 reaches (1,1,0), the level at the terminal D' becomes high. Reference numerals 51-60 identify 2-input OR gates, 61-70 identify 2-input AND gates, and 71 and 72 identify 5-input AND gates, connected as shown in the drawing to convert the light receiving portion signal from the converting circuit 49 into the object position signal to be delivered to signal lines 73 and 74. For example, when the incident position of the light beam when the level of the signal line 43 becomes high and the light emitting element 1c illuminates is on the light receiving portion D, namely when the object is at the position D2, only the level at the terminal D' of the converting circuit 49 becomes high so that the level of the outputs of the OR gates 51, 53, 56 and 57 is high, while the level of the outputs of the OR gates 52, 54, 55, 58, 59, and 60 is low. Here, because only the level of the signal line 43 is high, only the output level of the AND gate 63 becomes high. Consequently, a high level signal is produced in the signal line 73 connected to the output of the OR gate 71, while a low level signal is produced in the signal line 74 connected to the output of the OR gate 72. The converting circuit 47 controls the output of the signal lines 73 and 74 based on the inputs from the signal lines 23-25, 41-45 in such a manner that when the object is at the position D2 the level of the signal line 73 is high, while that of the signal line 74 is low when other light emitting elements illuminate. Even when the object is at another position a predetermined signal is always produced regardless of the illuminant light emitting element 1a-1e. The relation between the object positions D1-D4 and the signal lines 73 and 74 is shown in FIG. 9.
FIG. 10 shows a signal evaluating circuit 107 for evaluating the object position signal. Shift registers 76-80 carry out the 2-bit parallel-in-serial-out operation and take in the data from the inputs D1 and D2 and transmit the data from an output Q by the clock input when a P input is high level. 2-input AND gates 81-85 have one input connected to the signal lines 41-45 and the other input connected to the signal line 75, whereby by the combination of the signals produced in the signal lines 41-45 and 75 parallel input signals to the shift registers 76-80 are formed.
FIG. 12 shows the timing chart of the signals produced in the signal lines 41-45 and 75. By parallel signals the object position signals formed by the light beam from the light emitting elements 1a-1e are stored in the shift registers 76-80. Reference symbols T1-T13 in FIG. 10 identify timing signals delivered from the timing circuit (not shown). FIG. 13 shows the timing chart of a reference clock pulse CP and each timing signal.
AND gates 86-90 deliver the object position signals stored in the shift registers 76-80 in sequence via an OR gate 91 when the level of the timing signals T1-T5 becomes high, respectively. 2-bit shift registers 93 and 95 take in the clock input from the D input based on the clock input, whereby 2-bit outputs Q1 and Q2 are respectively connected to a digital comparator 97. The digital comparator 97 compares the data from the shift register 93 with that from the shift register 93 is greater than data A from the shift register 95 in such a manner that when data B from the shift register 95 the level at terminal A<B becomes high.
A D type Flip Flop 99 stores the A<B output of the digital comparator 97. Reference numerals 101 and 103 identify AND gates and 105 an OR gate, constituting a select gate for the D input of the shift register 95. When the level of the Q output of the Flip Flop 99 is high, the data transmitted from the shift register 93 is put in the shift register 95, while the level of a Q output is high the data in the shift register 95 is put in again. Furthermore, all the shift registers 76-80, 93, 95 and the flip flop 99 are reset by a power-up clear circuit (not shown) when measurement is started. With the above construction, the data input from the shift registers 76-80 in sequence to the shift register 93 is compared with the data of the shift register 95 in such a manner that only when the data of the shift register 93 is greater than the data of the shift register 93 is it transferred to the shift register 95. Otherwise the data of the shift register 95 is held. Consequently, at the termination of the timing chart in FIG. 13, the greatest amount of data from the object position signals stored in the shift registers 76-80 is stored in the shift register 95. As is clear from the relation in FIG. 9, the greatest amount of data corresponds to the signal for the shortest distance from the object position data delivered corresponding to the focus targets 6a-6e.
Furthermore, in the present embodiment, after termination of the distance measuring operation for individual focus targets 6a-6e, focusing of the photographic lens is adjusted based upon the object position data stored in the shift register 95.
FIG. 11 shows a control circuit 109. D type Flip Flops 111-116 constitute a shift register 140. A NOR gate 117 is delivered with the Q output of the Flip Flops 111-116, wherein the level of the Q output of each of the Flip Flops 111-116 is low, the level of the D input of the Flip Flop 111 is high. Reference numeral 119 identifies a counter whose clock input is the reference clock CP, and reference numeral 121 identifies an AND gate whose inputs are the Q output of the Flip Flop 116 and the Q4 outputs of the counter 119, whereby the AND gate 121 delivers the Q4 output of the counter 119 as the clock of the shift register 140, as long as the level of the Q output of the Flip Flop 116 is high. Reference numeral 123 identifies an AND gate whose inputs are the Q2 and Q3 outputs of the counter 119 and the Q4 output inverted by an inverter 125, whereby the output of the AND gate 123 is connected to the signal line 75.
A switch 131 for changing the distance measuring range, is operatively associated with the change of the focal length of a photographic lens L so as to be closed when the photographic lens L is at the side of the short focal length and to be opened when the lens L is at the side of the long focal length. Reference numeral 132 identifies an inverter whose output is at a low level when the switch 131 is opened because the input is pulled up via a resistor 133 connected to the power source Vcc and whose output is at a high level when the switch 131 is closed because the input is earthed. AND gates 134 and 135 are respectively input with the Q output of the Flip Flops 111 and 115 and when the output of the inverter 132 is low, whereby when the switch 131 is opened, the level of the AND getes 134 and 135 are low because of the output level of the inverter 132, while when the switch 131 is closed, the AND gates 134 and 135 allow the passage of the Q outputs of the Flip Flops 111 and 115 because the output of the inverter 132 is high. The output of the AND gate 134 is connected to the signal line 41, the Q output of the Flip Flop 112 to the signal line 42, the Q output of the Flip Flop 113 to the signal line 43, the Q output of the Flip Flop 114 to the signal line 44 and the output of the AND gate 135 to the signal line 45.
When the distance measuring operation is started, the counter 119 and the Flip Flops 111-116 are reset by the power-up clear circuit (not shown) and the Q outputs of the Flip Flops 111-116 are all at low levels so that at this time the output of the NOR gate 117 is at a high level. Furthermore, at this time the Q output of the Flip Flop 116 is at a high level so that the Q4 output of the counter 119 is delivered as clock to the shift register 140 via the AND gate 121.
Now, suppose that the switch 131 is closed, namely, the photographic lens L is set at a short focal length. When the first clock is given to the shift register 140, the Q output of the Flip Flop 111 becomes high level so that the level of the signal line 41 becomes high, the light emitting element 1a flickers and the distance measuring operation for the focus target 6a in FIG. 1 starts. Furthermore, the Q output of the Flip Flop 111 becomes high, when the output of the NOR gate 117 becomes low. Then when the clock is input, the Q output of the Flip Flop 111 is low level, while the Q output of the Flip Flop 112 becomes high level so that the signal line 41 becomes low level, while the signal line 42 becomes high level so that the light emitting element 1b flickers and the object of the distance measuring operation is changed from the focus target 6a to the focus target 6b. In the same way the light emitting element 1c, 1d and 1e flicker. After that, when the 6th clock is input and the Q output of the Flip FLop 116 becomes high level, the Q output thereof also becomes low level so that the output of the AND gate 121 also becomes low level and the input of the clock to the shift register 140 is prohibited. Furthermore, at this time the signal lines 41-46 are all at low levels so that the light emitting elements 1a-1e are all put out. FIG. 12 shows the relation between the outputs of the signal lines 41-46 and 75 and the output of the counter 119. When the switch 131 is opened, namely the photographic lens L is set at the side of the long focal length, the signal lines 41 and 45 remain at low levels so that the light emitting elements 1a and 1e do not flicker and the disance measuring operation for the focus targets 6a and 6e are prohibited. Namely, in this case only the focus targets 6b, 6c and 6d inside the photographic range 5b at the side of the long focal length are selected. In this case, the AND gates 81 and 85 to which the signal lines 41 and 45 in FIG. 10 remain at low level so that the shift registers 76 and 80 remain reset by the power up clear circuit. Namely, in this case, the shift registers 76 and 80 keep holding the data (0, 0) for the position D1 of the most distant object, so that no influence is given to the operation of the signal evealuating circuit 107 giving priority to the short distance data. Other operations are the same as in the case of the short focal length so that the explanations are omitted.
The distance measureing system of the automatic focusing camera to which the present invention is applied is not limited to the above embodiment, and it goes without saying that even if the number of the light emitting is only one any camera having a distance measuring system so designed that a plurality of focus targets can be set, for example, a distance measuring system so designed that the projection direction can be changed by moving the light emitting element or the projection lens will do. Further, even if only one focus target can be set, the present invention can be applied to the distance measuring system by making the range of the focus target large or small according to the focal length of the photographic lens.
Further, the signal evaluation circuit which converts respective distance signals obtained for a plurality of focus targets into the most suitable distance measurement information is not always limited to the above embodiment. A proper method can be taken, for example, by using the mean signal of the above respective distance information as the distance information.
As mentioned above in detail, according to the present invention, in the case of the automatic focusing camera in which, by setting a plurality of focus targets, a wide range of the photographic picture plane is made as the distance measurement object, irrespective of the change in the photographic picture angle due to the change of the focal length of the photographic lens, the photographic picture plane can be made to coincide with the distance measuring range, so that the danger that the photographic lens would be focused at a wrong distance by the unnecessary distance measuring operation for the object outside of the photographic picture plane can completely be avoided, while the wasteful current consumption is avoided.
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Disclosed is an automatic focusing camera capable of measuring a wide range of distances by setting a plurality of focus targets in the photographic picture plane, so designed that when the photographic picture angle changes due to changes in the focal length of the photographic lens the distance is measured by focus targets whose numbers corresponds to the photographic picture angles, to avoid mismeasurement of the distance.
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BACKGROUND OF THE INVENTION
This invention relates to a lead bearing an electrode for connecting a living organ to an electrical device. Notwithstanding its various uses, this invention will be described as an endocardial pacing and sensing lead for connecting a pacemaker to cardiac tissue.
There are generally two types of body-implantable leads--one which requires surgery to expose that portion of the body to which the electrode is to be affixed and the other which is inserted in and guided to the desired location through a body vessel such as a vein. In the cardiovascular field, in particular, there are myocardial and endocardial type leads. Use of a standard myocardial lead such as that disclosed in U.S. Pat. No. 3,216,424, generally provides an excellent electrical contact but requires a thoracotomy in order to affix the electrodes in the outer wall of the heart. This type of surgery is quite strenuous on the patient, particularly an elderly one. Even the improved myocardial leads, e.g., the type disclosed in U.S. Pat. Nos. 3,416,534, 3,472,234 and 3,737,579, require a minor transthoracic surgery to obtain access to the myocardium in order to screw the electrode in place in heart tissue with a special tool or surgical instrument.
Use of a standard endocardial lead of the type shown in U.S. Pat. No. 3,348,548, for example, does not involve serious surgery since the lead is inserted in and guided through a selected vein. However, endocardial leads currently in use are difficult to place and to maintain in proper position and do not insure the best electrical contact since the electrode merely rests against the inner wall of the heart or endocardium at or near the apex of the right ventricle. As a result, the electrodes of such prior art leads tend to become dislodged from their proper position, often resulting in loss of heart capture and thus loss of stimulation of the patient's heart. Also, since the electrodes of an endocardial lead are not secured in the cardiac tissue, the lead tends to move with each contraction of the heart muscle, thereby forming an undesirable callous or fibrotic growth on the inner wall of the right ventricle. Another problem is that with the contraction of the heart, the tip or distal electrode may occasionally puncture the heart wall, resulting in serious injury to the heart and a loss of heart capture.
Many attempts have been made to develop an endocardial lead that can be simply and reliably secured for chronic pacing through endocardial tissue. Typical of such lead designs are those disclosed in U.S. Pat. Nos. 3,754,555 and 3,814,104 which involve a mechanism carried within the lead for advancing prongs or hooks from recesses in the distal end of the lead into endocardial tissue after the lead has been transvenously advanced and positioned within the heart. A further variation on this approach involves the use of a hollow sleeve or introducer catheter of the same length as the lead to shroud the electrode while it is advanced transvenously into the desired position in the heart, whereupon the electrode is advanced from the sleeve or catheter introducer into endocardial tissue. Typical of these latter designs are those disclosed in U.S. Pat. No. 3,844,292 and in the article entitled "New Pacemaker Electrodes" by Max Schaldock appearing in Vol. 17 Transactions: American Society for Artificial Internal Organs, 1971, pp. 29-35.
These prior art endocardial lead designs have not been completely successful in achieving the objects of reliable chronic securement in the endocardial tissue. The prongs or hooks of the former type at times fail to remain in place, or become caught in trabecular cardiac tissue and the electrode remains displaced from and in poor electrical contact with the endocardium. The catheters or sleeves of the latter type add undesirable bulk to the lead as it is advanced through the vein and its increased stiffness makes positioning the electrode tip in the desired location in the heart difficult. In both instances, the complexity of such leads reduces their statistical reliability while raising their cost. If the implanting surgeon should erroneously advance the prongs or hooks from their recesses in the electrode tips or if the same occurs through a malfunction of the lead during advancement of the lead through the veins and heart valves, serious injury could occur as the prongs or hooks snag the valves or the tissue lining the veins.
The body-implantable lead of the present invention combines all the advantages of both the myocardial and endocardial leads with none of the attendant disadvantages of each of these leads as currently found in the prior art. One of the features of the present invention is the provision of a body-implantable intravascular lead which can be lodged in and permanently secured to or removed from the body tissue which it is desired to stimulate, without the use of complex electrode advancement mechanisms or bulky sleeves or catheter introducers. Another feature of the invention is that the body of the lead exclusive of the novel electrode comprises a reliable design that enjoys demonstrated reliability in chronic use and is easily placed in the heart according to well known and proven techniques.
SUMMARY OF THE INVENTION
The above features and advantages of the present invention, as well as others, are accomplished by providing a body-implantable, intravascular lead comprising electrically conductive lead means adapted to be connected at one end to a source of electrical energy and electrode means affixed to the opposite end of the lead means and adapted to be firmly lodged in and permanently secured to or removed from tissue inside the body at a desired location. The lead means and the portion of the electrode means affixed to the lead means are sealed from living animal body fluids and tissue by a material substantially inert to body fluids and tissue. Sleeve means are provided for permitting the lead means and electrode means to be inserted into and guided through a body vessel to a desired location and position inside the body without causing injury to the body vessel and for permitting the electrode means to be firmly lodged in and permanently secured to body tissue at the desired location through the retraction of the sleeve means.
Preferably, the electrode means comprises a rigid helix or corkscrew of a suitable electrode material, and the sleeve means comprises a tube of suitable resilient material affixed to the distal end of the lead means and surrounding and extending beyond the tip of the helix, the tube having a plurality of circumferential pleats which enable it to collapse upon itself as the electrode is screwed into body tissue. Other features, advantages and objects of the present invention will hereinafter become more fully apparent from the following description of the drawings, which illustrate a preferred embodiment.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a view of a preferred embodiment of the body-implantable, intravascular lead of the present invention including in part an inside elevation partly in longitudinal section of the electrode end portion of the lead; and
FIG. 2 shows the lead of FIG. 1 being lodged in and permanently secured to the tissue forming the apex of the right ventricle of the heart.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to the preferred embodiment of the invention depicted in FIG. 1, there is shown an intravascular endocardial lead comprising an elongated lead portion 10, a distal electrode end portion 12 and a proximal terminal end portion 13. The lead, in bipolar configuration, comprises a pair of closely wound, coiled conductors 14, 15 each in the form of a spring spirally wound about and along the axis of the conductor. The spring coils 14, 15 extend through the length of the lead 10 in separate lumens of a jacket or sleeve 16 of electrically insulating material.
Each spiral conductor 14, 15 is formed of electrically conductive material offering low electrical resistance and also resistant to corrosion by body fluids. A platinum-iridium alloy is an example of a suitable material. Sleeve 16 is formed of an electrically insulating material, and preferably a silicone rubber such as clean room grade Silastic available from Dow Corning Corporation. This material is additionally suitable because it is inert and well tolerated by body tissue.
At the proximal end 13 of the lead 10, the conductors 14 and 15 are received in and crimped to tubular terminal pins 17 and 18, respectively. A bifurcated boot 19 of the same material as jacket 16 is molded about the terminal pins 17, 18 and the terminal ends of coils 14 and 15 and jacket 16, with the pins 17 and 18 projecting therebeyond. These pins are adapted for insertion in receptacles provided on the pulse generator, which can comprise any suitable implantable pulse generator such as that shown for example in U.S. Pat. No. 3,057,356.
Each of the pins 17, 18 and the respective spiral conductors 14 and 15 is hollow and is thereby adapted to receive a stiffening stylet 20 that extends through the length of the lead 10. The stylet 20 stiffens the lead 10. Its distal end, at the distal end 12 of the lead 10, is bent slightly, while its proximal end, adjacent the proximal end 6 of the lead, is formed to provide means, such as the loop 21, for rotating the stylet about its axis to thereby direct the distal end 12 of the lead as it is inserted through the vein. The stylet imparts rigidity to the proximal portion of the leads and can be manipulated to introduce the appropriate curvature to the distal, electrode end portion facilitating the insertion of the lead into and through a vein, for example one of the jugular veins, to advance the distal end 12 of the lead into the right ventricle of the heart.
At the distal end of the lead 10, a pair of electrodes 22 and 23 are welded or otherwise electrically connected to the ends of the conductors 14 and 15, respectively. The electrode 23 preferably takes the form of a ring of corrosive resistent, electrically conductive material, e.g., platinum or a platinum alloy, a metal oxide or a carbon compound. The ring electrode 23 encircles both coiled conductors 14 and 15. Electrode 22 is similarly electrically connected to the distal end of coiled conductor 14, and the length of coiled conductor 14 extending between electrodes 22 and 23 is insulated by a jacket 24 of the same material as the sleeve 16 molded thereto. In this way, the entire lead is electrically insulated when it is connected to the pulse generator from the body except at the electrodes 22 and 23.
The lead 10 of FIGS. 1 and 2 as described hereintofore corresponds to that disclosed in U.S. Pat. No. 3,348,548. The lead 10 thus far described has been shown to be capable of withstanding constant, rapidly repeated flexing over a period of time which can be measured in years. The conductor coils are wound relatively tightly, although there can be a slight space between adjacent turns. This closely coiled construction provides a maximum number of conductor turns per unit length, thereby providing optimum strain distribution. The spirally coiled spring construction of the conductors also permits a substantial degree of elongation, within the elastic limits of the material, as well as distribution along the conductor of flexing stresses which otherwise might be concentrated at a particular point. Both the conductors 14 and 15, and the insulating bodies 16, 19 and 24 are elastic, and this, together with the coiled construction of the conductors, assures maximum distribution of flexing strains.
Turning now to the improvement of the present invention, it comprises the electrode 22 which further comprises tissue piercing and retaining means and an integral introducer sleeve means for protecting intravascular body vessels from damage by the tissue piercing means during insertion and guidance of the lead that on its own accord retracts from the tissue piercing and retaining means as the same are advanced into and/or through endothelial tissue. More specifically, the electrically conductive electrode 22 is formed in the practice of this invention in the shape of a circular corkscrew or helix 25 having about 5 turns extending about 1/4 inch in length and having a nominal outside diameter approximating that of the insulated body of the lead 10, e.g., about 3.2 mm. The corkscrew 25 may be insulated by a thin nonconductive material except for its tip or one or more turns or a portion thereof, so that stimulation current density may be increased in proportion to the conductive electrode area. The helix 25 is welded or otherwise electrically connected to a terminal junction 27 of the conductor 14. Preferably, the helix 25 has a sharpened tip 26 for piercing endocardial tissue and a sufficient number of turns so that as the lead 10 and electrode 22 is rotated by rotation of the proximal terminal end portion 13, the helix 25 may advance through the endocardial tissue into myocardial tissue and be retained therein and inhibited from dislodgement therefrom by the turns of the helix 25.
An introducer sleeve or shroud 28 is fitted over the turns and tip 26 of the helix 25 and sealed to the jacket 24 about the junction 27. The introducer sleeve 28 is made entirely of a silicone rubber compound or other suitable material in a configuration of a thin-walled, accordian-like pleated tube having a number of pleats at least equal to and accommodating the turns of the corkscrew electrode 25. When relaxed, as shown in FIG. 1, the pleats are extended and form 90° angles with respect to one another. The sleeve 28 in its relaxed state is about 0.3 inches in length, has an outside maximum pleat diameter of about 0.16 inches and a wall thickness of about 0.01 inches.
The introducer sleeve 28 is designed to afford protection to the body vessel or vein through which the lead is introduced and to the endothelial tissue of a body organ until the desired implantation position is reached. In the cardiac pacemaker application, once the lead is in the ventricle and is ready to be secured in the desired position of the endocardium, the accordian-like pleats of the sleeve 28 will collapse and fold back over the turns of the helix 25 as it is screwed into the endocardium.
Turning now to FIG. 2, there is shown an illustration of the partially introduced lead 10 of the present invention in a vein (position A) and the completed introduction and permanent securement of the electrode 23 in the tissue forming the apex of the right ventricle of a heart (position B).
In FIG. 2, the heart 30 in cross-section comprises the four chambers, namely, the right ventricle 31, the right atrium 32, the left atrium 33 and the left ventricle 34. In the placement of an endocardial lead, it is preferable to use a venous approach on the low pressure side of the heart, that is, through a vein, e.g., the right or left external jugular veins or the right or left cephalic veins 35, the superior vena cava 36, the right atrium 32, the tricuspid valve 37 and the right ventricle 31. During introduction of the lead 10, it must travel a convoluted course through the veins and must pass through the valve 37 without causing any damage to the tissue. It is also desirable that the lead 10 have a small cross-section so that it will easily pass through the veins without causing excessive stretching of the veins.
In position A of FIG. 2, the distal end 12 of the lead 10 is shown in part. As it is advanced, the sharp tip of the helix 25 is shrouded by the sleeve 28, so that it cannot snag the lining of the veins and the valve 37. Likewise, if the lead 10 is withdrawn, the tip of the electrode 25 is still shrouded and will not injure the intravascular tissue.
In position B, the lead 10' is illustrated screwed into the endocardium at the apex of the right ventricle 31. The corkscrew electrode 25' is fully screwed in by rotation of the entire lead by manipulation of the proximal end 13 (not shown in FIG. 2) of the lead 10'. As it is pressed against the endocardium during the rotation of the lead 10', the sleeve 28' progressively collapses back in its pleats, and the turns of the helix 25' slip past the open end of the sleeve 28' and turn into the cardiac tissue.
In clinically testing the operation of the lead 10 of the present invention, it has been found that the corkscrew or helix 25 can be easily and repeatedly introduced through the vein, through the valve and screwed into the endocardium, unscrewed and withdrawn from the body through the same path without causing any significant damage to the tissue that the lead contacts. As the lead is unscrewed, the pleats of the sleeve 28 expand and the sleeve slips back over the turns of the corkscrew electrode 22. The ease of using the lead of the present invention and the positive securement afforded by a corkscrew or helical electrode design make it readily superior to any of the prior endocardial lead designs.
Although a bipolar lead design has been illustrated in the description of the preferred embodiment, it will be understood that unipolar leads (that is a lead carrying but one electrode and conductor) may as readily employ the novel electrode design of the present invention. Also, it should be understood that other electrode designs or positions along the lead could be substituted for that of the electrode 23. It should be understood that although the use of the lead 10 has been described for use in a cardiac pacing system, lead 10 could as well be applied to other types of body stimulating systems.
It should be further understood, of course, that the foregoing disclosure relates only to the best mode known to the inventor of many possible modes of practicing the invention and that numerous modifications may be made therein without departing from the spirit and scope of the invention as set forth in the appended claims.
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A body-implantable, intravascular lead affixed with a pin or pins at its proximal end adapted to be connected to pulse generator and with an electrode or electrodes at its distal end adapted to be securely and permanently attached to a body organ through endothelial tissue. An electrode in the form of a rigid, electrically conductive helix with a sharp tip at the distal end of the lead is adapted to be screwed through endothelial tissue into the body organ. To allow the insertion and guidance of the lead through a body vessel without snagging the body vessel, the lead carries a sleeve shrouding the helix during introduction of the lead that retracts as the corkscrew electrode is screwed into the organ and re-expands to cover the helix in the event that the helix is unscrewed and withdrawn.
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BACKGROUND OF THE INVENTION
In the manufacture of paper, it is customary to dry paper to a relatively low moisture content in order to achieve a uniform CD (cross direction) moisture profile. This is true despite the fact that it is known that paper having a relatively high moisture content will fold better, finish easier and give less trouble from curling than paper of lower moisture content. Moreover, printing paper having a high initial moisture content, when conditioned at normal press room humidity, comes to equilibrium by loss of moisture (with a desirably higher moisture content) than paper of lower moisture content which comes to equilibrium by absorption of moisture. However, in order to overcome moisture profile problems originating at the wet end, press section and drier sections of a papermachine, it is common practice to dry the rawstock to a relatively low moisture content. Thus, as regards the paper industry, the controlled and uniform application of moisture to rawstock and/or coated webs is a goal of great interest, and by the present invention, such a goal has been achieved.
Several methods have been proposed in the prior art for applying moisture to a moving sheet or web. Examples of these include roll applicators such as the Dahlgren-type systems, electrostatic spray systems, steam shower devices and water doctor systems particularly as disclosed in the following prior U.S. Pat. Nos.: 3,379,170, 3,776,471, 3,873,025, 3,467,541, 3,735,929, 3,922,129, 3,625,743, 3,782,330.
In general, however, the methods disclosed in the above noted patents involve the use of expensive, complicated and unreliable equipment without any means for achieving a uniform CD moisture profile and/or for the controlled application of small quantities of moisture.
Other examples for adding moisture to a web include, a method and apparatus for applying steam to and condensing moisture on a web that is backed by a heat conducting body as disclosed in U.S. Pat. No. 2,370,811, and a device similar to that disclosed herein that directs a humid atmosphere toward the web, as disclosed in U.S. Pat. No. 3,238,635. However, a careful review of the latter mentioned patents will show that in one case, condensation of steam vapor on the web is produced because the web is backed by a heat sink or metal roll through which a cooling fluid is passed. Meanwhile, in the other patent, where the humid atmosphere directed toward the web is derived from steam, the final mixture applied to the web is so complete that the steam loses all identity as such in the humid atmosphere, and, the emitted premixture is not impelled or jetted adjacent to the web.
In contrast to the methods and apparatus disclosed in the above noted prior art, applicants' invention utilizes a method whereby steam in a substantially dry state is emitted under pressure and at a velocity greater than that of a traveling web into the region between a web and a steamfoil nozzle device. The emitted steam produces a low pressure region between the traveling web and the steamfoil and disrupts the boundary layer air associated with the traveling web to permit intimate contact of the steam with the web. When the steam mixes with the boundary layer air associated with the traveling web, condensation in and on the web occurs to add moisture to the web.
In this respect, applicants' invention relies on principles previously disclosed in connection with the use of airfoil type web drying systems for use in drying paper webs. The latter principles are fully disclosed in the following prior U.S. Pat. Nos. and publications: 3,587,177, 3,711,960, 3,650,043, 3,629,952
TAPPI, April 1973, Vol. 56, No. 4, pp. 86-89
TAPPI, June 1974, Vol. 57, No. 6, pp. 105-107
TAPPI, April 1976, Vol. 59, No. 4, pp. 92-96
Accordingly, it may be seen from the above noted disclosures that although the general operating principles behind applicants' invention have been previously proven, applicants are the first to utilize those principles with the application of steam to a web to add moisture to the web.
SUMMARY OF INVENTION
In general, the present invention is directed to a method and apparatus for adding moisture to a traveling web of paper or the like. More specifically, the present invention utilizes substantially dry steam to add moisture to a traveling web when the web is passed over a steamfoil nozzle device and steam is emitted under pressure and at a high temperature and velocity from the slot portion of the steamfoil into the region between the web and steamfoil wherein the steam mixes with the boundary layer air associated with the traveling web and condensation in and on the web occurs. The emitted steam at high velocity disrupts the boundary layer surrounding the traveling web to produce an intimate contact of the steam with the relatively cooler web. With the web in close proximity to the steamfoil, the reduction in pressure produced by the high velocity steam flow draws the web toward the steamfoil. However, the web becomes stabilized near the steamfoil when a dynamic balance is established to position the traveling web near but not touching the steamfoil. The gap or space between the traveling web and the steamfoil depends primarily upon the draw length, web tension, and steam flow rate. When the steam mixes with the boundary layer air associated with the traveling web, condensation in and on the web occurs to add moisture to the web. Thus it may be seen that the steamfoil device of the present invention with its high velocity steam flow effectively provides several desirable results including, (1) a disruption of the boundary layer air associated with the traveling web to produce an intimate contact between the steam flow and the web, (2) an enhanced and uniform moisture pick-up by the web, and (3) a dynamically balanced condition in the region of the steamfoil which stabilizes the web thus obviating the undesirable web fluttering and non-uniform moisture addition that occurs when steam nozzles are placed normal to a web. For a typical production installation, the steam velocity rate at the slot of the steamfoil should be greater than the web velocity and the pressure in the steamfoil should be above atmospheric pressure. Experience has shown that a steam pressure of at least about 0.1 inch of water is required for practical operation. Since the steam is introduced at a pressure above atmospheric pressure, and the steam flow velocity is maintained at a level greater than web speed, the present method produces substantially the same results notwithstanding the direction of web travel, i.e., counter to, or in the same direction as the emitted steam flow direction.
DESCRIPTION OF DRAWING
FIG. 1 of drawing illustrates schematically a typical installation of an airfoil nozzle device for use in adding moisture to a web of paper or the like; and,
FIG. 2 shows an enlarged sectional view of a typical airfoil nozzle device.
DETAILED DESCRIPTION
Referring to the drawing, it may be seen that the steamfoil nozzle devices 10 are typically located between an unwind stand 11 and a rewind stand 12 so as to direct the steam flow either counter to or in the same direction as the web travel. The web may pass over one or more turning rolls 13,14 prior to the steamfoil for conditioning a web before calendering, or the steamfoil may be located after a typical calender stack designated by the rolls 15,16. It should be understood, however, that many other locations on or off the papermachine may be chosen for the steamfoil device or devices depending upon the end results required and the type of web being conditioned. Moreover, where two or more steamfoil nozzle devices are employed, the units may be located together on one side of the web, or on each side of the web substantially as utilized in the airfoil type web drying systems disclosed in the prior art.
FIG. 2 shows in some detail a typical steamfoil nozzle device suitable for the present invention. Basically, the steamfoil device 10 consists of an integral plenum chamber 17 that extends across the web from side-to-side with a steam inlet 18. It is understood that the connections to the plenum chamber also include suitable condensate separators, drains, pressure and temperature measuring devices and steam flow control valves (not shown). The steamfoil nozzle device 10 also includes at the top portion thereof an integral steam emitting slot 19 and a foil member 20. The slot portion 19 and foil portion 20 provide a restricted opening for discharge of steam vapor under pressure into the region defined by the foil member 20 and the web. It should be understood, however, that the foil member 20 may be a separate member or provided as an extension of the plenum chamber 17 as desired. The only requirement for the system is that the slot 19 and foil 20 should be located in close proximity to one another to provide the results mentioned hereinbefore. As will be noted from the aforementioned prior art, the top of the plenum 17 could readily serve as the foil member.
The effectiveness of the preferred embodiment of the present invention will be demonstrated by considering the following Examples.
EXAMPLE I
Two paper samples in web form (a 38 lb/ream Marva Web Gloss rawstock and an 80 lb/ream Sterling Litho Gloss machine finished coated paper, both products of Westvaco Corporation ream size 500 sheets measuring 25×38 inches) were treated with steam from a modified airfoil nozzle device manufactured by TEC Systems, Inc. De Pere, Wisconsin. The modifications to the airfoil device consisted of those required to convert it for use with steam. The direction of web travel was the same as the direction of the emitted steam flow and the web traveled approximately 13 inches before being rewound in order to minimize evaporation of the applied moisture. The gap between the web and steamfoil was maintained at approximately 1/8 inch with the results shown in Table I.
TABLE I______________________________________Effect of Web Temperature and Speed on MoisturePickup Gap - 1/8 inch Between Web and SteamfoilWeb Steam Web Web MoistureTemp. Press Speed Moisture Pickup(° F.) (inches H.sub.2 O) (fpm) (%) (%)______________________________________(38 lb. Marva Web Rawstock) 80 Control -- 3.6 -- 80 1.0 1000 5.8 2.2 80 1.0 1500 5.35 1.75 80 3.0 500 6.5 2.9 80 3.0 1000 6.2 2.6 80 3.0 1500 5.7 2.1160 Control -- 2.0 --160 3.0 1000 3.75 1.75160 3.0 1500 3.20 1.2160 3.0 500 3.95 1.95160 1.0 1000 3.40 1.40160 1.0 1500 3.15 1.15(80 lb. Sterling Litho) 80 Control -- 3.60 -- 80 2.25 500 5.25 1.65 80 2.25 1000 4.40 0.80 80 2.25 1500 4.0 0.40170 Control -- 1.20 --170 2.25 500 1.88 0.68170 2.25 1000 1.50 0.30170 2.25 1500 1.40 0.20______________________________________
Based on the results obtained in Example I, several variables were found to affect moisture pickup including steam pressure in the steamfoil device, web temperature and web speed. For a web temperature of 80° F. (measured prior to steamfoil device), a web speed of 1500 fpm and a steam pressure of 3 inches of H 2 O, the moisture content of the web was increased from an initial level of 3.6% to 5.7% with the Marva Web Gloss rawstock, representing a gain of approximately 0.79 lb/ream. When the web temperature was increased to 160° F., all other conditions remaining the same, moisture pickup was reduced to about 1.2%. A reduction in steam pressure from 3 inches to 1 inch of H 2 O (steam flow rate reduced from about 165 ft/sec. to about 95 ft/sec) produced a reduction in moisture pickup of approximately 20%. Similarly, the moisture pickup dropped as the web speed was increased. However, a reduction in moisture pickup with the hotter web would be consistent with both the smaller energy sink provided by the web and the reduced driving force for steam condensation.
Since two possible mechanisms are deemed possible for moisture transfer to the web with the present invention, namely, (1) condensation of steam in and on the web caused by contact of the steam with the cooler web, and (2) impingement on the web of water droplets, i.e., the partial condensation of the steam into water droplets as a result of the mixing of the steam with the boundary layer air in the region between the web and steamfoil, the temperature of the incoming web plays a major role in determining the moisture pickup. For instance, the maximum possible moisture transfer by condensation (assuming an excess supply of steam) is limited by the initial temperature of the web. Also, since the web is heated by the steam condensing on its surface, as the web temperature increases, the driving forces for condensation decrease. Obviously, no further net condensation on or in the web would be expected to occur once the web reached 212° F.
EXAMPLE II
A second sample of the 50 lb/ream Marva Web Gloss rawstock was treated with the steamfoil nozzle device as described in Example I to study the effect of varying the gap between the web and airfoil. The results obtained are shown in Table II.
TABLE II______________________________________Effect of Gap on Moisture PickupWeb Speed: 1000 fpmWeb Temperature: 80° F.Gap Steam MoistureDimension Pressure Pickup(inches) (inches H.sub.2 O) (%)______________________________________1/8 1.0 2.481/8 1.0 2.201/4 1.0 1.621/4 1.0 1.801/2 1.0 1.01/2 1.0 1.101 1.0 0.631 1.0 0.602 1.0 0.342 1.0 0.351/8 3.0 3.001/4 3.0 2.501/2 3.0 2.00______________________________________
As can be seen from the results in Table II, the level of moisture picked up by the web decreased as the foil-to-web gap was increased. Other observations noted were that the amount of steam condensed in the region between the web and steamfoil was affected by the quantity of ambient air or boundary layer air carried into the gap by the traveling web, and that the process produced an overall efficiency of from about 5-15%.
EXAMPLE III
A 60 lb./ream machine finished coated paper (Velco Web Gloss paper, a product of Westvaco Corporation) was treated with the steamfoil substantially as disclosed in the prior two Examples. The steamfoil was arranged to emit the steam flow in a direction opposite to the direction of web travel and the gap between the web and steamfoil was allowed to be determined naturally by the steam flow which attracted the web toward the foil. The observed gap was about 1/8 inch. After passing over the steamfoil, the web traveled approximately 16 feet to a rewind stand at a web speed of 2000 fpm taking about 1/2 second. Steam pressure in the steamfoil was varied from 0.5 to 5 inches of water and produced moisture pickups as shown in Table III.
TABLE III______________________________________Moisture Pickup vs. Steam PressureWeb Speed: 2000 fpmWeb Steam Web MoistureTemp. Pressure Moisture Pickup(° F.) (inches H.sub.2 O) (%) (%)______________________________________130 Control 3.48 --130 0.5 4.00 0.52130 1.0 4.33 0.85130 2.0 4.35 0.87130 5.0 4.62 1.14130 Control 3.56 --130 3.0 4.40 0.84130 4.0 4.46 0.90______________________________________
From the results shown in Table III, it can be seen that the moisture pickups tended to increase with increasing steam pressure at constant web speed. The moisture application was uniform and free of droplets. The effect of the mixing of the boundary layer air with the steam flow was quite visible with the steam/air mixture ranging from several feet ahead of the steamfoil to about 1 to 2 feet behind the steamfoil.
EXAMPLE IV
A 50 lb/ream machine finished coated paper (Field Web Offset paper manufactured by Westvaco Corporation) was treated with the steamfoil device described hereinbefore prior to passing the paper through a supercalender. The objective of the experiment was to determine the limits of moisture application suitable for improving the finishing characteristics of the paper without producing picking. Web temperature was maintained at about 80° F. and the gap between the web and foil at about 1/2 inch. The steamfoil was located approximately 10 inches prior to entering the nip of a single nip cotton/steel supercalender apparatus operating at 400 pli. Steam flow was directed opposite to the direction of web travel, and the results are set forth in Table IV.
TABLE IV______________________________________SteamPress Calender Web Moisture(inches Speed Moisture Pickup VisualH.sub.2 O (fpm) (%) (%) Observations______________________________________Control -- 3.20 -- no picking0.1 400 4.00 0.80 no picking0.1 1500 3.85 0.65 no picking0.5 400 5.18 1.98 picking1.0 400 5.40 2.20 picking2.0 400 5.85 2.65 picking______________________________________
From the results set forth in Table IV it may be seen that only the smallest moisture pickups produced a condition where there was no picking on the steel roll. Thus, as the moisture pickup by the web increased, the coated web began to leave deposits of coating on the surface of the steel roll. However, the experiment demonstrated that low levels of moisture could be applied uniformly to a web and produce improvements in the finishing characteristics of the paper.
Thus is may be seen that the method and apparatus of the present invention provides a satisfactory process for adding moisture to coated and uncoated webs of paper which is uniform and controllable. It will be understood, however, that the present invention could provide equally good results for webs of other material which require an increased moisture content. Moreover, it will be understood that the present invention is subject to modifications and changes to the preferred embodiment fully disclosed which do not depart from the spirit and scope of the appended claims.
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Moisture is added to a traveling web of paper or the like by passing the web over one or more steamfoil nozzle devices which emit substantially dry steam vapor into the region between the web and the steamfoil. The steamfoil nozzle or nozzles extend across the web from side-to-side and the velocity of the emitted steam vapor is such that it produces a pressure differential between the side of the web adjacent the steamfoil and the opposite side of the web so that the web is urged toward the steamfoil where it rides on a cushion provided by the steam vapor and the boundary layer air surrounding the web. The steam vapor condenses on and in the relatively cool web when the web is passed over the steamfoil and the substantially dry steam vapor is mixed with the boundary layer air associated with the web. The steam flow disrupts the boundary layer air to permit intimate contact of the steam with the web to add moisture to the web.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a divisional of application Ser. No. 11/348,909, filed Feb. 7, 2006 U.S. Pat. No. 7,527,104, entitled “Selectively Activated Float Equipment,” which issued May 5, 2009, the entirety of which is incorporated herein by reference.
BACKGROUND
The present invention relates generally to fluid control valves for production well equipment. In particular, this invention relates to back pressure valves for reverse cementing applications.
Production wells typically have valves and valve seats also known as check valves and back pressure valves. These valves are utilized in different applications in various industries including but not limited to the oil and gas industry. Current back pressure valves supply a one direction flow and a negative flow from the other direction. This may be desirable when a controlled flow is important for such purposes as safety well control while placing a casing string and/or tubing in a potentially active well.
Typical valves may be mechanically manipulated to selectively change the direction of flow during operations and then selectively change the flow direction back to an original direction. Valves are usually manipulated between configurations by mechanical movement of the casing/tubing, or placing an inter string inside the casing/tubing string to apply weight on the valve so as to hold the valve in an open configuration. Other mechanisms for manipulating valves include disabling the valve with a pressure activated ball or plug allowing flow to enter the casing/tubing string. But these valves cannot be reactivated, if desired. Other valves are manipulated when the casing bottoms in the rat hole at the bottom of the well bore so that the valve is mechanically held open by the set down weight.
SUMMARY OF THE INVENTION
The present invention relates generally to fluid control valves for production well equipment. In particular, this invention relates to back pressure valves for reverse cementing applications.
More specifically, one embodiment of the present invention is directed to a valve for a well pipe, the valve having the following parts: a valve collar connectable to the well pipe; an index piston coaxially positioned within the valve collar for longitudinal translation within the valve collar between closed, flow-open, and locked-open configurations; a detent in the index piston, wherein the detent restricts fluid flow in a circulation direction through a flow path through the index piston; a spring that biases the index piston toward the closed and locked-open configurations; and a plug of the valve collar that mechanically communicates with the index piston to be in corresponding closed, flow-open, and locked-open configurations.
According to a further aspect of the invention, there is provided a valve for a well pipe, the valve being made up of different components including: a valve collar connectable to the well pipe, wherein the valve collar comprises an indexing lug; an index piston coaxially positioned within the valve collar for longitudinal translation within the valve collar between closed, flow-open, and locked-open configurations, wherein the index piston comprises an index pattern comprising closed, flow-open, and locked-open positions such that when the indexing lug is positioned at the closed, flow-open, and locked-open positions, the index piston is configured in the closed, flow-open, and locked-open configurations, respectively; a detent in the index piston, wherein the detent restricts fluid flow in a circulation direction through a flow path through the index piston; a spring that biases the index piston toward the closed and locked-open configurations; and a plug of the valve collar that mechanically communicates with the index piston to be in corresponding closed, flow-open, and locked-open configurations.
Another aspect of the invention provides a method of regulating fluid circulation through a well casing, the method having the following steps: attaching a valve to the casing; running the valve and casing into the well, wherein the valve is in a closed configuration to maintain relatively higher fluid pressure outside the casing compared to the fluid pressure in the inner diameter of the casing; circulating fluid down the inner diameter of the casing and through the valve to the outside of the casing, wherein the valve is manipulated by the fluid circulation to an open configuration; and ceasing the circulating fluid, wherein the valve is manipulated to a locked-open configuration.
The features and advantages of the present invention will be readily apparent to those skilled in the art upon a reading of the description of the exemplary embodiments, which follows.
BRIEF DESCRIPTION OF THE DRAWINGS
A more complete understanding of the present disclosure and advantages thereof may be acquired by referring to the following description taken in conjunction with the accompanying drawings.
FIG. 1A is a cross-sectional side view of an embodiment of a valve of the present invention, wherein the valve is shown in a closed configuration.
FIG. 1B is a schematic side view of an embodiment of an index pattern and indexing lug, wherein the indexing lug is located in a closed position.
FIG. 2A is a cross-sectional side view of the valve of FIG. 1A , wherein the valve is shown in a flow-open configuration.
FIG. 2B is a schematic side view of the index pattern and indexing lug of FIG. 1B , wherein the indexing lug is located in a flow-open position.
FIG. 3A is a cross-sectional side view of the valve of FIGS. 1A and 2A , wherein the valve is shown in a locked-open configuration.
FIG. 3B is a schematic side view of the index pattern and indexing lug of FIGS. 1B and 2B , wherein the indexing lug is located in a locked-open position.
FIG. 4 is a cross-sectional side view of an embodiment of a valve of the present invention fixed in a casing by a cement attachment.
FIG. 5A is a cross-sectional side view of an embodiment of a valve of the present invention, wherein the valve is shown in a closed configuration.
FIG. 5B is a schematic side view of an embodiment of an index pattern and indexing lug, wherein the indexing lug is located in a closed position.
FIG. 6A is a cross-sectional side view of the valve of FIG. 5A , wherein the valve is shown in a flow-open configuration.
FIG. 6B is a schematic side view of the index pattern and indexing lug of FIG. 5B , wherein the indexing lug is located in a flow-open position.
FIG. 7A is a cross-sectional side view of the valve of FIGS. 5A and 6A , wherein the valve is shown in a locked-open configuration.
FIG. 7B is a schematic side view of the index pattern and indexing lug of FIGS. 5B and 6B , wherein the indexing lug is located in a locked-open position.
DETAILED DESCRIPTION OF THE EMBODIMENTS
The present invention relates generally to fluid control valves for production well equipment. In particular, this invention relates to back pressure valves for reverse cementing applications. The details of the present invention will now be described with reference to the accompanying drawings. This specification discloses various valve embodiments.
Referring to FIGS. 1A , 2 A, and 3 A, cross-sectional side views of a valve 1 are illustrated. The valve 1 has several major components including: a valve collar 10 , a detent in the form of a ball cage 20 , an index piston 30 , an index pattern 40 , a spring 50 , and a poppet plug 60 . FIGS. 2A and 3A also illustrate cross-sectional side views of the valve 1 . In FIG. 1A , the valve 1 is shown in a closed position. In FIG. 2A , the valve 1 is shown in a flow-open position. In FIG. 3A , the valve 1 is shown in a locked-open position. FIGS. 1B , 2 B, and 3 B illustrate schematic side views of the index pattern 40 . In each of these figures, an indexing lug 11 is shown in a different position as described more fully below.
Referring to FIGS. 1A , 2 A, and 3 A, each of the major components of the valve 1 are described. The valve collar 10 is a cylindrical structure that houses the other major components. The valve collar 10 has three sections, including: the indexing section 12 , the mounting section 13 , and the seat section 14 . The mounting section 13 has female threads at its upper and lower ends, wherein male threads of the indexing section 12 are made up to the upper end of the mounting section 13 and male threads of the seat section 14 are made up to the lower end of the mounting section 13 . The indexing section 12 has a shoulder 15 wherein the inside diameter of the indexing section 12 is smaller below the shoulder as compared to above the shoulder 15 . The mounting section 13 has a stem mount 16 that extends from the inside diameter side wall of the mounting section 13 . The stem mount 16 is an arm having an annular eyelet at its distal end for receiving a stem 33 of the index piston 30 . The seat section 14 has a beveled valve seat 18 for receiving the poppet plug 60 .
The ball cage 20 is a somewhat umbrella-shaped structure mounted to the top of the index piston 30 that serves as a ball valve type of detent. The ball cage 20 has a support shaft 21 that extends along the longitudinal central axis of the ball cage 20 . The ball cage 20 also has a cylindrical strainer section 22 that has an outside diameter slightly smaller than the inside diameter of the indexing section 12 of the valve collar 10 . The strainer section 22 is mounted to the support shaft 21 via a top plate 23 . The strainer section 22 has a plurality of side holes 24 that allow fluid communication through the strainer section 22 . The top plate 23 also has a plurality of top holes 25 that also allow fluid communication through the ball cage 20 . The ball cage 20 is connected to the index piston 30 via the support shaft 21 , which extends into a recess in the top of the index piston 30 . The support shaft 21 is threaded, welded, or otherwise connected to the index piston 30 . The lower edge of the strainer section 22 sits on the top of the index piston 30 and may also be connected thereto. The ball cage 20 also comprises a plurality of balls 26 , which are freely allowed to move about within the ball cage 20 . The outside diameter of the balls 26 are larger than the inside diameter of the side holes 24 and top holes 25 so that the balls 26 are retained within the ball cage 20 .
The index piston 30 has a plurality of flow ports 31 that extend through the index piston 30 parallel to the longitudinal central axis of the piston 30 . The inside diameter of the flow ports 31 are smaller than the outside diameter of the balls 26 of the ball cage 20 . An annular seal 32 is positioned in a recessed near the top of the outside circumference of the index piston 30 to form a seal between the index piston 30 and the valve collar 10 . The annular seal 32 restricts fluid flow between the two structures even as the index piston 30 translates longitudinally within the valve collar 10 . The indexing piston 30 also has an indexing J-Slot 34 in its exterior wall. The indexing J-Slot 34 has an index pattern 40 described in more detail below. The stem 33 extends from the bottom of the index piston 30 so as to connect the poppet plug 60 to the index piston 30 through the stem mount 16 . The poppet plug 60 is threaded, welded, molded, or otherwise fastened or connected to the end of the stem 33 .
As shown in FIGS. 1A , 2 A, and 3 A, the spring 50 is positioned concentrically around the stem 33 of the index piston 30 . At its upper end, the spring engages the lower face of the index piston 30 and at its lower end, the spring 50 engages a spring shoulder 17 at the upper edge of the stem mount 16 . In FIG. 1A , the spring 50 is illustrated in a relaxed or expanded position, while in FIG. 2A , the spring 50 is completely compressed. In FIG. 3A , the spring 50 is only partially compressed.
The poppet plug 60 is connected to a lower most end of the stem 33 for longitudinal movement into and out of engagement with the valve seat 18 of the seat section 14 . The poppet plug 60 has a conical seal surface 61 for engagement with the valve seat 18 . The seal surface 61 terminates in a seal lip 62 that deflects slightly when the poppet plug 60 is inserted into the valve seat 18 . The deflection of the seal lip 62 ensures the integrity of the seal when the valve is closed.
Referring to FIGS. 1B , 2 B, and 3 B, the index pattern 40 defines several lug positions that are used to configure the valve in closed, flow-open, and locked-open positions. Closed positions 41 are located in the lower-most portions of the index pattern 40 . When the indexing lug 11 is located in one of the closed positions 41 , the valve 1 is configured in a closed configuration. Flow-open positions 42 are found in the upper-most portions of the index pattern 40 . As shown in FIG. 2B , when the indexing lug 11 is positioned in one of the flow-open positions 42 , the valve 1 is configured in a flow-open configuration. Locked-open positions 43 are found in a medium lower position of the index pattern 40 . When the indexing lug 11 is in a locked-open position 43 , the valve 1 is in a locked-open configuration. FIG. 3B illustrates the indexing lug 11 in a locked-open position 43 which corresponds to a valve 1 configuration that is locked-open as illustrated in FIG. 3A . FIG. 1B illustrates the indexing lug 11 in a closed position 41 , which corresponds to a closed valve 1 configuration as illustrated in FIG. 1A . FIG. 2B illustrates the indexing lug 11 in a flow-open position 42 which corresponds to a valve flow-open configuration as illustrated in FIG. 2A .
FIG. 4 illustrates a valve 1 of the present invention assembled into a casing 2 . The annular space between the valve collar 10 of the valve 1 and the casing 2 may be filled with a concrete or cement attachment 3 to allow the valve 1 to be drilled out of the casing should removal of the valve 1 become necessary. In other embodiments of the invention, the valve 1 may be connected to the casing 2 by any means known to persons of skill. For example, the valve 2 may be stung into a casing collar, or threaded into an internal casing flange.
The process for operating the valve is described with reference to FIGS. 1A , 2 A, and 3 A. When the valve is run into the well, the valve 1 is in the closed configuration with the spring 50 holding the valve 1 closed. In the illustrated embodiment, the spring 50 is compressed between the bottom face of the index piston 30 and the spring shoulder 17 . The force of the spring 50 biases the poppet plug 60 toward the valve seat 18 . In particular, the valve 1 is biased to a closed configuration. With the valve 1 in the closed configuration, the indexing lug 11 is located in a closed position 41 as shown in FIG. 1B . As the casing 2 and valve 1 are run into the well, increasing fluid pressure from below the valve 1 is checked against the poppet plug 60 and is not allowed to enter the inner diameter of the casing 2 .
When it is desired to open the valve 1 , fluid may be circulated down the inner diameter of the casing 2 to the valve 1 . Due to gravity, fluid moving in the circulation direction, or any other forces in play, the balls 26 within the ball cage 20 seat themselves in the tops of some of the flow ports 31 (see FIGS. 1A and 2A ). The circulating fluid then flows through the remaining open flow port(s) 31 . However, for fluid to flow through the valve 1 , the fluid pressure inside the inner diameter of the casing 2 must increase to overcome the fluid pressure outside the valve 1 and to overcome the bias force applied by the spring 50 . When the fluid pressure becomes large enough, the poppet plug 60 unseats from the valve seat 18 to allow fluid to circulate through the valve. The valve 1 becomes partially open.
As fluid is circulated through the valve 1 , the remaining open flow port(s) 31 present a relatively restricted cross-sectional flow area, a pressure differential is created across the valve 1 . As the flow rate increases, the pressure differential increases. When the pressure differential becomes great enough to overcome the bias force of the spring 50 , the valve 1 is reconfigured to the flow-open configuration (see FIG. 2A ). In this configuration, the valve 1 is completely open and the indexing lug 11 is driven to a flow-open position 42 in the index pattern 40 .
The relative movement of the indexing lug 11 and the index pattern 40 , as the valve 1 moves from the closed configuration to the flow-open configuration, is described with reference to FIGS. 1B and 2B . As the poppet plug 60 moves out of the valve seat 18 , the index piston 30 translates downwardly relative to the valve collar 10 and the indexing lug 11 . This relative movement corresponds to the indexing lug 11 moving upward in the index pattern from a closed position 41 to a flow-open position 42 (see FIGS. 1B and 2B ). As the indexing lug 11 approaches the flow-open position 42 , the indexing lug 11 contacts and slides along an upper ramp 44 . As the indexing lug 11 slides along the upper ramp 44 , the index piston, ball cage 20 and poppet plug 60 rotate and translate relative to the valve collar 10 . As long as fluid continues to circulate at a sufficient flow rate through the remaining open flow port(s) 31 from the inside diameter of the casing 2 to the exterior of the casing 2 , the indexing lug 11 is driven to the flow-open position 42 . Simultaneously, the spring 50 collapses and the indexing J-slot 34 moves across the indexing lug 11 so as to position the indexing lug 11 in the flow-open position 42 of the index pattern 40 (see FIGS. 1B and 2B ).
Fluid flow in the circulation direction through the valve 1 may be continued as long as desired to circulate the well. When flow in the circulation direction is discontinued (pumping stops), the pressure equalizes across the flow ports 31 allowing the spring 50 to push the poppet plug 60 upwards. This upward movement of the poppet plug 60 , stem 33 , and index piston 30 will index the indexing J Slot 34 to either the closed position 41 or the locked-open position 43 . The index pattern 40 has alternating closed positions 41 and locked-open positions 43 . Thus, each time flow in the circulation direction is continued and discontinued, the valve 1 will alternate between a closed configuration and a locked-open configuration. Because the index pattern 40 repeats itself indefinitely in circular fashion, there is no limit to the number of times the valve 1 may opened and closed.
The relative movement of the indexing lug 11 and the index pattern 40 , as the valve 1 moves from the flow-open configuration to the locked-open configuration, is described with reference to FIGS. 2B and 3B . When fluid flow in the circulation direction is discontinued, the valve 1 is no longed held in the flow-open configuration. The spring 50 pushes the index piston 30 upwardly relative to the valve collar 10 and the indexing lug 11 . This relative movement corresponds to the indexing lug 11 moving downward in the index pattern 40 from a flow-open position 42 to a locked-open position 43 (see FIGS. 2B and 3B ). As the indexing lug 11 approaches the locked-open position 43 , the indexing lug 11 contacts and slides along a lower ramp 45 . As the indexing lug 11 slides along the lower ramp 45 , the index piston 30 , ball cage 20 and poppet plug 60 rotate and translate relative to the valve collar 10 . The spring 50 expands to drive the indexing lug 11 to the locked-open position 43 . Simultaneously, the spring 50 expands and the indexing J-slot 34 moves across the indexing lug 11 so as to position the indexing lug 11 in the locked-open position 43 of the index pattern 40 (see FIGS. 2B and 3B ).
If the valve 1 had previously been in the locked-open configuration immediately before fluid flow in the circulation direction is started and stopped, the valve will then cycle to a closed configuration. The relative movement of the indexing lug 11 and the index pattern 40 , as the valve 1 moves from the flow-open configuration to the closed configuration, is described with reference to FIGS. 2B and 1B . When fluid flow in the circulation direction is discontinued, the valve 1 is no longed held in the flow-open configuration. The spring 50 pushes the index piston 30 upwardly relative to the valve collar 10 and the indexing lug 11 . This relative movement corresponds to the indexing lug 11 moving downward in the index pattern 40 from a flow-open position 42 to a closed position 41 (see FIGS. 2B and 1B ). As the indexing lug 11 approaches the closed position 41 , the indexing lug 11 contacts and slides along a lower ramp 45 . As the indexing lug 11 slides along the lower ramp 45 , the index piston 30 , ball cage 20 and poppet plug 60 rotate and translate relative to the valve collar 10 . The spring 50 expands to drive the indexing lug 11 to the closed position 41 . Simultaneously, the spring 50 expands and the indexing J-slot 34 moves across the indexing lug 11 so as to position the indexing lug 11 in the closed position 41 of the index pattern 40 (see FIGS. 2B and 1B ).
In certain embodiments of the invention, the valve 1 may be cycled between closed, flow-open and locked-open configurations an unlimited number of times as the index pattern 40 around the index piston 30 is a repeating pattern without end. In other embodiments of the invention, the index pattern 40 may have more than one locked-open position 43 , such that the different locked-open positions 43 have different heights in the index pattern 40 . Locked-open positions 43 of different heights hold the valve 1 open in different degrees so as to make it possible to provide restricted flow through the valve 1 in the reverse-circulation direction.
According to one embodiment of the invention, a casing string 2 is deployed with complete well control while making up the casing string 2 and positioning it into the desired location of the well bore. Once the casing 2 is positioned at its desired location and the top end of the casing is secured with safety valves (cementing head or swage) the back pressure valve 1 may be disabled (without casing/tubing movement) allowing flow from the well bore to enter the string and exit from the top of the string which in return will allow placement of desired fluids into the well bore and around the casing string 2 . When the fluid is at the desired location within the well bore the movement of fluid can be stopped by reactivating the back pressure valve 1 .
Certain embodiments of the invention include cementing float equipment back pressure valves for reverse cementing applications. These valves involve the use of an indexing mechanism to activate and deactivate the back pressure valve allowing fluid movement from desired directions. The activation process may be manipulated as often as desired during operations of running casing in the hole or the actual cementing operations.
The valve may be activated as follows. First, when the valve 1 is in the normal operation mode (closed position), flow from the outside is checked (see FIG. 1A ). The well may be circulated from the inside of casing to outside without deactivation of back pressure valve 1 . Increased flow rate creates pressure drop across flow ports 31 , thus indexing the valve into the open position (see FIG. 2A ). Releasing the flow pressure allows the lug to hold the valve 1 open (see FIG. 3A ). Flow from either direction can be achieved at this time (circulation or reverse-circulation) (see FIG. 3A ). The valve may be closed again by increased flow rate from the inner diameter to outside of casing/tubing 2 . ( FIG. 2A ) This allows the valve 1 to return to normal operation (no flow allowed from outside to inside). ( FIG. 1A ) This process can be repeated as often as desired.
The valve 1 allows complete well control while running the casing/tubing 2 in the hole with the ability to circulate the well without manually activating the indexing mechanism. When desired the valve can be locked-open to perform reverse circulation. If or when desired the valve can be activated again to shut off (check) the flow from annuals gaining complete well control again with the ability to release any pressure trapped on the side of the casing/tubing string. The valve can be activated and deactivated as often as desired.
Referring to FIGS. 5A , 6 A, and 7 A, cross-sectional side views of an alternative valve 1 are illustrated. The valve 1 has several major components including: a valve collar 10 , a detent flapper 27 , an index piston 30 , an index pattern 40 , a spring 50 , and a flapper plug 63 . In FIG. 5A , the valve 1 is shown in a closed position. In FIG. 6A , the valve 1 is shown in a flow-open position. In FIG. 7A , the valve 1 is shown in a locked-open position. FIGS. 5B , 6 B, and 7 B illustrate schematic side views of the index pattern 40 . In each of these figures, an indexing lug 11 is shown in a different position as described more fully below.
Referring to FIGS. 5A , 6 A, and 7 A, each of the major components of the valve 1 are described. Similar to the previously described embodiment, the valve collar 10 is a cylindrical structure comprising an indexing section 12 , a mounting section 13 , and a seat section 14 . As before, the indexing section 12 has a shoulder 15 . The mounting section 13 has a stem mount 16 that extends from the inside diameter side wall of the mounting section 13 . The stem mount 16 is an arm having an annular eyelet at its distal end for receiving a stem 33 of the index piston 30 . The seat section 14 has a beveled valve seat 18 for receiving the flapper plug 63 .
As shown in FIGS. 5A , 6 A and 7 A, the index piston 30 has a plurality of flow ports 31 that extend through the index piston 30 parallel to the longitudinal central axis of the index piston 30 . At least one detent flapper 27 is positioned at the opening of at least one of the flow ports 31 . An annular seal 32 is positioned in a recessed near the top of the outside circumference of the index piston 30 to form a seal between the index piston 30 and the valve collar 10 . The annular seal 32 restricts fluid flow between the two structures even as the index piston 30 translates longitudinally within the valve collar 10 .
In this embodiment of the valve 1 , the indexing section 12 of the valve collar also has an indexing J-Slot 34 in its interior wall. The indexing J-Slot 34 has an index pattern 40 . The stem 33 extends from the bottom of the index piston 30 through the stem mount 16 . As shown in FIGS. 5A , 6 A, and 7 A, the spring 50 is positioned concentrically around the stem 33 of the index piston 30 . At its upper end, the spring engages the lower face of the index piston 30 and at its lower end, the spring 50 engages a spring shoulder 17 at the upper edge of the stem mount 16 . In FIG. 5A , the spring 50 is illustrated in a relaxed or expanded position, while in FIG. 6A , the spring 50 is completely compressed. In FIG. 7A , the spring 50 is only partially compressed. The flapper plug 63 is connected to a lower most end of the seat section 14 of the valve collar 10 for pivotal movement into and out of engagement with the valve seat 18 of the seat section 14 . The flapper valve seats in the valve seat 18 and is biased to a closed position by a spring as is known in the art. The flapper plug 63 has a conical seal surface 61 for engagement with the valve seat 18 . The flapper plug 63 is opened by the stem 33 when the stem extends through to the seat section 14 to push the flapper plug 63 from its biased position in the valve seat 18 . When the index piston 30 and stem 33 are driven downwardly relative to the flapper valve, the stem extends through the valve seat 18 to push and hold the flapper valve open. In further embodiments of the invention, the poppet plug 60 or flapper plug 63 are replaced with any valve mechanism known to persons of skill.
Referring to FIGS. 5B , 6 B, and 7 B, the index pattern 40 defines several lug positions that are used to configure the valve in closed, flow-open, and locked-open positions. Closed positions 41 are located in the upper-most portions of the index pattern 40 . When the indexing lug 11 is located in one of the closed positions 41 , the valve 1 is configured in a closed configuration. Flow-open positions 42 are found in the lower-most portions of the index pattern 40 . As shown in FIG. 6B , when the indexing lug 11 is positioned in one of the flow-open positions 42 , the valve 1 is configured in a flow-open configuration. Locked-open positions 43 are found in a medium upper position of the index pattern 40 . When the indexing lug 11 is in a locked-open position 43 , the valve 1 is in a locked-open configuration. FIG. 7B illustrates the indexing lug 11 in a locked-open position 43 which corresponds to a valve 1 configuration that is locked-open as illustrated in FIG. 7A . FIG. 5B illustrates the indexing lug 11 in a closed position 41 , which corresponds to a closed valve 1 configuration as illustrated in FIG. 5A . FIG. 6B illustrates the indexing lug 11 in a flow-open position 42 which corresponds to a valve flow-open configuration as illustrated in FIG. 6A .
In the embodiments of the invention illustrated in FIGS. 5A , 6 A, and 7 A, one or more flapper valves 27 are seated in the tops of the flow ports 31 . To allow restricted flow through the flow ports 31 in the circulation direction, at least one of the flow ports 31 is not equipped with a flapper valve. In still further embodiments of the invention, the ball cage 20 or flapper valves 27 are replaced with any valving system known to persons of skill, wherein the valving system provides restricted fluid flow through the flow ports in the circulation direction, and unrestricted fluid flow through the flow ports 31 in the reverse-circulation direction.
The valve described with reference to FIGS. 5 , 6 and 7 is operated in a similar manner as that described for FIGS. 1 , 2 and 3 .
As described herein the detent in the indexing piston takes on many forms. In FIGS. 1A , 2 A, and 3 A, the detent is a fewer number of balls 26 than flow ports 31 . In alternative embodiments of the invention, the ball cage 20 retains the same number of balls 26 as flow ports 31 , but each of the balls has grooves in their exterior surfaces so that when the balls 26 lodge or seat themselves in the openings of the flow ports 31 , a relatively smaller amount of fluid passes through the grooves in the balls 26 and into the flow ports 31 . In FIGS. 5A , 6 A, and 7 A, the detent is a fewer number of detent flappers 27 than flow ports 31 in the indexing piston 30 . In an alternative embodiment of the invention, the detent has the same number of detent flappers 27 as flow ports 31 , but the detent flapper(s) 27 only partially closes the flow port(s) 31 when the detent flapper(s) 27 moves to a closed position. For example, where the flow port(s) 31 has a circular cross-section, the detent flapper(s) 27 has a half-moon cross-section to only partially close the flow port(s) 31 .
Therefore, the present invention is well-adapted to carry out the objects and attain the ends and advantages mentioned as well as those which are inherent therein. While the invention has been depicted, described, and is defined by reference to exemplary embodiments of the invention, such a reference does not imply a limitation on the invention, and no such limitation is to be inferred. The invention is capable of considerable modification, alteration, and equivalents in form and function, as will occur to those ordinarily skilled in the pertinent arts and having the benefit of this disclosure. The depicted and described embodiments of the invention are exemplary only, and are not exhaustive of the scope of the invention. Consequently, the invention is intended to be limited only by the spirit and scope of the appended claims, giving full cognizance to equivalents in all respects.
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A valve for a well pipe, the valve having the following parts: a valve collar connectable to the well pipe; an index piston coaxially positioned within the valve collar for longitudinal translation within the valve collar between closed, flow-open, and locked-open configurations; a detent in the index piston, wherein the detent restricts fluid flow in a circulation direction through a flow path through the index piston; a spring that biases the index piston toward the closed and locked-open configurations; and a plug of the valve collar that mechanically communicates with the index piston to be in corresponding closed, flow-open, and locked-open configurations.
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RELATED APPLICATION
This application is a continuation of U.S. application Ser. No. 13/205,826, filed Aug. 9, 2011, entitled “ARTICULATING CAVITY CREATOR,” now U.S. Pat. No. 9,119,639, which is incorporated herein by reference in its entirety.
BACKGROUND
Certain diagnostic or therapeutic procedures require the formation of a cavity in an interior body region. These cavity-forming procedures can be used to treat cortical bone which due to osteoporosis, avascular necrosis, cancer, or trauma, for example, may be fractured or prone to compression fracture or collapse and which, if not successfully treated, can lead to deformities, chronic complications, and an overall adverse impact upon the quality of life for the patient.
Vertebroplasty is where a medical-grade bone cement (such as polymethylmethacrylate, a.k.a., PMMA) is injected percutaneously via a catheter into a fractured vertebra. In this procedure, the bone cement is injected with enough pressure to enable the cement to compress and displace cancellous bone tissue. However, the direction and containment of the injected cement can be difficult to control since the space the bone cement will ultimately occupy is ill-defined, self-forming, and highly-dependent upon the internal composition of the cancellous bone in the vicinity of the injection.
To provide better bounding and control over injected bone cement, other procedures utilize devices for first forming cavities within the cancellous bone (and, accordingly, other interior body regions) prior to injecting bone cement into such a cavity. For example, some devices may utilize an expandable body or balloon that is deployed into the interior body region to form a cavity in, for example, cancellous bone tissue. These expandable body devices effectively compress and displace the cancellous bone to form an interior cavity that then receives a filling material intended to provide renewed interior structural support for cortical bone. However, the effectiveness of expandable or inflatable devices can still be negatively impacted by the internal composition of the cancellous bone in the vicinity of their use—unbeknownst to the surgeon performing the procedure because of a lack of tactile feedback—and removing the expandable or inflatable device may be difficult in certain applications of such processes.
SUMMARY
Various embodiments disclosed herein pertain to devices to create cavities within interior body regions. When deployed though a cannula emplaced into cancellous bone, for example, the distal end of the device can be extended beyond the distal end of the catheter and then be selectively curved into various shaped compression surfaces that, when rotated about a longitudinal axis, creates a void within the interior body. This extended compression surface can then be withdrawn back into the cannula for complete removal from the cannula, and a void filler such as bone cement may then be introduced into the void. For certain embodiments, this bone cement may be introduced through the same cannula used by the cavity creation device.
More specifically, certain embodiments disclosed herein are directed to an articulated tip assembly for creating a cavity in a body, the articulated tip assembly comprising a coil enclosure having a proximal end and a distal end (the coil enclosure being curvable), a shaft coupler coupled to the proximal end of the coil enclosure, a plurality of interconnecting curving elements enclosed within the coil enclosure and movably coupled to the shaft coupler, and a tip coupled to the distal end of the coil enclosure and coupled to the plurality of interconnecting curving elements.
Other implementations are directed to a device for creating a cavity in an interior body, the device comprising an articulated tip assembly, a shaft coupled to the articulated tip assembly, a lever assembly coupled to the shaft, and an off-center cable coupled to the articulated tip assembly and the lever assembly such that variable action of the lever assembly causes the articulated tip assembly to selectively curve, wherein rotation of the device causes the articulated tip assembly to rotate within the interior body. Yet other embodiments are directed to methods for creating a cavity in a target body using an articulated cavity creator, the method comprising inserting an articulated tip assembly into the target body, curving and rotating the articulated tip assembly, and then withdrawing the articulated tip assembly.
This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter.
BRIEF DESCRIPTION OF THE DRAWINGS
To facilitate an understanding of and for the purpose of illustrating the present disclosure, exemplary features and implementations are disclosed in the accompanying drawings, it being understood, however, that the present disclosure is not limited to the precise arrangements and instrumentalities shown, and wherein similar reference characters denote similar elements throughout the several views, and wherein:
FIG. 1A is a perspective view of an articulated cavity creator representative of various embodiments disclosed herein;
FIG. 1B is a side view of the articulated cavity creator of FIG. 1A ;
FIG. 1C is a bottom view of the articulated cavity creator of FIGS. 1A and 1B ;
FIG. 1D is a exploded perspective view of the articulated cavity creator of FIGS. 1A, 1B, and 1C ;
FIG. 2A is an exploded perspective view of an exemplary tip assembly comprising the distal end of an articulated cavity creator representative of several embodiments disclosed herein;
FIG. 2B is a side view of the exemplary tip assembly of FIG. 2A in a curved configuration;
FIG. 3A is a perspective view of a cavity creator tip representative of various embodiments disclosed herein;
FIG. 3B is a cross-sectional top view of the cavity creator tip of FIG. 3A ;
FIG. 3C is a side view of the cavity creator tip of FIGS. 3A and 3B ;
FIG. 3D is a proximal end view of the cavity creator tip of FIGS. 3A, 3B , and 3 C;
FIG. 4A is a perspective view of a cavity creator curving element representative of various embodiments disclosed herein;
FIG. 4B is a distal end view of the cavity creator curving element of FIG. 4A ;
FIG. 5A is a perspective view of a cavity creator shaft coupler representative of various embodiments disclosed herein;
FIG. 5B is a side view of the cavity creator shaft coupler of FIG. 5A ;
FIG. 6 is a side view of a cavity creator coil enclosure representative of various embodiments disclosed herein;
FIG. 7A is an exploded perspective view of an exemplary lever assembly of an articulated cavity creator representative of several embodiments disclosed herein;
FIG. 7B is an exposed side view of the exemplary lever assembly of FIG. 7A ;
FIG. 8A is side view of an exemplary rotation shaft of an articulated cavity creator representative of several embodiments disclosed herein;
FIG. 8B is a cross-sectional view of the exemplary rotation shaft of FIG. 8A ;
FIG. 9 is an exploded perspective view of an exemplary tensioner assembly comprising the proximal end of an articulated cavity creator representative of several embodiments disclosed herein;
FIG. 10A is a perspective view of a cavity creator tensioner representative of various embodiments disclosed herein;
FIG. 10B is a cross-sectional top view of the cavity creator tensioner of FIG. 10A ;
FIG. 10C is a partially-cross-sectional side view of the cavity creator tensioner of FIGS. 10A and 10B ;
FIG. 10D is a distal end view of the cavity creator tensioner of FIGS. 10A, 10B, and 10C ;
FIG. 11A is a perspective view of a cavity creator tension knob representative of various embodiments disclosed herein;
FIG. 11B is a side view of the cavity creator tension knob of FIG. 11A ;
FIG. 11C is a cross-sectional side view of the cavity creator tension knob of FIGS. 11A and 11B ;
FIG. 11D is a proximal end view of the cavity creator tension knob of FIGS. 11A, 11B, and 11C ;
FIG. 12A is a perspective view of a maximum cavity creatable utilizing certain embodiments of the cavity creator disclosed herein;
FIG. 12B is a side view of the maximum cavity of FIG. 12A further including the tip assembly of FIG. 2 in position within the interior body; and
FIG. 12C is an operational flow diagram illustrating a method for creating the cavity illustrated in FIGS. 12A and 12B utilizing certain embodiments of the cavity creator disclosed herein.
DETAILED DESCRIPTION
Certain terminology is used in the following description for convenience only and is not limiting. The words “right”, “left”, “lower”, and “upper” designate direction in the drawings to which reference is made. The words “inner”, “outer” refer to directions toward and away from, respectively, the geometric center of the described feature or device. The words “distal” and “proximal” refer to directions taken in context of the item described and, with regard to the instruments herein described, are typically based on the perspective of the surgeon using such instruments. The words “anterior”, “posterior”, “superior”, “inferior”, “medial”, “lateral”, and related words and/or phrases designate preferred positions and orientation in the human body to which reference is made. The terminology includes the above-listed words, derivatives thereof, and words of similar import.
In addition, various components may be described herein as extending horizontally along a longitudinal direction “L” and lateral direction “A”, and vertically along a transverse direction “T”. Unless otherwise specified herein, the terms “lateral”, “longitudinal”, and “transverse” are used to describe the orthogonal directional components of various items. It should be appreciated that while the longitudinal and lateral directions are illustrated as extending along a horizontal plane, and that the transverse direction is illustrated as extending along a vertical plane, the planes that encompass the various directions may differ during use. Accordingly, the directional terms “vertical” and “horizontal” are used to describe the components merely for the purposes of clarity and illustration and are not meant to be limiting.
FIG. 1A is a perspective view of an articulated cavity creator 100 representative of various embodiments disclosed herein. FIG. 1B is a side view of the articulated cavity creator 100 of FIG. 1A . FIG. 1C is a bottom view of the articulated cavity creator 100 of FIGS. 1A and 1B . FIG. 1D is a exploded perspective view of the articulated cavity creator 100 of FIGS. 1A, 1B, and 1C .
Referring to FIGS. 1A, 1B, 1C, and 1D (collectively referred to herein as “ FIG. 1 ”), an articulated cavity creator (“ACC”) may comprise a tip assembly 200 , an intra-catheter shaft 300 , a lever assembly 400 , a rotation shaft 500 , and a tensioner assembly 600 , each operatively coupled in order from distal end to proximal end of the ACC as shown in FIG. 1 . The ACC further comprises an off-center cable 120 and a midline cable 140 . The off-center cable 120 is fixedly coupled to the lever assembly 400 at its proximal end, passes longitudinally through the intra-catheter shaft 300 , and is fixedly coupled to the tip assembly 200 at its distal end. The midline cable 140 , in contrast, is effectively doubled-backed on itself with both ends 142 and 144 fixedly coupled to the tip assembly 200 and passing longitudinally through the intra-catheter shaft 300 , the lever assembly 400 , the rotation shaft 500 , and operationally coupling a rotational component 602 of the tensioner assembly 600 at its bend 146 . Each of these components and theirs functions are described in greater detail herein.
FIG. 2A is an exploded perspective view of an exemplary tip assembly 200 comprising the distal end of an articulated cavity creator 100 representative of several embodiments disclosed herein. FIG. 2B is a side view of the exemplary tip assembly 200 of FIG. 2A in a curved configuration.
Referring to FIGS. 2A and 2B (collectively referred to herein as “ FIG. 2 ”), the tip assembly 200 may comprise a cavity creator tip 210 , a plurality of interconnecting curving elements 230 , a coil enclosure 250 , and shaft coupler 260 for coupling to the intra-catheter shaft 300 . As shown in FIG. 2B , the proximal end 212 of the tip 210 , the curving elements 230 , and the distal end 264 of the shaft coupler 260 are movably coupled and enclosed within the hollow created by the coil enclosure 250 , thereby exposing the distal end 214 of the tip 210 beyond the distal end 254 of the coil enclosure 250 , as well as exposing the proximal end 262 of the shaft coupler 260 beyond the proximal end 252 of the coil enclosure 250 . Moreover, in several alternative embodiments the coil enclosure 250 may be replaced with other enclosures such as a sheath or a series of rings, for example, and that such alternative enclosures may be constructed of any of several suitable materials, including but not limited to rubber, latex, plastic or nitinol.
Further shown in FIG. 2B is the distal end of the doubled-back midline cable 140 running on both sides of the tip assembly 200 (one strand shown, the other strand behind and obstructed from view), both ends of which are fixedly coupled to the tip 210 and run down concurrent lateral channels (highlighted in other illustrations) on each side of the tip 210 , the curving elements 230 , and the shaft coupler 260 , and thereby pass through the hollow of the coil enclosure 250 and through the intra-catheter shaft 300 . This midline cable 140 provides the tension necessary to hold the tip 210 , the curving elements 230 , and the shaft coupler 260 movably coupled and enclosed within the hollow created by the coil enclosure 250 . Through the application of even tension by both strands of the midline cable 140 , curving of the tip assembly 200 in a vertical (up-and-down) direction is achievable as disclosed herein.
Also shown in FIG. 2B is the distal end of the off-center cable 120 fixedly coupled to the tip 210 and running down a top channel (highlighted in other illustrations) of the tip 210 , the curving elements 230 , and the shaft coupler 260 , and thereby passing through the hollow of the coil enclosure 250 and the intra-catheter shaft 300 . This off-center cable 120 provides variable tension on the top side of the tip assembly 200 causing the tip 210 , the curving elements 230 , and the shaft coupler 260 to together movably curve against the coil enclosure 250 (as shown) in various curved configurations depending on the amount of variable tension applied by the off-center cable 120 . As such, the curving elements 230 within tip assembly 200 cooperate to approximate a curved shape. Further, the tip assembly 200 may form such a curved shape around any object that the tip assembly 200 encounters as the off-center cable 120 is tensed along the top side of the tip assembly 200 .
The aforementioned curvable motions and restrictions of the tip assembly 200 are further complimented by the shaping of the proximal end 212 of the tip 210 , both ends of the curving elements 230 , and the distal end 264 of the shaft coupler 260 , which help assist curving of the tip assembly 200 in a vertical direction and help prevent curving in a horizontal direction. This shaping is discussed in greater detail later herein.
FIG. 3A is a perspective view of a cavity creator tip 210 representative of various embodiments disclosed herein. FIG. 3B is a cross-sectional top view of the cavity creator tip 210 of FIG. 3A . FIG. 3C is a side view of the cavity creator tip 210 of FIGS. 3A and 3B . FIG. 3D is a proximal end view of the cavity creator tip 210 of FIGS. 3A, 3B, and 3C .
Referring to FIGS. 3A, 3B, 3C, and 3D (collectively referred to herein as “ FIG. 3 ”), the cavity creator tip 210 (or simply “tip”) comprises a partial curving element 222 corresponding to the proximal end 212 and a head 224 corresponding to the distal end 214 . The partial curving element 222 further comprises two lateral channels 216 , one oriented to each side of the tip 210 , as well as a top channel 220 oriented to the top of the tip 210 . These channels 216 and 220 proceed through the head 224 to open at the distal end of the tip 210 as shown in the illustrations, and for certain embodiments these distal endpoints for the channels 216 and 220 at the head 224 may comprise fastening or welding points for fixedly coupling the both ends 142 of the doubled-back midline cable 140 , as well as the distal end of the off-center cable 120 , to the tip 210 . The head 224 may also comprise a distal edge 226 that is vertically flat (as shown) or, in other embodiments, may be formed to provide a rounded edge or an edge of some other form or shape. The head also comprises a stop surface 228 for engaging but not passing into the distal end of the coil enclosure 250 .
The partial curving element 222 , insertable into the distal end of the coil enclosure 250 , further comprises a partially-cylindrical convex proximal male end 202 for operatively coupling to a corresponding partially-cylindrical distal female end of a curving element 230 to facilitate curving of the tip assembly 200 in a vertical direction and help prevent curving in a horizontal direction (the partially-cylindrical shape being curved in the vertical direction but flat in the horizontal direction). Similarly, the two lateral channels 216 each comprise a slope surface 218 to allow curving of a tip assembly 200 in a vertical “up” direction (but not in a vertical “down” direction) against each strand of the midline cable 140 running through said lateral channels 216 .
FIG. 4A is a perspective view of a cavity creator curving element 230 representative of various embodiments disclosed herein. FIG. 4B is a distal end view of the cavity creator curving element 230 of FIG. 4A .
Referring to FIGS. 4A and 4B (collectively referred to herein as “ FIG. 4 ”), each such curving element 230 comprises two lateral channels 216 , one oriented to each side of the curving element 230 , as well as a top channel 220 oriented to the top of the curving element 230 . The curving element 222 further comprises a partially-cylindrical convex proximal male end 202 and a partially-cylindrical concave proximal female end 204 . The proximal male end 202 is shaped to operatively couple with the corresponding distal female end 204 of either another curving element 230 or shaft coupler 260 . Conversely, the distal female end 204 is shaped to operatively couple with the corresponding proximal male end 202 of either another curving element 230 or the distal end 212 of the tip 210 accordingly.
Both the proximal male end 202 and the distal female end 204 of the curving element 230 facilitate curving of the tip assembly 200 in a vertical direction and help prevent curving in a horizontal direction (the partially-cylindrical shape being curved in the vertical direction but flat in the horizontal direction). Similarly, the two lateral channels 216 each comprise a slope surface 218 to allow curving of a tip assembly 200 in a vertical “up” direction (but not in a vertical “down” direction) against each strand of the midline cable 140 running through said lateral channels 216 .
FIG. 5A is a perspective view of a cavity creator shaft coupler 260 representative of various embodiments disclosed herein. FIG. 5B is a side view of the cavity creator shaft coupler 260 of FIG. 5A .
Referring to FIGS. 5A and 5B (collectively referred to herein as “ FIG. 5 ”), the shaft coupler 260 comprises a partial curving element 222 ′ corresponding to the distal end 262 , a collar 266 centrally located, and an insertion component 268 corresponding to the proximal end 264 . The shaft coupler 260 further comprises two lateral channels 216 , one oriented to each side of the shaft coupler 260 , as well as a top channel 220 oriented to the top of the shaft coupler 260 , where all three channels run from the proximal end 262 to the distal end 264 of the shaft coupler 260 .
The partial curving element 222 ′, insertable into the proximal end of the coil enclosure 250 , further comprises a partially-cylindrical concave distal female end 204 for operatively coupling to a corresponding partially-cylindrical proximal male end 202 of a curving element 230 to facilitate curving of the tip assembly 200 in a vertical direction and help prevent curving in a horizontal direction (the partially-cylindrical shape being curved in the vertical direction but flat in the horizontal direction). The collar 266 comprises a first stop surface 272 for engaging but not passing into the distal end of the intra-catheter shaft 300 , as well as a second stop surface 274 for engaging but not passing into the proximal end of the coil enclosure 250 . The insertion component 268 , in turn, is insertable into the distal end of the intra-catheter shaft 300 and, for certain embodiments, may be fastening or welded to said intra-catheter shaft 300 .
FIG. 6 is a side view of a cavity creator coil enclosure 250 representative of various embodiments disclosed herein. The coil enclosure 250 is both compressible relative to the longitudinal direction as shown, as well as curvable relative from the longitudinal direction as shown. The proximal end 252 of the coil enclosure 250 operatively couples with the second stop surface 274 of the shaft coupler 260 , and the distal end 254 of the coil enclosure 250 operatively couples with the stop surface 228 of the tip 210 . The helical body 258 of the coil enclosure 250 forms a hollow 256 extending from the distal end 254 to the proximal end 252 of the coil enclosure 250 and effectively encloses the proximal end 212 of the tip 210 , the plurality of interconnecting curving elements 230 , and the distal end 264 of the shaft coupler 260 that comprise the tip assembly 200 . The tip assembly 200 , in turn, couples to the distal end of the intra-catheter shaft 300 , and the midline cable 140 and the off-center cable 120 fixedly coupled to the tip 210 pass through the tip assembly 200 and through the intra-catheter shaft 300 to the lever assembly 400 in the case of the off-center cable 120 , and through the lever assembly 400 and the rotation shaft 500 to the tensioner assembly 600 in the case of both strands of the midline cable 140 .
FIG. 7A is an exploded perspective view of an exemplary lever assembly 400 of an articulated cavity creator 100 representative of several embodiments disclosed herein. FIG. 7B is an exposed side view of the exemplary lever assembly 400 of FIG. 7A (with the left body 422 of the lever pivot 420 removed).
Referring to FIGS. 7A and 7B (collectively referred to herein as “ FIG. 7 ”), the lever assembly 400 comprises a receiver 410 , a lever pivot 420 (comprising a left body 422 and a right body 424 ) a lever 430 , and a lever spring 440 . Also shown for reference are the proximal end of the intra-catheter shaft 300 and the distal end of the rotation shaft 500 .
The distal end of the receiver 410 is coupled to the intra-catheter shaft 300 , while the proximal end of the receiver 410 is coupled to the distal end 448 of the lever pivot 420 . The lever pivot 420 is also movably coupled to the lever 430 via a pivot pin 428 where the pivot pin 428 is coupled at each end to the left body 422 and right body 424 of the lever pivot 420 and passes through the pivot channel 432 of the lever 430 to couple with the lever 430 . In various embodiments, pivot pin 428 may be fixedly coupled to the lever pivot 420 , the lever 430 , or neither (i.e., movably coupled to both). The lever spring 440 comprises a proximal end 442 operatively coupled to a boss 501 of the rotation shaft 500 , and a distal end 444 operatively coupled to a proximal surface 434 of the lever 430 .
As further illustrated in FIG. 7B , the midline cable 140 (one strand visible and the other strand obscured behind the visible strand) passes through the receiver 410 , the lever 430 , and the lever spring 440 . The off-center cable 120 passes through the receiver 410 and is fixedly connected to the lever 430 . In certain embodiments, as illustrated, the off-center cable 120 may be fixedly attached to a threaded coupling rod 122 that then screws through a channel 438 in the lever 430 and is affixed in position with a washer and nut combination 124 .
The lever spring 440 exerts pressure against the lever 430 to maintain the lever 430 in a longitudinally forward position (in the distal direction) which, in turn, keeps the tip assembly 200 in an uncurved orientation. However, pressure applied to the pressure surface 436 of the lever 430 causes the lever to pivot longitudinally backward (in the proximal direction) which, in turn, causes the tip assembly 200 to curve about an axis. (The motion of the tip assembly 200 thus carves a narrow path through, for example, cancellous bone.)
FIG. 8A is side view of an exemplary rotation shaft 500 of an articulated cavity creator 100 representative of several embodiments disclosed herein. FIG. 8B is a cross-sectional view of the exemplary rotation shaft 500 of FIG. 8A .
Referring to FIGS. 8A and 8B (collectively referred to herein as “ FIG. 8 ”), the rotation shaft 500 comprises a proximal end 502 for operationally coupling to a tensioner assembly 600 as well as a distal end 504 (e.g., a groove) for fixedly coupling to a lever assembly 400 . The rotation shaft 500 also comprises a central channel 510 through which the midline cable 140 passes. The proximal end 502 further comprises two coupling slots 512 to movably couple the tensioner (not shown) of the tensioner assembly 600 (described in more detail below). The rotation shaft 500 enables an operator (such as a surgeon) to rotate (or “twist”) the entire articulated cavity creator 100 and, in turn, rotate (or “spin”) the tip assembly 200 in a manner that, coupled with the variable curving ability provided by the lever assembly 400 , carves out a cavity within, for example, cancellous bone.
FIG. 9 is an exploded perspective view of an exemplary tensioner assembly 600 comprising the proximal end of an articulated cavity creator 100 representative of several embodiments disclosed herein. As illustrated, the tensioner assembly 600 comprises a tensioner 620 , a midline pin 640 , and a tension knob 650 . Also shown for reference is the proximal end 502 of the rotation shaft 500 , said proximal end comprising the two coupling slots 512 to movably couple the tensioner 620 .
FIG. 10A is a perspective view of a cavity creator tensioner 620 representative of various embodiments disclosed herein. FIG. 10B is a cross-sectional top view of the cavity creator tensioner 620 of FIG. 10A . FIG. 10C is a partially-cross-sectional side view of the cavity creator tensioner of FIGS. 10A and 10B . FIG. 10D is a distal end view of the cavity creator tensioner of FIGS. 10A, 10B, and 10C .
Referring to FIGS. 10A, 10B, 10C, and 10D (collectively referred to herein as “ FIG. 10 ”), the tensioner 620 comprises a tension head 622 fixedly coupled to a threaded shaft 632 for engaging the tension knob 650 . The tension head 622 further comprises a pin hole 624 , a cable return cavity 626 , and two slotting edges 628 . The two slotting edges 628 slidably engage the two coupling slots 512 of the rotation shaft 500 , thus preventing rotation of the tensioner 620 within the rotation shaft 500 while also ensuring that the tensioner perfectly rotates along with the rotation shaft 500 when it is rotated.
In operation, the proximal end of the doubled-back midline cable 140 , comprising a 180-degree turn in the cable, is inserted into cable return cavity 626 and the midline pin 640 is introduced through the pin hole 624 to hold the midline cable 140 in place (as shown in FIG. 10D ). In this manner, the midline cable 140 , being movable along the proximal rounded surface of the midline pin 640 , provides even tension throughout the entire device to the tip assembly 200 .
FIG. 11A is a perspective view of a cavity creator tension knob 650 representative of various embodiments disclosed herein. FIG. 11B is a side view of the cavity creator tension knob 650 of FIG. 11A . FIG. 11C is a cross-sectional side view of the cavity creator tension knob 650 of FIGS. 11A and 11B . FIG. 11D is a proximal end view of the cavity creator tension knob 650 of FIGS. 11A, 11B, and 11C .
Referring to FIGS. 11A, 11B, 11C, and 11D (collectively referred to herein as “ FIG. 11 ”), the tension knob 650 comprises a twist body 652 having a proximal end 654 and a distal end 656 and a threaded hole 658 running from the proximal end 654 to the distal end 656 . The distal end 656 abuts against the proximal end 502 of the rotation shaft 500 but is still able to rotate. The threaded hole 658 engages the threaded shaft 632 of the tensioner 620 enabling the tension knob 650 to draw the tensioner 620 back in a proximal direction by rotably turning the tension knob 650 in one direction (e.g. clockwise) and thereby increase the tension on the midline wire 140 . Conversely, by rotably turning the tension knob 650 in the opposite direction (e.g., counterclockwise), the threaded shaft 632 of the tensioner 620 is pushed forward in the distal direction and decreases tension on the midline wire 140 .
FIG. 12A is a perspective view of a maximum cavity 702 creatable utilizing certain embodiments of the articulated cavity creator 100 disclosed herein. FIG. 12B is a side view of the maximum cavity of FIG. 12A further including the tip assembly 200 of FIG. 2 in position within the interior body. FIG. 12C is an operational flow diagram illustrating a method 740 for creating the cavity illustrated in FIGS. 12A and 12B utilizing certain embodiments of the cavity creator disclosed herein.
Referring to FIGS. 12A, 12B, and 12C (collectively referred to herein as “ FIG. 12 ”), the method 740 comprises, at 742 , inserting a catheter into a target location such as an interior body (e.g., a region of cancellous bone). At 744 , inserting the articulated cavity creator 100 through the catheter such that the tip assembly 100 extends beyond the distal end of the catheter and into the target region. At 746 , the tip assembly 200 is curved and straightened by action of the lever 430 in combination with the articulated cavity creator 100 being rotated via the rotation shaft 500 . For example, in one approach, the tip assembly 100 might be incrementally curved through its range of motion (from straight to maximally curved), moving the tip 210 no more than its width with each increment, and at each increment rotating the rotation shaft 500 at least a full 360-degrees. In another approach, the rotation shaft might be rotated incrementally through a full rotation (360-degrees), rotating the tip 210 with each increment no more than the tip's 210 width in each increment position (such as when curved perpendicular to the intra-catheter shaft 300 ), and at each increment engaging the lever 430 to move the tip assembly 200 through its full range of motion from straight to maximally curved and back. At 738 , the articulated cavity creator 100 is removed.
It should be noted that specific features of the various embodiments disclosed herein can be performed manually by user-applied forces or, alternately, utilizing specialized motors. For example, the rotation and curving of the device to form a cavity can be performed manually by a surgeon who rotates the device via the rotation shaft and also curves the device by action of the lever assembly. Conversely, the rotation and/or the curving of the tip assembly can be performed by motorized components that may utilize, in certain implementations, microprocessors or other guidance systems to coordinate the rotation and curving motions to optimally form the cavity within the target body.
As will be readily appreciated by those of skill in the art, the various components described herein can be formed from a variety of biocompatible materials, such as cobalt chromium molybdenum (CoCrMo), titanium and titanium alloys, stainless steel or other metals, as well as ceramics or polymers. A coating may be added or applied to the various components described herein to improve physical or chemical properties, such as a plasma-sprayed titanium coating or Hydroxypatite. Moreover, skilled artisans will also appreciate that the various components herein described can be constructed with any dimensions desirable for implantation and cavity creation.
In addition, the various embodiments disclosed herein may be adapted for use in virtually any interior body region where the formation of a cavity within tissue is required for a therapeutic or diagnostic purpose. While several embodiments are herein described with regard to treating bones, other embodiments can be used in other interior body regions as well. In addition, it is also anticipated that certain embodiments could be used for purposes other than medical, such as construction, manufacturing, and excavation, among others; accordingly, nothing herein is intended to limit application of the various embodiments to purely medical uses.
Accordingly, the subject matter described above is provided by way of illustration only and should not be construed as limiting. Various modifications and changes may be made to the subject matter described herein without following the example embodiments and applications illustrated and described, and without departing from the true spirit and scope of the present invention, which is set forth in the following claims.
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Disclosed herein are devices for use through a cannula to create cavities within interior body regions. When deployed, the distal end of several such devices extend beyond the distal end of the catheter and can then be selectively curved into a shaped compression surface that, when articulated, creates a void within the interior body. This compression surface may then be withdrawn back into the cannula for removal and to make way for bone cement that, in certain instances, may be introduced through the same cannula.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Application No. 60/978,578, filed on Oct. 9, 2007. The entire disclosure of the above application is incorporated herein by reference.
FIELD
The present teachings generally relate to dual diaphragm assemblies. More particularly, the present teachings relate to a dual diaphragm assembly for a sanitation system. Additionally, the present teachings relate to a diaphragm assembly for a sanitation system having a waste chamber that drains toward an outlet.
BACKGROUND
A flush toilet basically operates to deliver a source of flush water to a bowl and transfer waste from the bowl to a remote location. Various types of systems are known, ranging from toilets that rely exclusively on flushing water for the transfer of waste to the remote location to vacuum system for assisting in the transfer of waste. While known systems have proven to be generally acceptable for their intended uses, a continuous need remains for improvement in the pertinent art.
SUMMARY
According to one particular aspect, the present teachings may provide a sanitary system includes a toilet, a source of flush water in fluid communication with the toilet, and a dual diaphragm pump assembly. The pump assembly includes a housing defining a working chamber, a water pump chamber and a waste pump chamber. A first diaphragm is disposed in the housing. The first diaphragm separates the water pump chamber and the working chamber. A second diaphragm is disposed in the housing. The second diaphragm separates the waste pump chamber and the working chamber. A common driver member interconnects the first diaphragm and the second diaphragm. A water inlet at least partially defines a water inlet path between a source of flush water and the water pump chamber. A water outlet at least partially defines a water outlet path between the water pump chamber and a bowl of the toilet. A waste inlet at least partially defines a waste inlet path between the bowl of the toilet and the waste pump chamber. A waste outlet is in fluid communication with the waste chamber. Movement of the driven member to a first position creates a positive pressure in the water pump chamber and a negative pressure in the waste pump chamber. Movement of the driven member to a second position creates a negative pressure in the water pump chamber and a positive pressure in the waste pump chamber.
According to another aspect, the present teachings may provide a waste pump for a sanitary system. The waste pump includes a housing defining a working chamber and a waste chamber. The waste chamber has a horizontally extending portion and a vertically extending portion. A waste diaphragm is disposed in the housing. The waste diaphragm separates the waste chamber and the working chamber. A driver member is disposed in the housing and is interconnected to the waste diaphragm. A waste inlet is in fluid communication with the vertically extending portion of the waste chamber. A waste outlet is in fluid communication with the vertically extending portion of the waste chamber. Movement of the driven member to a first position creates a negative pressure in the waste pump chamber and movement of the driven member to a second position creates a positive pressure in the waste pump chamber.
Further areas of applicability of the present teachings will become apparent from the detailed description provided hereinafter. It should be understood that the detailed description and specific examples, while indicating exemplary embodiments of the invention, are intended for purposes of illustration only and are not intended to limit the scope of the invention.
DRAWINGS
The present teachings will become more fully understood from the detailed description and the accompanying drawings in which the disclosed subject matter is drawn to scale, wherein:
FIG. 1 is an environmental view of a sanitation system in accordance with the present teachings.
FIG. 2 is a perspective view of a pump assembly and associated shroud in accordance with the present teachings.
FIG. 3 is another perspective view of a pump assembly and associated shroud in accordance with the present teachings.
FIG. 4 is a side view of a pump assembly in accordance with the present teachings.
FIG. 5 is a cross-sectional view taken along the line 5 - 5 of FIG. 4 .
FIG. 6 is a front view of a pump assembly in accordance with the present teachings.
FIG. 7 is a cross-sectional view taken along the line 7 - 7 of FIG. 6 .
FIG. 7A is a cross-sectional view similar to FIG. 7 , illustrating the driven member in a first position.
FIG. 7B is a cross-sectional view similar to FIG. 7 , illustrating the driven member in a second position.
FIG. 8 is a top view of a pump assembly in accordance with the present teachings.
FIG. 9 is a schematic view of a sanitation in accordance with the present teachings.
DETAILED DESCRIPTION
The following description of various aspects of the present teachings is merely exemplary in nature and is in no way intended to limit the invention, its application or uses.
With initial reference to the environmental view of FIG. 1 , a sanitation system including a pump assembly 10 constructed according to the teachings of the present disclosure is illustrated. The sanitation system is generally illustrated to include a flush toilet 11 and generally identified at reference character 10 . The particular toilet 11 shown in the drawings will be understood to be merely exemplary. In this regard, it will be appreciated the teachings of the present disclosure are not limited to any particular toilet.
With continued reference to FIG. 1 and additional reference to FIGS. 2 through 9 , the pump assembly 10 will be further described. In one particular application the pump assembly may be a dual diaphragm pump assembly 10 that is operative for delivering a source of flush water 13 to the toilet 11 and further operative for pumping waste water from the toilet 11 . The pump assembly 10 may include a housing 12 . As perhaps best shown in the cross-sectional views of FIGS. 5 and 7 , the housing 12 may define a plurality of chambers. The plurality of chambers may include a first chamber 14 , a second chamber 16 and a third chamber 18 . The first chamber may be a working chamber 14 . The second chamber may be a water chamber 16 . The third chamber may be a waste chamber 18 .
The working chamber 14 is disposed between the water chamber 16 and the waste chamber 18 . In the embodiment illustrated, the chambers 14 - 18 are horizontally arranged with the water chamber 16 above the working chamber 14 and the waste chamber 18 below the working chamber 14 . In other embodiments, water chamber 16 may be disposed below the working chamber 14 and the waste chamber 18 above the working chamber 14 . In still other embodiments, the chambers 14 - 18 may be vertically arranged.
A first membrane or diaphragm 20 may be disposed within the housing 12 to separate the working chamber 14 from the first chamber 16 . A second membrane or diaphragm 22 may be disposed within the housing 12 to separate the working chamber 14 from the second chamber 16 . The diaphragms 20 and 22 may be constructed of EPDM, other rubber or other suitable material. As will be addressed below, the diaphragms 20 , 22 may be constructed to cooperate with the housing 12 to retain the diaphragms 20 , 22 relative to the housing 12 .
The housing 12 may include a plurality of sections. The sections may be generally cylindrical or of other suitable shape. As illustrated, the housing 12 may include a first or upper section 24 , a second or intermediate section 26 and a third or lower section 28 . The first diaphragm 20 may be peripherally captured between the first and second sections 24 and 26 of the housing 12 . The second diaphragm 22 may be peripherally captured between the second and third sections 26 and 28 of the housing 12 . The sections of the housing 24 , 26 and 28 may be constructed of polypropylene or other suitable material.
As shown, the adjacent sections of the housing 12 may be integrally formed to include cooperating peripheral flanges for capturing the respective diaphragms 20 , 22 . The diaphragms 20 , 22 may be formed to include upper and lower peripheral beads. As shown in FIG. 5 , for example, the radially outermost portion of the diaphragms 20 , 22 may have a generally t-shaped cross section. The peripheral beads of the diaphragms 20 , 22 may be received in corresponding peripheral grooves of the adjacent housing sections.
The upper section 24 of the housing 12 may define an upper cavity 25 . The upper cavity 25 may receive a switch 25 for controlling actuation of the pump assembly 10 . Operation of the switch 25 will be understood to be conventional insofar as the present teachings are concerned.
The third section 28 may be integrally or otherwise formed to include a base portion 33 suitable for mounting the pump assembly 10 to a floor or other rigid surface with fasteners or the like. As perhaps most particularly shown in FIG. 7 , the third section 28 may be further formed to include a chamber floor 29 . The chamber floor 29 may be oriented generally horizontally and upwardly spaced from the base portion 33 .
The configuration of the waste chamber 18 allows the pump assembly 10 to more effectively move water and sewage given a lack of air within the chamber 18 . This is because water is incompressible as opposed to air. With a lack of air in the waste chamber 18 and a negative pressure created by the diaphragm 22 , water/sewage will substantially fill the waste chamber 18 . Then, with a positive pressure created by the diaphragm 20 , the waste chamber 18 near completely empties the water/sewage to more effectively draw in the most amount of water/sewage possible in the next movement of the diaphragm 22 . The waste chamber 18 is also particularly designed to drain completely toward the outlet 46 when the pump is off assembly 10 , such drainage reducing the amount of sewage left in the pump assembly 10 , thereby reducing the odor permeating from the toilet 11 .
The first and second sections 24 and 26 may be coupled to one another with a clamp arrangement 30 that circumferentially surrounds the housing 12 . Similarly, the second and third sections 26 and 28 may be coupled to one another with a substantially identical clamp arrangement 30 that circumferentially surrounds the housing 12 . The clamp arrangements 30 may include first and second components 32 and 34 coupled to one other with fasteners or in any manner well known in the art. The clamp arrangements 30 may define a circumferential groove for receiving the cooperating flanges of the adjacent housing sections. The clamp arrangements 30 may be constructed of acetal, polyoxymethylene, other plastic, or other suitable material.
A driven member or shaft 36 may be disposed in the housing 12 for reciprocal movement and may interconnect the first and second diaphragms 20 and 22 between a first position and a second position. The driven member 36 may include disc-shaped upper and lower members 37 and 39 coupled by an intermediate member 41 . The driven member 36 may be coupled to the respective diaphragms 20 and 22 with fasteners 38 , for example. Washers may be positioned on the side of the diaphragms 20 and 22 opposite the respective disc-shaped members 37 and 39 . The fasteners 38 may pass through the washers and the respective diaphragm 20 or 22 and threadably engage the respective upper or lower member 37 or 39 .
The driven member 36 is illustrated throughout the drawings in a neutral position between the first position and the second position. With reference to the cross-sectional views of FIGS. 5 and 7 , for example, the first position is upwardly displaced from that illustrated within the limits defined by the diaphragms 20 and 22 . Conversely and again with reference to FIGS. 5 and 7 , the second position is downwardly displaced from that illustrated within the limits defined by the diaphragms 20 and 22 .
A water inlet 40 may at least partially define a water inlet path between the source of flush water 13 and the water chamber 16 . A water outlet 42 may at least partially define a water outlet path between the water chamber 16 and a bowl of the toilet (not shown). A waste inlet 44 may at least partially define a waste inlet path between the bowl of the toilet and the waste chamber 18 . A waste outlet 46 may be in fluid communication with the waste chamber 18 . The waste outlet 46 may be disposed proximate the bottom of the waste chamber 18 to facilitate drainage of the waste chamber 18 . Valves 50 may be disposed in each of the water inlet path, the water outlet path, the waste inlet path and the waste outlet path for controlling the flow of water and waste. The valves may be one-way valves 50 .
A rotatable motor arm 52 may be coupled to the shaft 36 for reciprocating the shaft 36 between the first and second position. When the motor arm 52 is rotated about its axis, a crank arm 54 may turn inside a slot 56 (see FIG. 5 , for example) in the shaft 36 . Due to an offset of the crank arm 54 , the shaft 36 is reciprocally driven in opposition vertical directions, thereby displacing both diaphragms 20 and 22 in vertical directions. The motor associated with the motor arm 52 may be an electrical motor. The switch 37 carried at the top of the pump assembly 10 may actuate the electrical motor.
In response to actuation by the switch 37 , the driven member 36 is reciprocated between the first and second positions. The diaphragms 20 and 22 simultaneously cooperate with the associated one-way valves 50 operate to create a negative pressure to draw fluid into each pump and then a positive pressure to push fluid out of each pump. More particularly, when the driven member 36 moves the first position (up in FIG. 5 , water is drawn from the flush water source 13 and pumped to the toilet 11 . When the driven member 36 moves to the second position (down in FIG. 5 ) waste is drawn from the toilet 11 and pumped to a remote area 43 . The remote area 43 may be a holding tank, a sewer or other receptacle.
The waste chamber 18 is particularly adapted to pump water/sewage out of the toilet 11 and into a holding tank assembly 10 , sewer, or overboard in addition to being mounted to the floor and support the pump in a vertical orientation. The work chamber 14 includes a horizontally extending portion 18 A in communication with a vertically extending portion 18 B. The horizontally extending portion 18 A is sized and positioned such that upon downward translation of the shaft 36 , contents within the horizontally extending portion 18 A are near completely displaced.
The sanitation system may further include shroud for substantially concealing the pump assembly 10 . The shroud may be secured to the pump assembly 10 in any manner well known in the art. The shroud provides a neat appearance and a surface that is easy cleaned.
It will now be appreciated that a pump assembly 10 is provided potentially having a lower cost, quieter operation and a more reliable mechanism. In this regard, the dual diaphragm arrangement of the present teachings compares favorably with conventionally pumping mechanism incorporating a hard plastic impeller for evacuating waste from a bowl and a flexible rubber impeller that supplies fresh water to the bowl. Such conventional structures are loud and experience significant wear when run dry. The dual diaphragm arrangement of the present teachings greatly reduces noise associated with the pump assembly 10 and has the ability to run dry for extended periods of time without undue wear.
As shown in the drawings, the present teachings may be used to provide a common unit for both waste and water pumping. The flexibility of the present teachings anticipates additional applications. In this regard, the present teachings may be used as a single waste pump by eliminating the water pump or a single water pump by eliminating the waste pump. Additionally, the present teachings may be adapted for use with a dual waste pump where the water pump is replaced with a second waste pump or a dual water pump where the waste pump is replaced with a second water pump.
The description of the present teachings is merely exemplary in nature and, thus, variations that do not depart from the gist of the invention are intended to be within the scope of the invention. Such variations are not to be regarded as a departure from the spirit and scope of the invention. Furthermore, the present invention has been described with reference to two particular embodiments having many common and some distinct features. One skilled in the art will recognize that these features may be used singularly or in any combination based on the requirements and specifications of a given application or design.
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A pump assembly includes a housing defining a working chamber, a water pump chamber and a waste pump chamber. A first diaphragm separates the water pump chamber and the working chamber. A second diaphragm separates the waste pump chamber and the working chamber. A common driver member interconnects the first diaphragm and the second diaphragm. Movement of the driven member to a first position creates a positive pressure in the water pump chamber and a negative pressure in the waste pump chamber. Movement of the driven member to a second position creates a negative pressure in the water pump chamber and a positive pressure in the waste pump chamber.
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FIELD OF THE INVENTION
This invention relates to an improved apparatus and method for removing selected portions of material from a tire surface while the tire is rotating. The invention is particularly applicable to grinding the tread surface of a tire to improve its force variation characteristics, and may also be used to improve the tire's run-out, or out-of-roundness characteristic, as well as its conicity.
BACKGROUND OF THE INVENTION
The correction of tires to reduce force variations is called "tire uniformity optimization" or "TUO", and is disclosed in a number of publications including U.S. Pat. Nos. 3,724,137; 3,725,163; 3,849,942; 3,914,907 and 4,047,338. The apparatus of these patents all sense force variations imparted by a tire rotating against a load drum. They also generate electrical signals representing these force variations. In response to those signals, the methods and apparatus of all except the '163 patent move a grinding wheel into and out of cutting engagement with the tread surface of a tire. Because the force variations are caused by variations in the stiffness and geometrical dimensions of the tire about its circumference, the portions of the circumference where the force transmitted between the tire and the load drum is excessively high in relation to other portions may be corrected by removing rubber from the tire tread. This rubber removal reduces the tire's stiffness and tread thickness in these portions and consequently reduces the amount of force transmitted to levels closer to the force transmitted in other areas. In the method of the '163 patent, additional rubbery material is applied to the tread surface in areas of low force transmission instead of being removed in areas where the force is high.
In previous methods and apparatus for correcting force variations that employ rubber grinding or other cutting devices, such as those shown in the '137, '907, '338 and '942 patents referred to above, hydraulic pistons are used to move the grinding wheels into and out of engagement with the tread rubber. The pistons locate the grinding wheels at the desired cutting depths and are moved by pressurized hydraulic fluid. The fluid is controlled by a servo system that is designed to move the pistons and grinding wheels to their correct grinding positions. However, while the pressurized fluid pushes the grinding wheels in one direction, the tire being buffed pushes back on the grinding wheels; so the exact positioning of the pistons and grinding wheels is determined by a balancing of the pressure in the hydraulic system to position the grind wheel. Also, the pistons can be delayed and can oscillate as they travel to their full cutting depth during this hydraulic pressure/tire force balancing. Thus, one problem with using hydraulic pistons to locate the grinding wheels is that the wheels cannot be set at accurately fixed, predetermined cutting depths at the exact locations of the tire circumference where rubber removal is desired.
Another problem with the previous tire uniformity optimization systems is that the positioning of the grinding wheel is made without reference to the actual position of the surface of the tire where the grinding takes place. The run-out of the tire determines where the surface of the tire is at any given location of grinding, and must be taken into consideration in determining where to locate the grinding wheels to remove a desired thickness of rubber. While some previous systems use the run-out measurement to determine how much hydraulic pressure to apply to the pistons, this is for the purpose of reducing the areas of high run-out, a process which is called "tire trueing". However, this is not the same as using the run-out measurement to establish a reference position for the grinding wheels at each circumferential location on the tire, so that the grinding wheels can be moved inwardly from that reference position by the exact distance equal to the depth of the cutting desired at that location.
Still another problem with previous tire uniformity optimization methods and apparatus is that they are carried out at high speeds, usually about 60 revolutions per minute. While for a passenger tire this is equivalent to running at only about 5 miles per hour, that is a relatively fast speed for correcting tires for non-uniformities. Errors caused by grinding too much or too little or in the wrong areas can occur, and the final appearance of the tire can suffer because each circumferential portion being ground moves by the grinding wheel at a relatively fast rate, resulting in fewer passes of the grinding wheel during each pass of the tread portion. Consequently, a rougher grind is produced.
SUMMARY OF THE INVENTION
An object of the invention is to provide an apparatus for removing rubber from tires in which the cutting device that removes the rubber is accurately controlled and produces a smooth surface on the cut portions of the tire.
Another object of the invention is to provide a tire uniformity correction apparatus that accurately controls the grinding wheel or other cutting device that is used to remove the rubber in response to force variation measurements taken on the tire.
Yet another object of the invention is to provide a method of correcting tire uniformity in which a grinding wheel or other cutting device is accurately controlled to remove the desired thickness of rubber from the tire tread.
Still another object of the invention is to provide a method of grinding or cutting material from tires in which the tire is rotated at a relatively slow speed compared to speeds normally used for grinding and measuring force variations of tires, so that a relatively smooth surface is produced on the cut portions of the tire.
These and other objects and advantages are obtained by an apparatus and method in which a positioning means is designed to hold a cutting device in a fixed, accurately determined position relative to the tire surface for a predetermined increment of distance and is also designed to be varied during successive intervals corresponding to successive increments of the tire circumference. A computing device receives electrical signals representative of circumferential variations in a characteristic of the tire, and determines, based on these signals, the placement of the cutting device relative to the tire surface for each distance interval corresponding to an increment of the tire circumference. The computing device is connected to the positioning means and controls the positioning means to locate the cutting device at its proper location in each increment of the tire circumference, so as to remove the desired amount of material from each of these increments.
In one embodiment of the invention, a load wheel is movable into loaded engagement with the tread surface of the tire, and a load cell measures the variations in force transmitted between the tire and the load wheel. The electric signal generating means generates signals proportional to the force variations and the cutting device is in the form of a grinding wheel which removes rubber from the tire to reduce the force variations.
According to the method of the invention, force variations in a tire are reduced by measuring the magnitudes and locations of the force variations, and calculating from these measurements the depth of cutting required in each of a plurality of increments of the tire circumference. The radial run-out of the tire is also measured, and in response to the run-out measurements and cutting depth calculations, a cutting device is molded into engagement with the rotating tire at the calculated cutting depth relative to the run-out measurement at each increment of the tire circumference.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a top schematic view of a tire, a load drum and a tire uniformity optimization apparatus illustrating one embodiment of the present invention;
FIG. 2 is an enlarged top view of the tire uniformity optimization apparatus of FIG. 1;
FIG. 3 is a right-end view of the apparatus of FIG. 2, showing the frame on which the apparatus is mounted with a part thereof broken away in section, taken along line III--III of FIG. 2;
FIG. 4 is a partial view of the apparatus of FIGS. 1 through 3 with portions thereof broken away in section, taken along line IV--IV of FIG. 3;
FIG. 5 is a sectional view of a portion of the apparatus of FIGS. 1 through 4, taken along line V--V of FIG. 2;
FIG. 6 is a partial sectional view of the apparatus of FIGS. 1 through 5, taken along line VI--VI of FIGS. 2 and 3.
FIGS. 7, 8 and 9 are side views of three cutting devices or grind wheels which are designed for use with the apparatus of FIGS. 1 through 6;
FIG. 10 is a side view of a run-out measuring sensor designed for use with the method of the present invention and with the apparatus of FIGS. 1 through 6; and
FIGS. 11, 12 and 13 are block diagrams illustrating a preferred method of carrying out the present invention.
DESCRIPTION OF PREFERRED EMBODIMENTS
In FIG. 1, a tire T is mounted and inflated on a rim. A variable speed motor 4 rotates the tire T about its axis. The tire T is shown under load provided by a load wheel 6, rotatably supported on bearing blocks 8 on either side of the wheel. The blocks 8 are movable by electric motors 10 which operate by a ball-and-screw connection to bring the wheel 6 into and out of engagement with the tire T. A tire grinding apparatus 12 is located on the opposite side of tire T from load wheel 6.
A radial run-out transducer 14 is shown in FIG. 1 positioned on the surface of the tire T for sensing the variations in the tread diameter around the tire's circumference. The transducer 14 receives power from power source 16 and feeds the run-out signal through a signal conditioner 18 to a computer 20. Preferably a transducer 14 is positioned on each shoulder of the tire, so that the runout of each shoulder can be checked independently.
Load cells 22 are mounted on the axle of load wheel 6 to measure the force transmitted to the tire T as it rotates against the wheel 6. A power source 24 and electric signal conditioner 26 transform the force measurements sensed by the load cells 22 into electric signals which can be received and stored in the computer 20.
The computer 20 stores the electric signals received from the signal conditioner 26, assigning a force value to each of a large number of increments of the tire circumference. Preferably, there are at least 100 such increments and they should be of equal length. Thus in the case of 100 increments, which is a 3.6° arc of the tread. The computer is programmed to determine whether the differences in the force values of the various increments are below the chosen maximum limits beyond which it is not desirable to try to correct the tire. If the tire passes this test, the computer determines how much rubber must be removed from the tread increments having the force values that are too high. These calculations are made using a multiplier factor based on what previous experience with the tire being corrected indicates is the correct depth of cut required to reduce by a certain amount the force transmitted by the tire. This is the type of correction one would use to reduce the composite force variation of the tire. Alternatively, the first harmonic component and/or other harmonic components of the composite force variation pattern may be calculated and the increments to be ground and grinding depths in each increment may be based on the peaks occurring in one or more of these component patterns. The computer can be programmed to make these calculations using mathematical relationships well known in the art.
After the computer calculates the total depth of grinding required for each increment of the tread circumference, it sets the grinding depth at which rubber is to be removed from each increment during each revolution of the tire, according to a preset formula designed to remove relatively large amounts of rubber at the beginning of the grinding and to use smaller finishing cuts near the completion of the grinding. The computer combines these chosen grinding depths with the radial run-out values for each increment being ground to determine where the carriages holding the grinding wheels must be placed to grind the increments at their chosen depths. Based on this information, the computer sends commands to stepper motors 28 and 30 mounted on the apparatus 12 and shown in FIG. 3, to position grinding wheels 32 (FIGS. 1, 2 and 3) and 34 (FIG. 3) in their desired grinding location for each increment of the tire tread passing by them.
The grinding apparatus 12 is supported on column members 36 (FIGS. 1, 2 and 3). As best seen in FIGS. 2, vertical plates 38 and 40 are welded to plates 42 on the inside of each column to form supporting brackets that are held on the column 36 by bolts 44 and plates 46 on the outsides of the columns. Vertical dove tail rails 48 attached to the plates 40 form tracks on which supports 50 and 52 may be independently raised and lowered. As best seen in the sectional view of FIG. 6, the bearing support 50 may be raised and lowered by turning screw 54, which is rotatably held by a bracket 56 connected to plate 40 and threadably engage a collar 58 on bearing support 50. The screw 54 is powered by a stepper motor 59. A screw similar to screw 54 powered by a stepper motor 61 (FIG. 3) may be turned to raise and lower bearing support 52. This adjustment of the bearing supports 50 and 52 allows the grinding wheels 32 and 34 to be spaced at different distances apart to accommodate the grinding of different sizes of tires.
Horizontal frame members 62 and 64 are rotatably mounted on bearing supports 50 and 52 by means of trunions mounted in roller bearings. The trunion 66 and roller bearings 68 mounted on frame member 62 are shown in the partial section of bearing support 50 of FIG. 2. The frame members 62 and 64 may be rotated about their trunions by turning screws 70 and 72, rotatably mounted by brackets 74 and 76 on the sides of bearing supports 50 and 52. As shown in FIG. 6, the screw 70 threadably engages a collar 78 connected to the tube 80. The screw 70 is powered by a stepper motor 81. By turning the screw 70, the tube 80 may be raised or lowered to raise or lower arm 82 fixed to the top of the tube 80. As shown in FIG. 3, a link 84 connects the arm 82 to a pin 86 extending from the side of frame member 62, so that through this linkage, the turning of the screw 70 rotates the frame member 62 about the trunion 66. Likewise, screw 72, powered by a stepper motor 87, may be turned to move arm 88 and connected link 90 which is attached by pin 92 to frame member 64, thus rotating the member 64 about its horizontal trunion, which is not shown in the drawings. The rotation of the horizontal frame member 62 and 64 makes possible the setting of the grinding wheels 32 and 34 at different angles to the centerplane of the tire, so that tires of different tread profiles may be corrected.
Referring to FIGS. 2 and 3, the frame members 62 and 64 each support two round rails 94 and 96 respectively, fastened to the members 62 and 64 by brackets 98 and 100 respectively. Carriage 102 supporting grind wheel 32 is mounted on upper rail 94 by means of a slide bearing 104 and on the lower rail 94 by means of a bracket 105. Carriage 106 supporting grind wheel 34 is mounted on lower rail 96 by means of a slidebearing 108 (FIG. 3) and on the upper rail 96 by means of a bracket 109. As shown in FIG. 2, bellows 110 cover the rails 94 for protection, and they are mounted between the brackets 98 and slide bearings 104. Bellows 112 between brackets 100 and slide bearings 108 protect the rails 96.
Referring to FIG. 4, the carriage 102 and 106 are driven along rails 94 and 96 by stepper motors 28 and 30, mounted on frame members 62 and 64 by brackets 114 and 116 respectively. The stepper motors 28 and 30 drive threaded shafts 118 and 120, which engage brackets 105 and 109 to advance or pull back the carriages 102 and 106 to position their respective grinding wheels 32 and 34. The stepper motor 28 and 30 are provided with stop means that enables them to turn the shafts 118 and 120 by precise amounts in response to coded commands.
Because of the threaded screw means of advancing the carriages 102 and 106, the reaction forces caused by pressing the grinding wheels 32 and 34 against the tire T have very little effect on the positioning of the grinding wheels. This enables the apparatus 12 to grind the various increments of the tread circumference to the exact depths desired.
The drive system for the grinding wheels is illustrated in FIG. 5 for the grind wheel 34. An electric motor 122 mounted on the carriage 106 drives a pulley 124. The grind wheel 34 is fixed to a shaft 126 which is in turn rotatably mounted by ball bearings 128 on the carriage 106. A pulley 130 on the shaft 126 is connected by an endless belt 132 to the motor driven pulley 124. Thus, the motor 122 drives the grinding wheel 34 within its protective housing 134.
FIGS. 7 and 8 illustrate several grinding wheels 136 and 138 having two types of recommended cutting surfaces. The wheel 136 has spiral cutting edges which shave off the rubber from the tire much like a milling cutter machines a metal surface. The wheel 138 has cutting surfaces that function in a similar manner, but they are arranged in converging relationships to provide elongated separate cutting ridges 140.
FIG. 9 shows a grinding wheel 142 that has a contoured surface (143) to more closely match the shoulder ribs of a typical radial tire, in order to grind the tread more uniformly and over a wider surface area.
FIG. 10 illustrates a run-out transducer 14a that is especially designed for measuring the run-out of tires having wide lateral grooves. The transducer is equipped with an elongated curved plate 144 that is designed to bridge the gap between such lateral grooves, so that the transducer will not be subject to sudden impulses by a shorter plate hitting the walls of the grooves.
The preferred method of practicing the present invention is illustrated in the diagrams of FIGS. 11, 12 and 13.
As FIG. 11 shows, the tire is conveyed to a check point (148) at an inlet gate. When the tire arrives, the inlet gate opens (150) and the tire is centered over a chuck (152). The chuck moves up to seat the tire on the test rim (154), and the tire is inflated to seat the beads (156). After the beads are seated, the tire is pressurized to its inflation test pressure (158) which for most passenger tires is recommended at 30 PSI. When the tire has reached its test pressure, the motor 10 is operated to move the load wheel 6 into engagement with the tire (160), and one or more run-out probes 14 are moved into their measuring positions on the tread surface (162). The run-out of the tire is received by the computer 20, which commands the stepper motors 28 and 30 to advance the grind wheels 32 and 34 to their "ready" position, (164) spaced a short fixed distance from the tire tread and tracking the tread surface according to the run-out measurement taken by the run-out probes 14.
After a warm-up period (166), the tire is run in clockwise and/or counter clockwise directions at 60 RPM to take another reading of the run-out and also the measure of the force variation pattern of the tire (168). The run-out and force variation signals produce by the run-out and force variation signal conditioners 18 and 26 are digitized by the computer, by assigning a value for each measurement to each of 100 equal increments of the tire circumference (170). The run-out variations are compared with pre-set limits to determine whether the run-out should be corrected (172). If the run-out is not within these limits, it is checked to determine if it is within maximum limits for making it worthwhile to correct the tire (174) (FIG. 12). If the tire fails this test the run-out and force correction steps are by-passed and the grinding wheels and run-out probes are retracted (176). If the run-out variation is below the limits making correction worthwhile, the motors 28 and 30 advance the grinding wheels 32 and 34 to the proper grind depths in the increments where the run-out is too high (178). Preferably, the grinding wheels 32 and 34 are independently controlled by separate signals from transducers 14 on each shoulder of the tire. This will enable the tire to be corrected for conicity, as well as reducing the run-out variation.
After grinding to correct the run-out, and if desired the conicity, these measurements are checked again to determine whether they are below the limits compared in step (172). If not, the amount of time spent on run-out grinding is compared with a maximum grind time, so that too much time is not taken grinding a tire that is difficult to correct for run-out and conicity (182). If there is still time remaining on the grinding clock, the grinding step (178) is repeated.
When the run-out and conicity grinding are completed, the variations in the tire's force values for the various circumferential increments are compared with the acceptable force variation limits (184) (FIG. 1). If the force variation is acceptable the force correction steps are by-passed and the grinding wheels and run-out probes are retracted (176). If the force variation is not acceptable, the variation is compared with maximum values above which it is considered not worthwhile to correct the tire (186) (FIG. 13). If the force variation is above these maximum values, the correction is terminated and the grinding wheels and run-out probes are retracted (176) (FIG. 11).
If the variation in the force values is within the range in which it is worthwhile to correct the tire, the speed of the motor 4 rotating the tire T (FIG. 1) is reduced to an optimum speed below 60 RPM for force variation correcting the tire (188) and the required grinding depths are calculated by the computer 20 (190). Using these grinding depths, the computer 29 directs the stepper motors 28 and 30 to position the grinding wheels in their proper positions for reducing the force values in each increment of the tire circumferences that needs correction (192). During this correction the force variation values are continuously monitored by the computer 20 (194), and if the grinding depths need to be reset (196) and the depths which are needed for correction are below the maximum permissible depths for grinding (198) the grinding depths are reset (200) and the grinding to correct the force variation (192) continues. When the measured force variation that is being monitored is reduced to its limits of acceptability, the tire speed is increased back to 60 RPM (202) and the force variation is checked at this higher speed (204).
Following the force variation correction, the grinding wheels 32 and 34 and run-out probes 14 are retracted (176). Preferably, the computer calculates the location of the peak of the first harmonic of the radial force variation pattern of the corrected tire and a marking device marks the tire at this point (206). The motor 4 then reverses the direction of rotation of the tire (208) and tests the force variation of the tire at 60 RPM (210). The computer determines the tire grade and sets the markers for subsequent marking (212) and then the speed of the tire is reduced until the tire stops rotating (214). The motor 10 retracts the load wheel (216), the tire is deflated (218), removed from its chuck (220 and 222) and conveyed to a marking station (224) for tire grade marking (225). The tire is then conveyed through an exit gate (228) for appropriate disposition according to the grade it receives.
While several embodiments of the present invention have been shown and described, modifications and additions may of course be made without departing from the scope of the following claims.
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An improved apparatus and method are provided for cutting a tire surface to remove selected portions of rubber from the tire surface while the tire is rotating. The apparatus and method are especially useful in removing tread material from the tire to improve the force variation and runout characteristics of the tire. The material is removed by a cutting device such as a grinding wheel and a positioning device which holds the cutting device in a fixed cutting position for an incremental period of time while a corresponding incremental segment of the tire circumference, for instance a segment equal to 1/100 of the circumference (3.6°), passes by the cutter. A sensing device measures a characteristic of the tire, such as its radial forced variation, and radial run-out of the tire is also measured. Based on these measurements, a computing device determines the amount of material to be removed from each incremental segment of the tire circumference and controls the positioning device so that the cutter is located in the correct position for removing the desired amount of material from each incremental segment of the tire circumference.
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BACKGROUND OF THE INVENTION
[0001] Chemical preservatives such as sulfur dioxide help keep food fresh. Preservatives can be categorized into three general types: antimicrobials that inhibit growth of bacteria, yeasts, or molds; antioxidants that slow air oxidation of fats and lipids, which leads to rancidity; and a third type that blocks the natural ripening and enzymatic processes that continue to occur in foodstuffs after harvest.
[0002] Sulfur dioxide is a commonly used preservative as it serves all three functions, and its related compounds, sulfites are found in foods, alcoholic drinks (especially wines), and even in medications.
[0003] Sulfites inhibit microbial growth through a number of actions, they react with the energy currency of the cell, adenosine triphosphate; inhibit some metabolic pathways; and block cellular transport systems. Other antimicrobials alter microbial membrane or cell wall permeability or destroy the genetic material.
[0004] In addition to its antimicrobial action, sulfur dioxide inhibits degradation reactions in fruits, by blocking both enzymatic browning and a nonenzymatic browning reaction between reducing sugars and amino acids.
[0005] About 1% to 2% of people will have an allergic reaction to sulfites, which can consist of nasal congestion and sneezing, skin hives, or wheezing and difficulty breathing. People who have asthma and/or allergies to aspirin are particularly sensitive to sulfites and could even have a serious anaphylactic reaction, in which there is severe swelling of the throat, tongue, and airway, which obstructs breathing and can lead to death.
[0006] Examples of antimicrobials include propionic acid, which occurs naturally in strawberries, apples, violet leaves, grains, and cheese. This acid is effective against bread molds and the spores of the bacterium Bacillus mesentericus , which cause an inedible condition in baked goods called rope.
[0007] Other weak organic acid antimicrobials include benzoates, found naturally in cranberries, and sorbates. Because these compounds work best at a low pH—in the range that excludes much bacterial growth—they are used primarily as antifungals. Esters of p-hydroxybenzoic acid, also known as parabens, are similar to benzoic acid but effective at a higher pH. Many beverages, jams, pickled products, salads, cheeses, meats, and margarines contain benzoates or sorbates.
[0008] Nitrites and nitrates are the food industry's primary chemical defense against the bacterium Clostridium botulinum. They also impart a pink, fresh hue to cured meat. Nitrates readily convert to nitrites, which then react with the protein myoglobin to form nitric oxide myoglobin. During cooking, this is converted to nitrosohemochrome, a stable, pink pigment. In the absence of nitrates or nitrites, meat turns brown. However, nitrites react with amino acids to form the cancer causing agents, nitrosamines.
[0009] A third group of preservatives targets enzymes in the food itself that continue to metabolize after harvest. The enzyme polyphenoloxidase, for example, goes to work as soon as an apple or potato is cut. It browns the exposed surface. Acids such as citric acid and ascorbic acid (vitamin C) and erythorbic acid inhibit phenolase by making the pH uncomfortably low for the enzyme.
[0010] And metal-chelating agents such as EDTA (ethylenediamine tetraacetic acid) can remove the metal cofactors that many enzymes need. Chelators also make it difficult for plant bacterial and fungal enzymes to carry on.
[0011] As can be seen there is a need in the art for other food preservatives, preferably those that are in natural products. Some of the newest antimicrobials have been found in microorganisms themselves as they form their own chemical defenses when competing with each other for space and nutrients. For example, nisin and natamycin—cheese preservatives called bacteriocins—are harvested from microorganisms. Other potential natural preservative sources include honey, milk, and even dried plums as scientists seek new sources and combinations of safe, effective preservatives.
[0012] It is an object of the present invention to provide a safe effective naturally occurring preservative that is stable, and does not adversely affect the taste of food products.
SUMMARY OF THE INVENTION
[0013] According to the invention, Applicant's have found that the naturally occurring compound, ergothioneine has the ability to act as an antioxidant and chelator of heavy metals and may be used as a for food preservative for food, beverages, medicines and the like.
[0014] The invention thus relates to the novel use of ergothioneine and preferably, L ergothioneine, (also known as thiotane or thiotaine) having a chemical formula as seen in FIG. 1 , as a preservative in foods, medicines, and/or beverages. Ergothioneine was found to be very stable over time in and to have no deleterious effects on taste and consistency of food and beverages even when stored over a period of several years.
[0015] The invention includes a method of preserving beverages, medicines and other food stuffs by adding to the same an effective amount of ergothioneine, preferably L-ergothioneine. The invention also includes foods, beverages and medicines so modified, as well as methods of maintaining and improving overall health by administration of products fortified with this nutritionally valuable antioxidant.
[0016] In one embodiment, the ergothioneine is a replacement for all or part of sulfur dioxide or other sulfites used as a food preservative and can be used as an anti-microbial, and antioxidant without the allergic effects of sulfur and sulphites.
[0017] According to the invention, ergothioneine, preferably L-ergothioneine, may be used as a replacement for all or part of other known preservatives such as ascorbic acid, sodium nitrates, propionic acid, sorbic acid, benzoic acid, sodium erythorbate, erythorbic acid, ascorbic acid, sodium succinate, grape seed extract, pine bark extract, apple extract tea proplyphenols, succinic acid and preservatives like parabens, and sodium dehydro acetate.
[0018] Not only is ergothioneine useful as a food preservative, is a powerful antioxidant with health benefits for the consumer of foodstuffs and beverages so preserved. Thus, the composition, in addition to helping preserve the food or beverage product, also makes the product more nutritionally healthy. Thus another aspect of the invention is the use of ergothioneine, particularly, L-ergothioneine as an additive to food and beverages to add to the health benefits of the same.
[0019] Numerous studies have shown that consuming fruits and vegetables which are high in antioxidants may reduce the risk of developing chronic diseases. Ergothioneine, highly protective, nontoxic, naturally occurring compound with strong antioxidant properties and which provides cellular protection within the human body. One unit of L-Ergothioneine is approximately equivalent to 7000 units of Vitamin E. It is readily water soluble, reaches near millimolar concentrations in selected tissues, and stimulates the natural antioxidant defenses within cells.
[0020] The benefits of natural antioxidants such as vitamin C and vitamin E in cancer, aging and general health are well known. Newer natural antioxidants such as pyrogallol, lipoic acid and ubiquinone are now being introduced into the market. L-ergothioneine is unique among antioxidants in that it chelates heavy metal, while protecting cells (principally erythrocytes) from damage and has its own transport system for uptake into cells, See PCT published application number PCT WO 2005/116657, the disclosure of which is hereby incorporated in its entirety by reference.
[0021] While not wishing to be bound by any theory, it is postulated that ergothioneine which naturally occurs in red wine, may be responsible for some of the healthy effects of red wine noted of late, which has been attributed to the flavonoids and antioxidants present in red wine. They include the effects of helping to reduce the production of LDL, low density lipoprotein—sometimes referred to as “bad” cholesterol. Red wine has also been shown to have the effect of increasing HDL, high density lipoprotein, the so-called “good” cholesterol. These combined effects help to prevent blood clots and improve the lipid profile overall.
DESCRIPTION OF THE FIGURES
[0022] FIG. 1 is a depiction of the chemical structure of ergothioneine.
DETAILED DESCRIPTION OF THE INVENTION
[0023] Chemically L-ergothioneine (C 9 H 15 N 3 O 2 S.H 2 O) corresponds to the betaine of 2-thio-L-histidine, it is the only known naturally occurring 2-thio-imidazole amino acid to date. Its formula is shown in FIG. 1 . The compound is also known as thiotane or thiotaine, as used herein, the term L-ergothioneine shall also include thiotaine or thiotaine as exemplified by the compound (C 9 H 15 N 3 O 2 S.H 2 O) for the methods and compositions of the invention. The compound is extremely hydrophilic with a solubility limit of 0.9M at room temperature.
[0024] Ergothioneine is a phytonutrient and naturally occurring antioxidant that is very stable in the body. No toxicity to this compound has been shown. It is synthesized in fungi and a few bacteria, and present in both plants and animals. Animals are unable to synthesize L-ergothioneine and must obtain it from dietary sources. It is readily absorbed and is active in most mammalian tissues, concentrating especially in the liver, where it prevents certain types of free-radical-induced damage to cell membranes and organelles. For example, exogenous L-ergothioneine has been shown to prevent lipid peroxidation by toxic compounds in the liver tissue of rats. In a recent study comparing the inhibition of lip peroxide (“LPO”) formation by various compounds in mouse liver, L-ergothioneine both inhibited LPO formation and enhanced the decomposition of existing LPO.
[0025] Additionally, L-ergothioneine serves as an antioxidant and a cellular protector against oxidative damage. The antioxidant properties of L-ergothioneine include: a scavenger of strong oxidants; chelation of various divalent metallic cations; and plays a key role in the oxidation of various hemoproteins. L-ergothioneine has been shown to inhibit the damaging effects caused by the oxidation of iron-containing compounds, such as hemoglobin and myoglobin. These molecules are important in the body as carriers of oxygen, but because they contain divalent iron, they can interact with hydrogen peroxide via the Fenton reaction to produce the even more damaging hydroxyl radical. This has been suggested as a mechanism by which damage occurs during so-called reperfusion injury.
[0026] Studies have shown that ergothioneine is a powerful scavenger of hydroxyl radicals, but unlike other scavengers, ergothioneine is able to inhibit iron and copper-ion dependent generation of hydroxyl radicals (Alanmu, et al 1991). Also, ergothioneine has the ability to complex with divalent metal ions; such as copper, cadmium and mercury (Motohashi et al 1976). Ergothioneine is an excellent chelator of divalent metal ions. This is particularly important as iron and copper ions play a significant role in catalytic browning and instability issues in wine and other foods.
[0027] Processes for obtaining ergothioneine and L-ergothioneine synthetically and as purified from natural sources such as pig blood, or grains are known in the art and embodied, for example in U.S. Pat. No. 5,438,151, incorporated herein by reference. The composition is also commercially available from Oxis, International, Foster City, Calif., and from Toronto Research Chemicals, Inc., North York, Ontario, Canada. It is also commonly purified from filamentous fungi such as mushrooms, particularly mycelia. It may also be purified from liquid culture of mycelia of filamentous fungi from the mycelia, or as excreted into the culture supernatant.
[0028] According to the invention, traditional food additives, such as sulfur dioxide, ascorbic acid or erythorbic acids and/or their salts may be replaced partially or completely by ergothioneine, preferably L-ergothioneine. The addition of ergothioneine to foodstuffs and beverages not only can have an antioxidant effect but also an antimicrobial effect as well. Ergothioneine also has a phytonutrient benefits that may make the food more nutritional.
[0029] For example, in the wine making process sulfur dioxide is added to reduce oxidation and preserve wine during storage and fermentation. It is added at very high levels, 180 ppm to prevent rot and hoer deterioration. By the time the wine reaches the consumer, the sulfur dioxide has degraded and is present only at 60-60 ppm. The CU and most countries have established legal limits of sulfur dioxide limits in wine. In the stomach, much of the bound sulfur dioxide will be released by the acidity and warmth of the digestive system, becoming toxic to human health if above a safe limit. Typical limits are 260 mg/lit for red wines and 210 mg/lit for white wines. Sulfur dioxide is added at many stages during the wine making process and serves two, basic purposes, Firstly, it is an anti-microbial agent, and as such is used to help curtail the growth of undesirable fault producing yeasts and bacteria. Secondly, it acts as an antioxidant, safeguarding the wine's fruit integrity and protecting it against browning. According to the invention, all or part of the sulfur dioxide added to wine may be replaced with L-ergothioneine. For example wine makers concerned with overall texture of wine may want to hang and store grapes before crushing, ergothioneine could be added at this stage to help with the storage and to prevent breakdown of the grapes. L-ergothioneine may be added and used at different temperatures to improve overall effectiveness as it is more stable than sulfur dioxide. Ergothioneine could also be used to stabilize the lees, the sediment containing the grape skins from wine production.
[0030] As used herein the term ergothioneine shall be interpreted to include variants, homologs, optical isomers and the like which retain the antioxidant activity of ergothioneine or L-ergothioneine as demonstrated and described herein.
[0031] Ergothioneine from any source may be used according to the invention.
[0032] The preservative compositions of the invention comprise ergothioneine alone or in combination with other excipients, carriers, fillers additives and the like. In embodiments where the composition is in a liquid form, a carrier can be a solvent or dispersion medium comprising but not limited to, water, ethanol, polyol (e.g., glycerol, propylene glycol, liquid polyethylene glycol, etc.), lipids (e.g., triglycerides, vegetable oils, liposomes) and combinations thereof. The proper fluidity can be maintained, for example, by the use of a coating, such as lecithin; by the maintenance of the required particle size by dispersion in carriers such as, for example liquid polyol or lipids; by the use of surfactants such as, for example hydroxypropyl cellulose; or combinations thereof such methods. In many cases, it will be preferable to include isotonic agents, such as, for example, sugars, sodium chloride or combinations thereof.
[0033] In certain embodiments the preservative composition may comprise one or more binders, excipients, disintegration agents, lubricants, flavoring agents, and combinations thereof. In certain embodiments, a composition may comprise one or more of the following: a binder, such as, for example, gum tragacanth, acacia, cornstarch, gelatin or combinations thereof; an excipient, such as, for example, dicalcium phosphate, mannitol, lactose, starch, magnesium stearate, sodium saccharine, cellulose, magnesium carbonate or combinations thereof; a disintegrating agent, such as, for example, corn starch, potato starch, alginic acid or combinations thereof; a lubricant, such as, for example, magnesium stearate; a sweetening agent, such as, for example, sucrose, lactose, saccharin or combinations thereof; a flavoring agent, such as, for example peppermint, oil of wintergreen, cherry flavoring, orange flavoring, etc.; or combinations thereof the foregoing. Typical formulae for compositions are, well known in the art. In addition to proteinaceous and farinaceous materials, the compositions of the invention generally may include vitamins, minerals, and other additives such as flavorings, preservatives, emulsifiers and humectants. The nutritional balance, including the relative proportions of vitamins, minerals, protein, fat and carbohydrate, is determined according to dietary standards known in the veterinary and nutritional art.
[0034] The preservative composition of the present invention can further comprise a wide range of other optional ingredients. Non limiting examples of additional components include animal protein, plant protein, farinaceous matter, vegetables, fruit, egg-based materials, undenatured proteins, food grade polymeric adhesives, gels, polyols, starches, gums, flavorants, seasonings, salts, colorants, time-release compounds, minerals, vitamins, antioxidants, prebiotics, probiotics, aroma modifiers, textured wheat protein, textured soy protein, textured lupin protein, textured vegetable protein, breading, comminuted meat, flour, comminuted pasta, water, and combinations thereof.
[0035] Also useful herein, as an optional ingredient, is a filler. The filler can be a solid, a liquid or packed air. The filler can be reversible (for example thermo-reversible including gelatin) and/or irreversible (for example thermo-irreversible including egg white). Non limiting examples of the filler include gravy, gel, jelly, aspic, sauce, water, air (for example including nitrogen, carbon dioxide, and atmospheric air), broth, and combinations thereof.
[0036] Any food, beverage or medicine in need of preservatives, particularly antioxidants to enhance stability, shelf life and the like may be treated with the methods and compositions of the invention. Some non-limiting examples include canned, frozen, dried, or fresh fruits and vegetables or products containing the same, wines (red or white), pet foods, fruit juices, food colorings and dyes, vegetable oils, butter, meats, cereals, chewing gum, baked goods, snack foods, dehydrated potatoes, beer animal feed, food packaging, cosmetics, rubber products, and petroleum products, cookies, crackers, beet sugar, and pie dough.
[0037] Preservative compositions according to the present invention may by applied to a product in a number of ways. For example, such compositions may be sprayed, injected, dipped or poured directly onto products. Alternatively, preservative compositions may be frozen and products may be placed in contact with the frozen preservative compositions. Further, preservative compositions may be spray dried, freeze-dried and/or powdered and then applied to products. Preservative compositions may be added to a finished product or may be added at any step in the production processes of a product.
[0038] Alternatively, the preservative of the invention as described above can be individually or collectively added to the final product or to what becomes the final product, or in a process of making the final product, either separately or all together at once.
[0039] The following examples are non-limiting and are only for purposes of illustration. All references cited herein are hereby incorporated in their entirety by reference.
EXAMPLES
[0040] According to the invention, sulfur dioxide was replaced in whole or in part with L-ergothioneine in Pinot noir wines at bottling. After 18 months of storage, it was found that the ergothioneine was still present in the wine and did not result in any deleterious impact on taste of the resultant wine.
[0000]
TABLE 1
Addition of various concentration of SO 2 and L-ergothioneine (ERGO)
to Pinot noir wines at bottling and concentration of ERGO and color
values found in the wines after 18 months of bottle storage.
SO 2 Added/ERGO
ERGO Found
Color
Abs
Added (mg/L)
(mg/L)
L
a
b
(520/420)
0/0
7.2
24.09
0.74
0.04
1.04
30/0
7.3
24.07
0.68
0.02
1.08
70/0
7.5
24.09
0.72
0.04
1.09
0/10
8.8
24.11
0.75
0.09
1.06
0/30
29.8
24.07
0.76
0.03
1.04
0/50
55.4
24.1
0.82
0.09
1.07
0/70
81.2
24.08
0.74
0.03
1.04
10/60
77
24.12
0.77
0.08
1.14
20/50
72.4
24.12
0.79
0.07
1.14
30/40
55.5
24.08
0.65
0.02
1.11
40/30
44.9
24.11
0.79
0.05
1.13
50/20
37.8
24.14
0.85
0.08
1.11
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The invention relates to the novel use of ergothioneine and preferably, L ergothioneine, as a nutritional additive and preservative in foods, medicines, and/or beverages. According to the invention, the powerful antioxidant ergothioneine was found to be very stable over time in and to have no deleterious effects on taste or consistency of food and beverages even when stored, over a period of several years. In a preferred embodiment, ergothioneine may be used as a replacement for all or part of the antimicrobial/preservative sulfur dioxide or other sulfites traditionally used in the wine making process.
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BACKGROUND OF THE INVENTION
This invention relates to memory systems comprised of hub devices connected to a memory controller by a daisy chained controller channel. The hub devices are attached to or reside upon memory modules that contain memory devices. More particularly, this invention relates to allowing the memory devices on the same controller channel to operate at varying frequencies.
Most high performance computing main memory systems use multiple memory modules with multiple memory devices connected to a controller by one or more controller channels. All memory modules connected to the same controller channel operate at the same controller frequency and all of their memory devices operate at the same frequency. The ratio of the controller channel frequency to the memory device clock frequency is typically a fixed integer. These restrictions limit the memory device operating frequencies when mixed within a channel. Due to the fixed ratio of channel frequency to memory device frequency, channels that are not able to attain the highest data rate will operate with a decrease in both channel and memory device frequency. These typical main memory systems must operate no faster than the slowest memory module on the channel. When a channel is populated with a memory module that is slower than the others, the entire channel, and perhaps the entire memory system, must slow down to accommodate the capabilities of the slow memory module.
The reductions in memory system operating frequency result in a corresponding reduction in computer system main memory performance. What is needed is a memory system that operates its controller channel at the highest supported rate while operating all memory devices on the memory modules at their highest supported rates. This capability would maximize the performance of the main memory system.
BRIEF SUMMARY OF THE INVENTION
Exemplary embodiments include a method for deriving clocks in a memory system. The method includes receiving a reference oscillator clock at a hub device. The hub device is in communication with a controller channel via a controller interface and in communication with a memory device via a memory interface. A base clock operating at a base clock frequency is derived from the reference oscillator clock. A memory interface clock is derived by multiplying the base clock by a memory multiplier. A controller interface clock is derived by multiplying the base clock by a controller multiplier. The memory interface clock is applied to the memory interface and the controller interface clock is applied to the controller interface.
Additional exemplary embodiments include a computer program product for deriving clocks in a memory system. The computer program product includes a storage medium readable by a processing circuit and storing instructions for execution by the processing circuit for facilitating a method. The method includes receiving a reference oscillator clock at a hub device. The hub device is in communication with a controller channel via a controller interface and in communication with a memory device via a memory interface. A base clock operating at a base clock frequency is derived from the reference oscillator clock. A memory interface clock is derived by multiplying the base clock by a memory multiplier. A controller interface clock is derived by multiplying the base clock by a controller multiplier. The memory interface clock is applied to the memory interface and the controller interface clock is applied to the controller interface.
Additional exemplary embodiments include a hub device in a memory system. The hub device includes a memory interface, a controller and a clock derivation mechanism. The memory interface is utilized for transmitting and receiving data from a memory device located on a memory module. The transmitting and receiving occur in response to a memory interface clock operating at a memory module clock frequency. The controller interface is utilized for transmitting and receiving data from a controller channel in response to a controller interface clock operating at a controller channel clock frequency. The clock derivation mechanism facilitates: receiving a reference oscillator clock; deriving a base clock operating at a base clock frequency from the reference oscillator clock; deriving the memory interface clock by multiplying the base clock by a memory multiplier; deriving the controller interface clock by multiplying the base clock by a controller multiplier; applying the memory interface clock to the memory interface; and applying the controller interface clock to the controller interface.
Further exemplary embodiments include a memory system. The memory system includes a controller, a controller channel in communication with the controller, one or more memory modules and one or more hub devices. The memory modules each include one or more memory devices. The hub devices buffer addresses, commands and data. Each hub device is in communication with one or more of the memory modules and in communication with the controller via the controller channel. Each of the hub devices are independently configured with a controller channel operating frequency and a memory device operating frequency suing multiples of a base clock derived from a reference oscillator clock. The controller channel operating frequency is utilized for communicating with the controller channel. The memory device operating frequency is utilized for communicating with the memory devices.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring now to the drawings wherein like elements are numbered alike in the several FIGURES:
FIG. 1 depicts an exemplary memory system with multiple levels of daisy chained memory modules with point-to-point connections;
FIG. 2 depicts an exemplary memory system with hub devices that are connected to memory modules and to a controller channel by a daisy chained channel;
FIG. 3 depicts an exemplary hub device using m:n clocking with a forwarded controller interface bus clock reference;
FIG. 4 depicts an exemplary hub device using m:n clocking with a separately distributed clock reference;
FIG. 5 depicts an exemplary memory system controller channel with a controller interface forwarded reference clock and independent memory device frequencies using m:n clocking;
FIG. 6 depicts an exemplary memory system controller channel with a separately distributed reference clock and independent memory device frequencies using m:n clocking; and
FIG. 7 is a table of sample controller and memory interface data rates with m:n ratios that may be implemented by exemplary embodiments.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Exemplary embodiments pertain to computer memory systems constructed of memory modules interconnected by a controller channel originating from a controller. The memory modules are attached to hub logic devices that are further attached to memory devices on the memory modules. The memory controller channel operates at a common clock frequency. Each memory module receives a common reference oscillator frequency, either by a forwarded controller interface bus clock on the controller channel or by separate reference oscillator input signal. The hub devices are uniquely configured to operate their attached memory devices at operating frequencies that may be non-integer multiples of the reference oscillator frequency. This enables memory modules of varying memory device speed grades to be operated at independent frequencies while residing on a memory controller channel that operates at a common clock frequency.
Exemplary embodiments include memory systems constructed of one or more memory modules 110 that are connected to a memory controller 102 by a daisy chained controller channel 114 as depicted in FIG. 1 . The memory modules 110 contain both a hub device 112 that buffers commands, address and data signals to and from the controller memory channel 114 as well as one or more memory devices 108 connected to the hub device 112 . The downstream portion of the controller channel 114 transmits write data and memory operation commands to the hub devices 112 . The upstream portion of the controller channel 114 returns requested read data to the controller 102 . In exemplary embodiments, each of the hub devices 112 may be independently configured with a controller channel operating frequency and a memory device operating frequency to allow the controller channel 114 to be operating at one frequency and the memory devices 108 to be operated at a different frequency. In addition, each memory module 110 in the memory system and its associated memory devices 108 may be operating at different operating speeds, or frequencies.
FIG. 2 depicts an alternate exemplary embodiment that includes a memory system constructed of one or more memory modules 110 connected to hub devices 112 that are further connected to a memory controller 102 by a daisy chained controller channel 114 . In this embodiment, the hub device 112 is not located on the memory module 110 ; instead the hub device 112 is in communication with the memory module 110 . The controller channel 114 may be constructed using multi-drop connections to the hub devices 112 or by using point-to-point connections. As depicted in FIG. 2 , the memory modules 110 may be in communication with the hub devices 112 via multi-drop connections and/or point-to-point connections. Other hardware configurations are possible, for example exemplary embodiments may utilize only a single level of daisy chained hub devices 112 and/or memory modules 110 .
FIG. 3 depicts an exemplary hub device 112 using m:n clocking with a forwarded controller interface bus clock reference 322 as the reference oscillator clock. The hub device 112 includes a clock domain crossing function 304 , a memory interface 302 , a controller interface 306 , and a phased lock loop (PLL) 308 (also referred to herein as a clock derivation mechanism because it may be implemented in other manners including software and/or hardware). The memory interface 302 sends data to and receives data from memory devices 108 on the memory module 110 via a mem_data bus 310 operating at ‘2*Y’ Mbps and clocked by a memory_clock 312 with a frequency of ‘Y’ MHz. The controller interface 306 communicates with downstream memory modules 110 via a downstream_drv 314 (to drive data and commands downstream) and a downstream_rcv 316 (to receive data). In addition, the controller interface 306 communicates with upstream memory modules 110 or the controller 102 (if there are no upstream memory modules 110 ) 110 via an upstream_rcv 318 (to receive data and commands) and an upstream_drv 320 (to drive data and commands upstream).
Exemplary embodiments of the present invention use two configurable integer ratios, named ‘m’ and ‘n’, within the hub device 112 to allow each memory module 110 within the controller channel 114 to operate at a common channel frequency (also referred to herein as a controller channel clock frequency) but with a unique memory device frequency (also referred to herein as a memory module clock frequency). ‘m’, a controller multiplier, is defined as the ratio of controller channel frequency, ‘X’ to a small, fixed, base clock frequency such as, but not limited to 133 MHz, 100 MHz, 66 MHz, etc. Hub devices 112 that use the clock forwarded on the controller channel 114 as their internal reference clock will divide the frequency of the forwarded controller interface bus clock reference 322 by ‘m’ to create, for example, a 133 MHz base clock. If the intended controller interface frequency is not evenly divisible by the base clock frequency, then the controller interface frequency is derived by rounding down to the next integer multiple of the frequency of the base clock (‘b’). This base clock will be used as the reference oscillator clock and input to a PLL 308 where it will be multiplied by ‘m’ to produce a cleaned up and distributed version of the controller interface clock. ‘n’, the memory multiplier, is defined as the ratio of the memory device clock frequency to the base frequency (e.g., 133 MHz). Hub devices 112 multiply the 133 MHz base clock by ‘n’ in their PLL 308 to produce the cleaned up memory interface clock running at ‘Y’ MHz. The resulting controller channel frequency to memory device operating frequency ratio is ‘m:n’.
Because the ratio of controller interface to memory interface operating frequency is known by the hub device 112 , a simplified clock domain crossing function 304 is employed in the hub device 112 to transfer controller interface information to and from the memory interface 302 . If the controller interface 306 and/or memory interface 302 operate using double data rate (DDR) clocking, the data rates (in Mbps) will be twice the respective interface clock frequency, (i.e., 2X and/or 2Y). If DDR is used on both interfaces, the ratio of the data rates will also be ‘m:n’.
FIG. 4 depicts an exemplary hub device using m:n clocking with a separately distributed reference clock 402 input to the PLL 308 as the reference oscillator clock. Main memory systems that use a separately distributed reference clock 402 can also use ‘m:n’ clocking. In this case, the frequency of the incoming reference clock 402 must be an integer multiple of the frequency of the base clock (e.g., 133 MHz). The reference clock 402 operating at a frequency of ‘W’ MHz is divided by an integer ‘L’ to produce the 133 MHz base clock that is used as the input clock to the multipliers in the PLL 308 . If the separately distributed reference clock 402 has a frequency that is equal to 133 MHz, then ‘L’ is simply one. The PLL 308 multiplies the base clock by ‘m’ to produce the cleaned up controller interface clock whose frequency is ‘X’. The PLL 308 also multiplies the base clock by ‘n’ to produce the memory interface clock whose frequency is ‘Y’. A simplified clock domain crossing function 304 is used to transfer information between the logic in the controller interface 306 and the memory interface 302 .
FIG. 5 depicts an exemplary memory system controller channel 114 with a controller interface forwarded reference clock 322 and independent memory device frequencies using m:n clocking. Memory systems that use ‘m:n’ clocking are able to operate their memory modules 110 at uniquely configured memory interface frequencies equal to the highest frequency supported by their memory devices 108 . FIG. 5 shows a single channel of a memory system in which the memory module labeled DIMM 0 502 is configured to operate its memory devices 108 at the ‘Y0’ frequency while the memory module labeled DIMM 1 504 is configured to operate its memory devices 108 at the ‘Y1’ frequency. Both DIMM 0 502 and DIMM 1 504 operate at a common, ‘X’ controller interface frequency. FIG. 6 depicts an exemplary memory system channel with a separately distributed reference clock 402 and independent memory device frequencies using m:n clocking to maximize frequencies and performance.
If the memory channel frequency, ‘X’ is limited by its electrical and/or timing requirements in a particular system, the memory device frequencies can still be maximized through the use of m:n clocking. This maximization of operating frequencies results in an optimization of memory channel, and therefore computer system, performance.
When configuring a memory system for optimum performance using m:n clocking, users should first evaluate the highest supported controller channel frequency. This is rounded down to the next integer multiple of the base clock frequency, (e.g., 133 MHz) and yields ‘X’. ‘X’ is divided by the base clock frequency to determine ‘m’ for all hub devices 112 in the controller channel 114 . For each memory module 110 in the controller channel 114 , users should evaluate the highest supported memory device operating frequency. This will be a function of hub device 112 and memory device 108 specifications along with the results of electrical analysis of the memory interface 302 on the memory module 110 itself. This maximum operating frequency should be rounded down to the next integer multiple of the base clock frequency, yielding ‘Y’ for that memory module 110 . ‘Y’ is divided by the base clock frequency to determine ‘n’ for that particular memory module 110 and/or hub device 112 .
FIG. 7 is a table of sample controller and memory interface data rates with m:n ratios that may be implemented by exemplary embodiments. Memory systems using m:n clocking are highly flexible and can be greatly optimized. The following table shows various m and n values, data rates and m:n ratios for a base clock frequency of 133 MHz. Some interesting integer m:n ratios are highlighted with a ‘*’ to illustrate settings that can be used to recreate the more typical, fixed data rate ratios at various controller channel and memory device operating frequencies.
Exemplary embodiments may be utilized to maximize the performance of a memory system by operating the controller channel at its highest supported rate while at the same time operating all memory devices on the memory modules at their highest supported frequencies. The frequencies of the memory devices on each memory module connected to the controller channel can be different for each memory module, allowing memory devices of varying speeds to be optimized on the same controller channel.
As described above, the embodiments of the invention may be embodied in the form of computer-implemented processes and apparatuses for practicing those processes. Embodiments of the invention may also be embodied in the form of computer program code containing instructions embodied in tangible media, such as floppy diskettes, CD-ROMs, hard drives, or any other computer-readable storage medium, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the invention. The present invention can also be embodied in the form of computer program code, for example, whether stored in a storage medium, loaded into and/or executed by a computer, or transmitted over some transmission medium, such as over electrical wiring or cabling, through fiber optics, or via electromagnetic radiation, wherein, when the computer program code is loaded into and executed by a computer, the computer becomes an apparatus for practicing the invention. When implemented on a general-purpose microprocessor, the computer program code segments configure the microprocessor to create specific logic circuits.
While the invention has been described with reference to exemplary embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the invention. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the invention without departing from the essential scope thereof. Therefore, it is intended that the invention not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this invention, but that the invention will include all embodiments falling within the scope of the appended claims. Moreover, the use of the terms first, second, etc. do not denote any order or importance, but rather the terms first, second, etc. are used to distinguish one element from another.
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A system, method and storage medium for deriving clocks in a memory system. The method includes receiving a reference oscillator clock at a hub device. The hub device is in communication with a controller channel via a controller interface and in communication with a memory device via a memory interface. A base clock operating at a base clock frequency is derived from the reference oscillator clock. A memory interface clock is derived by multiplying the base clock by a memory multiplier. A controller interface clock is derived by multiplying the base clock by a controller multiplier. The memory interface clock is applied to the memory interface and the controller interface clock is applied to the controller interface.
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TECHNICAL FIELD
This disclosure relates generally to semiconductor micro-electromechanical systems (MEMS) technology, and more particularly to spatial light modulators (SLMs).
BACKGROUND
Semiconductor spatial light modulators (SLMs) are suitable for digital imaging applications, including projectors, televisions, printers, and other technology. A DIGITAL MICROMIRROR DEVICE (DMD) is a type of SLM invented in 1987 at TEXAS INSTRUMENTS INCORPORATED of Dallas, Tex. The DMD is a monolithic semiconductor device based on micro-electromechanical systems (MEMS) technology. The DMD generally comprises an area array of bi-stable movable micromirrors forming picture elements (pixels) fabricated over an area array of corresponding addressing memory cells and associated addressing electrodes disposed under the micromirrors. The addressing electrodes are selectively energized by a control circuit with a voltage potential to create an electrostatic attraction force causing the respective micromirrors to tilt towards the respective address electrode. In some applications, the micromirror may be provided with a voltage potential as well. One embodiment of a DMD is disclosed in U.S. Pat. No. 7,011,015 assigned to the same assignee of the present disclosure, the teachings of which are incorporated herein by reference.
The fabrication of the above-described DMD superstructure typically uses a CMOS-like process with a completed SRAM memory circuit. Through the use of multiple photomask layers, the superstructure is formed with alternating layers of aluminum for the address electrodes, hinges, spring tips, mirror layers, and hardened photoresist for sacrificial layers that form air gaps.
The monolithic nature of the design and build of the DMD pixel technology is associated with quasi-planar structures interacting electrostatically with the tilting micromirrors. This presents a problem with the ability to shrink structures while attempting to maintain electrostatic entitlement. In the end, the design becomes more and more sensitive to electrostatic torque delivery originating from the edges of planar members and all the variations that this can create.
The electrostatic efficiency of a torsional spatial light modulator is limited by an elevated address electrode that is parallel to the micromirror when the micromirror is horizontal and not tilted, but which address electrode is angled with respect to the micromirror when tilted toward the address electrode. Providing a higher bias operation to increase torque generation on each address side of the micromirror can provide complications, such as field gradient induced migration of species in the headspace which ultimately can cause failure of the SLM. It can also create shorting where rounded features of raised binge together with a high field (and field gradient) can result in either catastrophic or transient current which can sputter metal from the binge or completely open up the base of the vias. The CMOS node capabilities to deliver additional bias are also problematic as the paths are shrunk.
SUMMARY
This disclosure provides a sloped electrode for a torsional spatial light modulator.
In a first example embodiment, a method comprises depositing a photoresist spacer layer upon an upper surface of a substrate, and exposing the spacer layer to a grey-scale lithographic mask to shape an upper surface of the spacer layer. A control member is formed upon the shaped upper surface such that the control member is non-parallel to the substrate. A positionable image member is formed over the control member, where the image member is configured to be positioned as a function of the control member to form a spatial light modulator (SLM).
In some embodiments, the upper surface of the spacer layer is sloped with respect to the substrate by the grey-scale lithographic mask by masking a selected portion of the spacer layer. The control member comprises an address electrode having a sloped portion. The image member is substantially parallel to the control electrode when tilted over and towards the control electrode to establish a substantially uniform energy density. The substrate includes memory configured to control a position of the image member, and the image member has a light reflective upper surface configured to modulate incident light and form an image. The image member is formed on a torsion hinge, and the control member is elevated above the substrate and positioned below the image member.
In another example embodiment, a method comprises depositing a spacer layer upon an upper surface of a substrate, and forming an address electrode using a grey-scale lithographic mask to shape an upper surface of the spacer layer. A positionable image member over the substrate is configured to be positioned as a function of the address electrode to form a spatial light modulator (SLM).
In some embodiments, the address electrode is formed to be elevated above the substrate and positioned below the image member, wherein the address electrode is sloped with respect to the substrate. The image member is substantially parallel to the address electrode when tilted. The substrate includes memory configured to control a position of the image member, wherein the image member has a light reflective upper surface configured to modulate incident light and form an image, and the image member is formed on a torsion hinge.
In another example embodiment, a method comprises depositing a photoresist spacer layer upon an upper surface of a substrate including memory, and exposing the spacer layer to a grey-scale lithographic mask to shape an upper surface of the spacer layer. A control member is formed upon the shaped upper surface, and a positionable image member is formed over the control member. The image member is substantially parallel to the control member when tilted as a function of the memory to form a spatial light modulator (SLM).
In some embodiments, the image member has a light reflective upper surface configured to modulate incident light and form an image, and the image member is formed on a torsion hinge. Other technical features may be readily apparent to one skilled in the art from the following figures, descriptions, and claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of this disclosure and its advantages, reference is now made to the following description, taken in conjunction with the accompanying drawings, in which:
FIG. 1 illustrates an exploded view of a MEMS pixel element in accordance with this disclosure;
FIG. 2A , FIG. 2B and FIG. 2C illustrate three primary considerations with a tilted MEMS pixel;
FIG. 3 illustrates an example embodiment of the M1 layer including the address electrode and the bias bus formed on the memory cell;
FIG. 4 illustrates an image of the top of the first sacrificial photoresist spacer layer when processed over the M1 layer;
FIG. 5 illustrates the M2 layer including the elevated address electrodes, hinge and spring tips superimposed on top of the photoresist topography shown in FIG. 4 ;
FIG. 6 shows a high-resolution, optical interferometer capture of a 7.6 μm DMD pixel specifically looking at the M2 level, showing a significant amount of curling in the elevated address electrodes and the spring tips;
FIG. 7 illustrates curling in the elevated address electrode reducing the combined angle between the mirror and the elevated address electrodes;
FIG. 8 illustrates a pair of sloped and elevated address electrodes according to this disclosure;
FIG. 9 illustrates a top perspective view of the address electrodes for the pixel shown in FIG. 1 ;
FIG. 10 illustrates a top perspective view of the sloped elevated address electrodes according to this disclosure;
FIG. 11 illustrates a graph of the mirror angle as a function of the voltage applied to the address electrodes;
FIG. 12 illustrates the speed of the mirror crossover for the address electrode configurations shown in FIG. 9 and FIG. 10 ;
FIGS. 13-22 illustrate an example process according to this disclosure;
FIG. 23 illustrates the maximized energy density between the mirror and the elevated address electrodes;
FIGS. 24-34 illustrate another example embodiment whereby a shaped address electrode is formed that is completely angled and without a horizontal portion; and
FIG. 35 illustrates another example embodiment of an elevated sloped address electrode that has an extended length providing electrostatic torque gains while maintaining a relatively uniform electric field and field gradient.
DETAILED DESCRIPTION
FIGS. 1 through 35 , discussed below, and the various examples used to describe the principles of the present invention in this patent document are by way of illustration only and should not be construed in any way to limit the scope of the invention. Those skilled in the art will understand that the principles of the present invention may be implemented in any suitable manner and in any type of suitably arranged device or system.
FIG. 1 is an exploded view of a pixel element 10 , shown in this example embodiment as a DMD pixel. Pixel element 10 is one of an array of such pixel elements fabricated on a wafer (substrate), using semiconductor fabrication techniques. Pixel element 10 is a monolithically integrated MEMS superstructure cell fabricated over a SRAM memory cell 11 formed on the wafer. Two sacrificial photoresist layers have been removed by plasma etching to produce air gaps between three metal layers of the superstructure. For purposes of this description, the three metal layers are “spaced” apart by being separated by these air gaps.
The uppermost first metal (M3) layer 14 has a reflective mirror 14 a . The air gap under the mirror 14 a frees the mirror 14 a to rotate about a compliant torsion hinge 13 b , which is part of the second metal (M2) layer 13 . The mirror 14 a is supported on the torsion hinge 13 b by a via 14 b . Elevated address electrodes 13 a also form part of the M2 layer 13 and are positioned under mirror 14 a . A third metal (M1) layer 12 has address electrodes 12 a for the mirror 14 a formed on the wafer, the address electrodes 12 a and 13 a each being connected to and driven with a voltage potential by memory cell 11 . The M1 layer 12 further has a bias bus 12 b which electrically interconnects the mirrors 14 a of all pixels 10 to bond pads 12 c at the chip perimeter. An off-chip driver (not shown) supplies the bias waveform necessary to bond pads 12 c for proper digital operation.
The mirrors 14 a may each be 7.4 μm square and made of aluminum for maximum reflectivity. They are arrayed on 8 μm centers to form a matrix having a high fill factor (˜90%). Other dimensions of the mirrors 14 a may be provided depending on the application. The high fill factor produces high efficiency for light use at the pixel level and a seamless (pixelation-free) projected image. The hinge layer 13 under the mirrors 14 a permits a close spacing of the mirrors 14 a . Because of the underlying placement of the hinges 13 b , an array of pixel elements 10 is referred to as a “hidden hinge” type DMD architecture.
In operation, electrostatic fields are developed between the mirror 14 a and its address electrodes 12 a and 13 a , creating an electrostatic torque. This torque works against the restoring torque of the hinge 13 b to produce mirror rotation in a positive or negative direction. The mirror 14 a rotates until it comes to rest (or lands) against spring tips 13 c , which are part of the hinge layer 13 . These spring tips 13 c are attached to the underlying address layer 12 , and thus provide a stationary but flexible landing surface for the mirror 14 a.
FIG. 2A , FIG. 2B and FIG. 2C illustrate three primary considerations with a tilted MEMS pixel 10 and the electrostatic considerations present. FIG. 2A shows a theoretical electrostatic distribution between the elevated address electrode 13 a and the mirror 14 a . As shown in FIG. 2B , upward curl is a commonplace condition with the quasi-planar elevated address electrodes 13 a which gives additional edge sensitivities. Ideally, it is desired to have a uniform total distribution of the electrostatic field (and force/torque) across the elevated address electrode 13 a as shown in FIG. 2C .
Adding to the differential stress of M2 layer, additional curl results in address electrodes 13 a and spring tips 13 c due to topography coupling in layer 12 through the first sacrificial photoresist spacer layer 15 ( FIG. 4 ), referred to as “binge”. Chemical mechanical planarization (CMP) cannot be acted on the binge in the photoresist. Furthermore, because of the gaps between electrodes 12 a , the photoresist will fill partially. This non-uniformity is what creates the topography variations.
FIG. 3 shows an example embodiment of the M1 layer 12 including the address electrode 12 a and the bias bus 12 b formed on the memory cell 11 . FIG. 4 is an image of the top of the first sacrificial photoresist spacer layer 15 when processed over M1 layer 12 . The high features, shown in black in this grey-scale image, show a mounding feature in spacer layer 15 forming the binge over the address electrode 12 a.
FIG. 5 shows the M2 layer 13 including the elevated address electrodes 13 a , hinge 13 b and spring tips 13 c superimposed on top of the photoresist topography shown in FIG. 4 , with the notable binge at the outer edge of the elevated address electrodes 13 a (with respect to the hinge 13 b ). The binge over the address electrodes 12 a consequently causes a variation in the associated elevated address electrodes 13 a and spring tips 13 c which are processed over the binge, also referred to as curling.
FIG. 6 shows a high-resolution, optical interferometer capture of a 7.6 μm DMD pixel specifically looking at the M2 level 13 . There is a significant amount of curling in the elevated address electrodes 13 a and the spring tips 13 c , each which may curl about 2.5 degrees. Scale in this image is exaggerated to show the degree to which the elevated address electrodes 13 a and as well as the spring tips 13 c are canted in the opposite direction and act to degrade the electrostatic efficiency of the elevated address electrodes 13 a . The curling diminishes the gap between the mirror 14 a and the adjacent elevated address electrodes 13 a during dynamic operation. This is a common location for marginality of the pixel 10 design and is directly correlated to bias destruct and operational space margin. This curling reduces the combined angle between the mirror 14 a and the elevated address electrodes 13 a to about 14.5 degrees, as shown in FIG. 7 . This undesirably gives significant sensitivity to the specific shapes of these address electrode edges to the electrostatic torque delivery and thereby operation and margin of the pixel.
According to this disclosure, the address electrodes 12 a and 13 a are combined to form a single address electrode that is both sloped and elevated such that the mirror 14 a is positioned substantially parallel to the combined address electrode when tilted. A sub-wavelength grey-scale lithography masking process is used to form the shaped address electrode. Advantageously, the surface area of the sloped and elevated address electrode provides electrostatic gains and maximizes energy density in the tilted (latched) state. By sloping the outer portion of the address electrode, the sloped surface can be laterally extended partially or entirely the geometrical length of the mirror 14 a without causing collisions because of the additional gap margin obtained by a degree of parallelism between the mirror 14 a and the raised and sloped address electrode.
FIG. 8 illustrates one example embodiment of a pair of sloped and elevated address electrodes 20 having an upper surface comprising an outer sloped portion 22 and an inner horizontal portion 24 each facing the mirror 14 a above. In an alternative example embodiment, the entire address electrode 20 can be sloped and the horizontal portion 24 is omitted. The horizontal portion 24 is positioned close to the torsion hinge 13 b , and the sloped portion 22 angles downwardly away from the horizontal portion 24 . In one example embodiment, the sloped portion 22 is angled at 16 degrees with respect to horizontal, and the tilted mirror 14 a is angled 12 degrees with respect to horizontal when it lands on the spring tips 13 c . Of course, other angles may be suitable in other embodiments.
The sloped portion 22 of address electrode 20 is substantially parallel with the mirror 14 a in the tilted state, which maximizes electrostatic energy density while maintaining margin, and which helps to ensure that electrostatic energy is uniformly distributed. In other embodiments, different angles of the sloped portion 22 and the mirror 14 a tilt can be selected to establish the angle between the tilted mirror 14 a and the sloped electrode portion 22 . In one embodiment, the angle of each can be the same such that the mirror 14 a and the sloped portion 22 are parallel to each other.
FIG. 9 illustrates a top perspective view of the address electrodes 12 a and 13 a for the pixel 10 shown in FIG. 1 . FIG. 10 illustrates a top perspective view of the address electrodes 20 according to this disclosure. The opposing inner edges of the address electrodes 20 have a notch or recess 26 to provide clearance for the torsion hinge 13 b (not shown).
FIG. 11 illustrates a graph of the angle of the mirror 14 a as a function of the voltage applied to the address electrodes for the address electrode configurations shown in FIG. 9 and FIG. 10 . The address voltage is ramped up from zero, and it can be seen that elevated sloped electrode 20 has a pull-in threshold of about 7.5 volts, about 2 volts lower than the 9.5 volt pull-in voltage for the combination of address electrodes 12 a and 13 a.
FIG. 12 illustrates the speed of the crossover of the mirror 14 a for the address electrode configurations shown in FIG. 9 and FIG. 10 . Crossover is defined as the mirror 14 a crossing from one tilted state to the other tilted state. The sloped electrode 20 provides a faster crossover, where the landed electrostatic moment is increased by a factor of about 2×.
Referring to FIGS. 13-23 there is shown the fabrication process using a sub-wavelength grey-scale lithography masking process according to this disclosure to create the sloped and elevated address electrodes 20 . The mirror 14 a is formed using a second sacrificial spacer level according to conventional resist patterning processes and will not be described here in detail.
FIG. 13 illustrates the sacrificial photoresist deposition of spacer layer 15 upon the substrate 11 including the memory cells (also referred to as a carrier), illustrating the non-planar surface of spacer layer 15 conforming to the non-planar surface of substrate 11 .
FIG. 14 illustrates exposing the photoresist of spacer layer 15 to a grey-scale mask 28 .
FIG. 15 illustrates developing and etching the exposed photoresist of spacer layer 15 to realize a selectively shaped photoresist upper surface 30 of the spacer layer 15 having a pair of angled upper surfaces 31 each extending downwardly from a flat central portion 32 .
FIG. 16 illustrates a blanket deposition of M2 layer 13 over the spacer layer 15 . The M2 layer 13 comprises a metal layer of aluminum or other material as desired. Advantageously, the M2 layer 13 conforms to the shape of the upper surface 30 of spacer layer 15 and thus has a pair of angled surfaces 34 and a flat central portion 35 .
FIG. 17 illustrates the deposition of a pattern photoresist layer 36 upon the M2 layer 13 , which is also referred to as a pattern resist level.
FIG. 18 illustrates exposing the photoresist of layer 36 to define a pattern 38 in the M2 layer 13 , the pattern 38 corresponding to shaped electrodes 20 to be created in M2 layer 13 .
FIG. 19 illustrates developing and stripping the exposed layer 36 to produce the pattern 38 .
FIG. 20 illustrates etching the M2 layer 13 to define address electrodes 20 in the M2 layer 13 over the spacer layer 15 .
FIG. 21 illustrates removing the pattern resist 38 such that electrodes 20 remain over the spacer layer 15 .
FIG. 22 illustrates removing the sacrificial spacer layer 15 , resulting in the electrodes 20 formed from M2 layer 13 , each having a sloped portion 22 and a flat portion 24 as shown in FIG. 8 and FIG. 10 .
FIG. 23 illustrates the combined angle between the mirror 14 a and the sloped portion 22 of address electrode 20 is about 4 degrees. This advantageously improves the electrostatic torque delivery while maintaining a substantially uniform electric field and field gradient.
FIGS. 24-34 illustrate another example embodiment of the disclosure whereby a shaped address electrode 40 is formed that is completely angled and without a horizontal portion, wherein like numerals refer to like elements.
FIGS. 25-26 illustrate shaping the spacer layer 15 using a sub-wavelength grey-scale lithography masking process such that an upper surface 30 of photoresist layer 15 has a pair of angled surfaces 42 extending downwardly from an apex 44 .
FIG. 27 illustrates a blanket deposition of M2 layer 13 over the spacer layer 15 . The M2 layer 13 comprises a metal layer of aluminum or other material as desired. Advantageously, the M2 layer 13 conforms to the shape of the upper surface 30 of spacer layer 15 and thus has a pair of angled surfaces 46 extending from an apex 48 .
FIG. 28 illustrates the deposition of a pattern photoresist layer 36 upon the M2 layer 13 , which is also referred to as a pattern resist level.
FIG. 29 illustrates exposing the photoresist of layer 36 to define a resist pattern 50 in the M2 layer 13 , the resist pattern 50 corresponding to shaped electrodes 40 to be created in M2 layer 13 .
FIG. 30 illustrates developing and stripping the exposed layer 36 to produce the resist pattern 50 .
FIG. 31 illustrates etching the M2 layer 13 to define address electrodes 40 in the M2 layer 13 over the spacer layer 15 .
FIG. 32 illustrates removing the resist pattern 50 such that electrodes 40 remain over the spacer layer 15 .
FIG. 33 illustrates removing the sacrificial spacer layer 15 , resulting in the electrodes 40 formed from M2 layer 13 , each having a sloped portion.
FIG. 34 illustrates the combined angle between the mirror 14 a and the sloped portion of address electrode 40 is about 4 degrees. This advantageously improves the electrostatic torque delivery while maintaining a substantially uniform electric field and field gradient.
FIG. 35 illustrates another example embodiment of an elevated sloped address electrode 60 formed according to the process described and shown in FIGS. 23-34 , but wherein the resist pattern 50 in FIG. 32 is extended to form address electrode 60 that is longer than address electrode 40 . This extended address electrode 60 provides electrostatic torque gains while maintaining a relatively uniform electric field and field gradient.
Although the figures have illustrated different circuits and operational examples, various changes may be made to the figures. For example, the spacer layer 15 can be exposed by the grey-scale masking to create other shapes in the address electrodes, and also shape other features of the pixel 10 .
It may be advantageous to set forth definitions of certain words and phrases used throughout this patent document. The terms “include” and “comprise,” as well as derivatives thereof, mean inclusion without limitation. The term “or” is inclusive, meaning and/or. The phrase “associated with,” as well as derivatives thereof, may mean to include, be included within, interconnect with, contain, be contained within, connect to or with, couple to or with, be communicable with, cooperate with, interleave, juxtapose, be proximate to, be bound to or with, have, have a property of, have a relationship to or with, or the like. The phrase “at least one of,” when used with a list of items, means that different combinations of one or more of the listed items may be used, and only one item in the list may be needed. For example, “at least one of: A, B, and C” includes any of the following combinations: A, B, C, A and B, A and C, B and C, and A and B and C.
While this disclosure has described certain embodiments and generally associated methods, alterations and permutations of these embodiments and methods will be apparent to those skilled in the art. Accordingly, the above description of example embodiments does not define or constrain this disclosure. Other changes, substitutions, and alterations are also possible without departing from the spirit and scope of this disclosure, as defined by the following claims.
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A method of forming a micro-electromechanical systems (MEMS) pixel, such as a DMD-type pixel, by depositing a photoresist spacer layer upon a substrate. The photoresist spacer layer is exposed to a grey-scale lithographic mask to shape an upper surface of the photoresist spacer layer. A control member is formed upon the shaped spacer layer, and has a sloped portion configured to maximize energy density. An image member is configured to be positioned as a function of the control member to form a spatial light modulator (SLM).
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FIELD OF THE INVENTION
The present invention relates to directional drilling and more specifically to an arrangement of drilling motor assemblies suitable for use in downhole drilling operations.
BACKGROUND
Directional drilling can be described as the intentional deviation of a wellbore from the path it would naturally take. This is accomplished through the use of whipstocks, bottomhole assembly (BHA) configurations, instruments to measure the path of the wellbore in three-dimensional space, data links to communicate measurements taken downhole to the surface, mud motors and special BHA components and drill bits. In some cases, such as drilling steeply dipping formations or unpredictable deviation in conventional drilling operations, directional-drilling techniques may be employed to ensure that the hole is drilled vertically.
The most common way to directional drill is through the use of a bend near the bit in a downhole steerable mud motor. Directional drilling is accomplished with the alternating combination of two drilling operations. In the sliding mode the drill string is slowly rotated to orient the bend in the desired direction so that the bend points the bit in a direction different from the axis of the wellbore. Once oriented by pumping mud through the mud motor, the bit turns while the drill string does not rotate but rather slides, allowing the bit to drill in the direction it points. When a particular wellbore direction is achieved, that direction may be maintained by rotating the entire drill string so that the bit does not drill in a single direction off the wellbore axis, but instead sweeps around and its net direction coincides with the existing wellbore.
In directional drilling operations the sliding phase of drilling lacks the efficiency associated with rotating the drill string. This inefficiency is a result of the drag of the sliding drill string along the borehole and the sole use of the mud motor for drilling the borehole.
In recent years the industry has seen the development of rotary steerable systems for used in directional drilling. These systems employ the use of specialized downhole equipment to replace conventional directional tools such as mud motors. A rotary steerable tool is designed to drill directionally with continuous rotation of the drill string from the surface, eliminating the need to slide a steerable mud motor. Continuous rotation of the drill string allows for improved transportation of drilled cuttings to the surface resulting in better hydraulic performance and reduced well bore tortuosity due to utilizing a steadier steering model. Rotary steerable systems are costly as compared to mud motor systems, so more the traditional mud motor systems are more economically preferable in conventional directional drilling applications.
The subject matter of the present disclosure is directed to overcoming, or at least reducing the effects of, one or more of the problems set forth above.
SUMMARY
A directional drilling system and method are provided for directional drilling a borehole by continuous rotating of the drill string in combination with an arrangement of drilling motor assemblies at the lower end of the drill string to effect drilling along a curved path and a substantially straight path. A first drilling motor assembly is coupled to a drill bit and operable to rotate the drill bit to effect drilling of the borehole. The first drilling motor assembly is configured to angularly tilt the rotational axis of the drill bit relative to the axis of the section of the borehole being drilled to provide directionality to the borehole. A second drilling motor assembly, positioned on the drill string above the first drilling motor assembly is operable to rotate the first drilling motor assembly in a direction opposite the direction of rotation imparted to the drill string from the surface and to the drill bit by the first drilling motor assembly. The rotational speed of the second drilling motor assembly is controlled by a control assembly. A control assembly associated with the second drilling motor assembly controls fluid flow through the second drilling motor assembly so that the first drilling motor assembly is substantially rotationally stationary with respect to the rotating drill string when drilling a curved path of the borehole.
The foregoing summary is not intended to summarize each potential embodiment or every aspect of the present disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagrammatic view of the apparatus in use for directional drilling;
FIG. 2 is a diagrammatic view of the second drilling motor assembly illustrating the fluid flow path through the second drilling motor assembly
FIG. 3 is a schematic view of the fluid control system for controlling fluid flow through the second drilling motor assembly.
DETAILED DESCRIPTION
In describing various locations relative to the Figures the term “downhole” refers to the direction along the axis of the wellbore that looks toward the furthest extent of the wellbore. Downhole is also the direction toward the drill bit location. Similarly, the term “lower end” refers to the portion of the assembly located at the downhole end of the respective assembly. The term “uphole” refers to the direction along the axis of the wellbore that leads back to the surface, or away from the drill bit. Similarly, the term “upper end” refers to the portion of the assembly located at the uphole end of the respective assembly. The term “clockwise” refers to rotation to the right as seen looking downhole and the term “counterclockwise” refers to rotation to the left as seen looking downhole. In a situation where the drilling is more or less along a vertical path, downhole is truly in the down direction, and uphole is truly in the up direction. However, in horizontal drilling, the terms up and down are ambiguous, so the terms downhole and uphole are necessary to designate relative positions along the drill string.
Referring to FIG. 1 , the drill string 10 within a borehole 12 is rotatable by a drilling rig 14 located at the earth's surface 16 . Rotation of the drill string 10 is provided from the surface in a manner known in the art, such as by a rotary table or a top drive system. A bottom hole assembly 18 , commonly referred to as a BHA, is coupled to the downhole end of the drill string 10 . The BHA 18 comprises a drill bit 20 at the downhole end of the BHA 18 which is coupled to a first drilling motor assembly 22 , which may comprise a downhole steerable mud motor. The first drilling motor assembly 22 includes a bent housing member 24 . An MWD assembly 26 is coupled to the uphole end of the first drilling motor assembly 22 . A control assembly 28 is coupled to the uphole end of the MWD assembly 26 and a second drilling motor assembly 30 is coupled to the uphole end of the control assembly 28 . The uphole end of the second drilling motor assembly drilling 30 is connected to drill string 10 .
In the illustrated embodiment the first drilling motor assembly 22 , as known in the drilling art, comprises a connecting sub, which connects the first drilling motor assembly 22 to the drill string 10 , a power section, which consists of the rotor and stator; a transmission section, where the eccentric power from the rotor is transmitted as concentric power to rotate the drill bit 20 in a first direction; a bearing assembly which protects from off bottom and on bottom pressures; and a bottom sub which connects the first drilling motor assembly 22 to the drill bit 20 . In the preferred embodiment the drill bit 20 is rotated by the first drilling motor assembly 22 in a first rotational direction for drilling the borehole 12 . In the preferred embodiment, the first rotational direction is clockwise.
The bent housing 24 is included in the first drilling motor assembly 22 . The bent housing assembly 24 can be configured to have a bend using different bend angle settings. The bent housing assembly 24 may comprise a fixed bent housing assembly, which has a fixed bend angle, or an adjustable bent housing assembly, which has the ability to pre-set the bend angle before the BHA is placed in the borehole or which has the ability to adjust the bend angle during the drilling operations. Typically, the bent housing assembly 24 can have an angle setting from 0 degrees to 4 degrees. The amount of bend angle is determined by rate of directional change needed to reach the drilling target zone.
The MWD assembly 26 , coupled to the uphole end of the first drilling motor assembly 22 , may contain a steering system, incorporating magnetometers and accelerometers to measure and transmit data related to inclination, direction and orientation of the BHA 18 within the borehole 12 to equipment at the surface. An operator can periodically or continuously monitor the tool face orientation of the BHA 18 through periodic data surveys of inclination, direction and orientation to control the drilling process. An example of the process of monitoring tool face is shown in U.S. Pat. No. 6,585,061, which is incorporated herein by reference.
The control assembly 28 is coupled to the uphole end of the MWD assembly 26 and the downhole end of the second drilling motor assembly 30 is coupled to the uphole end of the control assembly 28 . The second drilling motor assembly 30 , coupled at the uphole end to the drill string 10 , includes a power section, which consists of the rotor and stator; a transmission section, where the eccentric power from the rotor is transmitted as concentric power which can rotate the first drilling assembly 22 in a second direction; a bearing assembly which protects from pressures; and a bottom sub which connects the second drilling motor assembly 30 to the first drilling motor assembly 22 . In the preferred embodiment, the second drilling motor assembly 30 comprises a low speed, high torque power section, having a rotational speed in the range from approximately 25 rpm to approximately 80 rpm and a torque range from approximately 2,500 ft. lbs. to 28,000 ft. lbs. depending on the motor diameter which can be of a diameter from 2⅞ inches to 11¼ inches, and configured for rotating the first drilling motor assembly 22 in the second direction. In the preferred embodiment, the second direction is the counterclockwise.
As the general operation of the second drilling motor assembly 30 is known in the art of drilling, such operation will not be detailed in reference to FIG. 2 . Rather, in FIG. 2 there is illustrated in more detail the second drilling motor assembly 30 showing the fluid flow path noted by arrows 32 through the second drilling motor assembly 30 . Fluid is pumped from the surface through the drill pipe 10 into the uphole end of the second drilling motor assembly 30 which is connected to the drill pipe 10 . The fluid flows into the central annulus 34 in the downhole direction where a portion of the fluid flows through the passage 36 through the upper flex shaft 38 and a portion of the fluid is diverted to flow in the annulus 40 between the housing 42 and the upper flex shaft 38 . The fluid flowing in the annulus 40 continues to flow through the second drilling motor assembly 30 passing through the rotor/stator section 44 to provide rotational motion of the stator 47 in the counterclockwise direction. The portion of the fluid flow through the passage 36 through the upper flex shaft 38 continues to flow in the downhole direction through the lower flex shaft 48 which is connected to the downhole end of the rotor 46 . Coupled to the downhole end of the lower flex shaft 48 is the control assembly 28 , which will be described in more detail in reference to FIG. 3 .
The control assembly 28 , may be coupled to the uphole end of the MWD assembly 26 and the downhole end of the second drilling motor assembly 30 or the control assembly 28 may be incorporated into the second drilling motor assembly 30 , as illustrated in FIG. 2 .
Referring to FIG. 3 , control assembly 28 is illustrated in more detail. In the illustrated configuration the uphole end of control assembly 28 is connected to the downhole end of the second drilling motor assembly 30 . The downhole end portion of the lower flex shaft 48 is supported within the housing of the second drilling motor assembly 30 by radial bearing 50 . The downhole end portion of flow tube 48 cooperates with poppet 54 to form a control valve to control the fluid flow through rotor 46 of the second drilling motor assembly 30 . Control of the fluid flow through rotor 46 of the second drilling motor assembly 30 allows for control of the rotational rate of the second drilling motor assembly 30 , which further allows for control of the direction and rate of rotation of the first drilling motor assembly 22 .
In the illustrated embodiment, control assembly 28 further includes a turbine assembly 56 driven by fluid flow for generating electrical power for the electronics 58 located in the control assembly 28 . The electronics 58 controls the operation of poppet 54 as well as other devices, such as pressure sensor 60 , located in control assembly 28 . Pressure sensor 60 detects, by way of port 62 , pressure command signals transmitted from pressure signaling equipment (not illustrated) locate at the surface 16 . It should be recognized that various pressure transmission methods are commonly used in the drilling industry, for example one such system is illustrated in U.S. Pat. No. 5,390,153 which is incorporated herein by reference. In addition, various other methods of transmission are known in the industry, such as wired drill pipe and electromagnetic methods.
The drilling system described herein allows for the continuous rotating of the drill string while orienting in a specific drilling direction and rotating while drilling a substantially straight borehole. In a typical drilling operation, drill string 10 rotation at the surface varies from approximately 30 to 120 rpm. In the event that orientation is required to control deviation or direction of the borehole 12 , the drill string 10 rotation from the surface would be slowed preferably to between approximately 35 to 65 rpm. The control assembly 28 will be activated in response to a pressure signal sent from the surface to control fluid bypass through the second motor assembly 30 to regulate the rotational speed of the first drilling motor assembly 22 to a substantially non-rotating position relative to the drill string 10 . As torque from the first drilling motor assembly 22 driving the bit 20 changes, the control assembly 28 will control the fluid bypass through the second motor assembly 30 to maintain the rotation speed of the first drilling motor assembly 22 to a substantially non-rotating position relative to the drill string 10 . After the desired direction or inclination of the borehole has been achieved, rotation of the drill string 10 from the surface will be increased to the normal range and the control assembly 28 would be set for a fluid bypass level, approximately 50% in the preferred embodiment, typical for normal drilling operations. The tool face data for monitoring the relative rotational position of the first drilling motor assembly 22 is be derived from the MWD assembly 26 .
The foregoing description of preferred and other embodiments is not intended to limit or restrict the scope or applicability of the inventive concepts conceived of by the Applicants. In exchange for disclosing the inventive concepts contained herein, the Applicants desire all patent rights afforded by the appended claims. Therefore, it is intended that the appended claims include all modifications and alterations to the full extent that they come within the scope of the following claims or the equivalents thereof.
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A directional drilling system and method are provided for directional drilling a borehole by continuous rotating of the drill string in combination with an arrangement of drilling motor assemblies at the lower end of the drill string to effect drilling along a curved path and a substantially straight path. A first drilling motor assembly is coupled to a drill bit and operable to rotate the drill bit to effect drilling of the borehole. A second drilling motor assembly, positioned on the drill string above the first drilling motor assembly, is operable to rotate the first drilling motor assembly in a direction opposite the direction of rotation imparted to the drill string from the surface and to the drill bit by the first drilling motor assembly. A control system associated with the second drilling motor assembly controls fluid flow through the second drilling motor assembly so that the first drilling motor assembly is substantially rotationally stationary with respect to the rotating drill string when drilling a curved path of the borehole.
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RELATED APPLICATIONS
[0001] The present application is related to U.S. Provisional Patent Application, Ser. No. 60/951586, filed on Jul. 24, 2007, which is incorporated herein by reference and to which priority is claimed pursuant to 35 USC 119.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The invention relates to the field of photodynamic use of radiation for treatment of tissue and in particular to the establishment of individual maximum safe radiant exposures in medical use of pulsed lasers.
[0004] 2. Description of the Prior Art
[0005] With respect to safe levels of personal skin exposure to laser irradiation, the threshold question is how can an individual pulsed photothermal radiometric measurement be used to determine individual maximum safe radiant exposure. This question is illustrated schematically in FIG. 1 , where five differently pigmented individuals are to the mapped to corresponding individual maximum safe radiant exposures (imsre). This question has been investigated, for example by Jung B J et.al. “Hand-held pulsed photothermal radiometry system to estimate epidermal temperature rise during laser therapy”, Skin Res. Technol. 2006;12:292-297 (Beckman Laser Institute group, UC Irvine). Jung states: . . .
. . . a maximum safe radiant exposure . . . can be defined above which epidermal thermal damage would occur. . . . A measure of epidermal heating would provide clinicians with an objective means to determine H max . Pulsed photo-thermal radiometry (PPTR) can provide accurate measurements of epidermal heating.
[0007] Altshuler et al. U.S. Pat. No. 6,015,404 very generally describes a diagnostic feed-back to a laser system for use with systems applying laser energy to treat a selected dermatology problem. The method and apparatus protect skin not under treatment in skin regions affected by the laser by detecting, with a suitable sensor, at least a selected parameter in the skin region affected by the delivered laser energy and performing a control function to effect the desired protection by use of a feedback mechanism which is operative in response to an output from the sensor. For some embodiments, two laser pulses may be utilized, which pulses are spaced by a time which is preferably greater than the thermal relaxation time for affected regions not under treatment, for example an epidermis through which the energy is passed to an area under treatment, but is less than the thermal relaxation time of the area under treatment. The first of the pulses serves as a prediagnosis pulse which is clearly below the damage threshold for protected areas, with the sensor output for the first pulse being utilized to control at least one parameter of the second pulse.
[0008] So far, the published literature has only hinted at predicting the individual maximum safe radiant exposure, but have never disclosed an operable method or apparatus to actually make a reliable prediction. Previous publications have always aimed at quantifying the pigmentation and then implying that this number could then be used to determine the individual maximum safe radiant exposure, but without showing how. To implement the idea implicitly according to prior art approaches requires that a few modeling steps be involved:
[0009] invert the pulsed photo-thermal radiometric temporal signal to a depth profile of the chromophores (giving the melanin concentration in the epidermis); and
[0010] The result of step 1 is used in a forward model to calculate the threshold temperature at the basal layer (epidermal-dermal junction). If pre-cooling is involved, (which is common clinical practice) this process is required to be quantified as well, with a new array of uncertainties and assumptions.
[0011] Each of these steps involves determination, estimation or assumption of various skin parameters (optical, thermal and geometrical) and cryogen cooling parameters. The process also requires an assumption of a damage model. The resulting individual maximum safe radiant exposure depends critically on the accuracy of these assumptions. This is schematically illustrated in the FIG. 2 which illustrates the complexity of this approach.
[0012] The complexity of these two modeling steps has prevented researchers from actually using pulsed photo-thermal radiometric signals to predict individual maximum safe radiant exposure. Moreover, the above approach is very vulnerable for noise in the pulsed photo-thermal radiometric signal thereby reducing the robustness of the prediction.
BRIEF SUMMARY OF THE INVENTION
[0013] The illustrated embodiment of the invention is an improvement in a method for making pulsed photothermal radiometric measurements to determine individual maximum safe radiant exposure (IMSRE) of biological subjects corresponding to radiant energy exposure (RE) without any use of a biological model. The method includes a calibration methodology, which comprises the steps of applying a statistical regression to an empirical data set of individual maximum safe radiant exposures (IMSRE) and temporal radiant energy exposures (RE) applied to a sample population of the subjects to determine a individual maximum safe radiant exposure (IMSRE) corresponding to each temporal radiant energy exposure (RE). The IMSRE is set so that using the statistical regression separation of the data set into an acceptable injury grouping and an unacceptable injury grouping is obtained with a predetermined limitation of the proportion of subjects having unacceptable injury at a temporal radiant energy exposure (RE) below the corresponding individual maximum safe radiant exposure (IMSRE). The separation of the data set is thus used to predict an individual maximum safe radiant exposure (IMSRE) for a corresponding temporal radiant energy exposure (RE) to a biological subject not included in the sample population.
[0014] The step of applying a statistical regression to an empirical data set of individual maximum safe radiant exposures (IMSRE) and temporal radiant energy exposures (RE) to determine a individual maximum safe radiant exposure (IMSRE) corresponding to each temporal radiant energy exposure (RE) comprises in one embodiment the step of applying a partial least squares (PLS) regression to quantify a relationship between the individual maximum safe radiant exposures (IMSRE) and temporal radiant energy exposures (RE) in the data set.
[0015] In another embodiment the step of applying a statistical regression to an empirical data set of individual maximum safe radiant exposures (IMSRE) and temporal radiant energy exposures (RE) to determine a individual maximum safe radiant exposure (IMSRE) corresponding to each temporal radiant energy exposure (RE) comprises the step of approximating the statistical regression by the relation:
[0000]
IMSRE
i
=
K
RE
D
Δ
T
i
,
[0016] where RE D is a radiant exposure of a diagnostic laser pulse, which comprises the temporal radiant energy exposure (RE), where ΔT i is a measured temperature increase at a predetermined time after the laser diagnostic pulse, and where K is an empirically determined calibration constant determined empirically on the basis of the data set.
[0017] The predetermined time after the laser diagnostic pulse comprises a time period at which contribution to heat absorption in the skin from the hair follicles is negligible while contribution to heat absorption in the skin from the melanin bearing epidermal layer is dominant over contribution to heat absorption in the skin from deeper chromophores.
[0018] In one embodiment the predetermined time after the single laser diagnostic pulse comprises a measurement at approximately 20 ms. In particular, the predetermined time after the single laser diagnostic pulse comprises a single measurement at approximately 20 ms.
[0019] In another embodiment the step of applying a statistical regression to an empirical data set of individual maximum safe radiant exposures (IMSRE) and temporal radiant energy exposures (RE) to determine a individual maximum safe radiant exposure (IMSRE) corresponding to each temporal radiant energy exposure (RE) comprises the step of approximating the statistical regression by an inverse proportionality relationship between individual maximum safe radiant exposures (IMSRE) and a temperature increase ΔT in targeted tissue in the subject induced by a sub-therapeutic laser pulse comprising the temporal radiant energy exposures (RE).
[0020] In one embodiment the step of applying a statistical regression to an empirical data set of individual maximum safe radiant exposures (IMSRE) and temporal radiant energy exposures (RE) to obtain a separation of the data set into an acceptable injury grouping and an unacceptable injury grouping with a predetermined limitation of the proportion of subjects having unacceptable injury at a temporal radiant energy exposure (RE) below the corresponding individual maximum safe radiant exposure (IMSRE) comprises the step of obtaining the separation of the data set with a limitation of 3% or less of the subjects having unacceptable injury at a temporal radiant energy exposure (RE) below the corresponding individual maximum safe radiant exposure (IMSRE).
[0021] In another embodiment the step of applying a statistical regression to an empirical data set of individual maximum safe radiant exposures (IMSRE) and temporal radiant energy exposures (RE) applied to a sample population of the subjects to determine a individual maximum safe radiant exposure (IMSRE) corresponding to each temporal radiant energy exposure (RE) comprises the step of applying a statistical regression to an empirical data set generated by employing a plurality of measurements over time starting from when a diagnostic laser pulse is applied to approximately one second thereafter to determine individual maximum safe radiant exposure (IMSRE).
[0022] The step of applying a statistical regression comprises the step of using partial least squares regression (PLS) to determine an individual maximum safe radiant exposure vector (IMSRE i ) whose components are individual maximum safe radiant exposure values from the data set in which a predetermined damage threshold is just reached, where RE values that caused the predetermined damage threshold are used as the individual maximum safe radiant exposure values, and where T i is a vector whose components are reciprocal pulsed photo-thermal radiometric signals T I corresponding to the individual maximum safe radiant exposure values in IMSRE I , where K is a vector having the same length as T i and is determined using PLS from IMSRE i =K×T i , where IMSRE i is the matrix product K×T i .
[0023] The illustrated embodiment of the invention is also a method for applying a photothermal pulse to the skin of a patient with an individual maximum safe radiant exposure (IMSRE) without any use of a biological model. The photothermal pulse is applied to the skin with a radiant exposure at or below the individual maximum safe radiant exposure (IMSRE) as determined by using a statistical regression to an empirical data set of individual maximum safe radiant exposures (IMSRE) and temporal radiant energy exposures (RE) applied to a sample population of patients by obtaining a separation of the data set into an acceptable injury grouping and an unacceptable injury grouping with a predetermined limitation of the proportion of subjects having unacceptable injury at a temporal radiant energy exposure (RE) below the corresponding individual maximum safe radiant exposure (IMSRE), from which separation of the data set the individual maximum safe radiant exposure (IMSRE) for a corresponding temporal radiant energy exposure (RE) to the patient has been determined.
[0024] The illustrated embodiment of the invention is also an apparatus comprising a source of a photothermal pulse to be applied to the skin of a patient with an individual maximum safe radiant exposure (IMSRE) without any use of a biological model. A controller is coupled to the source where the radiant exposure provided by the photothermal pulse to the skin from the source as regulated by the controller is maintained at or below the individual maximum safe radiant exposure (IMSRE) as determined by using a statistical regression to an
[0025] In one embodiment the controller regulates the source to provide the photothermal pulse to the skin at or below the individual maximum safe radiant exposure (IMSRE) as determined by applying partial least squares (PLS) regression to quantify a relationship between the individual maximum safe radiant exposures (IMSRE) and temporal radiant energy exposures (RE) in the data set.
[0026] In another embodiment the controller regulates the source to provide the photothermal pulse to the skin at or below the individual maximum safe radiant exposure (IMSRE) as determined by approximating the statistical regression by the relation:
[0000]
IMSRE
i
=
K
RE
D
Δ
T
i
,
[0027] where RE D is a radiant exposure of a diagnostic laser pulse, which comprises the temporal radiant energy exposure (RE), where ΔT i is a measured temperature increase at a predetermined time after the laser diagnostic pulse, and where K is an empirically determined calibration constant determined empirically on the basis of the data set.
[0028] In one embodiment the controller regulates the source to provide the photothermal pulse to the skin at or below the individual maximum safe radiant exposure (IMSRE) as determined by approximating the statistical regression by an inverse proportionality relationship between individual maximum safe radiant exposures (IMSRE) and a temperature increase ΔT in targeted tissue in the subject induced by a sub-therapeutic laser pulse comprising the temporal radiant energy exposures (RE).
[0029] The controller regulates the source to provide the photothermal pulse to the skin at or below the individual maximum safe radiant exposure (IMSRE) as determined by obtaining the separation of the data set with a limitation of 3% or less of the subjects having unacceptable injury at a temporal radiant energy exposure (RE) below the corresponding individual maximum safe radiant exposure (IMSRE).
[0030] The controller regulates the source to provide the photothermal pulse to the skin at or below the individual maximum safe radiant exposure (IMSRE) as determined by applying a statistical regression to an empirical data set generated by employing a plurality of measurements over time starting from when a diagnostic laser pulse is applied to approximately one second thereafter to determine individual maximum safe radiant exposure (IMSRE).
[0031] The invention also includes a recordable medium for storing instructions for a computer-controlled source of a photothermal pulse to be applied to the skin of a patient with an individual maximum safe radiant exposure (IMSRE) without any use of a biological model comprising instructions for controlling the source to provide a radiant exposure of the skin to the photothermal pulse at or below the individual maximum safe radiant exposure (IMSRE) as determined by using a statistical regression to an empirical data set of individual maximum safe radiant exposures (IMSRE) and temporal radiant energy exposures (RE) applied to a sample population of patients by obtaining a separation of the data set into an acceptable injury grouping and an unacceptable injury grouping with a predetermined limitation of the proportion of subjects having unacceptable injury at a temporal radiant energy exposure (RE) below the corresponding individual maximum safe radiant exposure (IMSRE), from which separation of the data set the individual maximum safe radiant exposure (IMSRE) for a corresponding temporal radiant energy exposure (RE) to the patient has been determined.
[0032] The instructions for controlling the source comprise instructions which control the source at or below the individual maximum safe radiant exposure (IMSRE) so as to obtain the separation of the data set with a limitation of 3% or less of the subjects having unacceptable injury at a temporal radiant energy exposure (RE) below the corresponding individual maximum safe radiant exposure (IMSRE).
[0033] What is disclosed below is an apparatus and method or methods to process a pulsed photo-thermal radiometric signal into a predicted individual maximum safe radiant exposure value. More specifically, what is disclosed is the calibration itself, including the data set and the K value.
[0034] The disclosure recognizes the following causal chain: a higher pigmentation→more laser light absorption→more heat→lower individual maximum safe radiant exposure; and then implements a method on the following principle: a sub-therapeutic laser pulse (low laser energy) induces a small temperature increase which is measured with an Infra-red detector. This provides a measure for the individual's pigmentation and thus for the individual maximum safe radiant exposure.
[0035] While the apparatus and method has or will be described for the sake of grammatical fluidity with functional explanations, it is to be expressly understood that the claims, unless expressly formulated under 35 USC 112, are not to be construed as necessarily limited in any way by the construction of “means” or “steps” limitations, but are to be accorded the full scope of the meaning and equivalents of the definition provided by the claims under the judicial doctrine of equivalents, and in the case where the claims are expressly formulated under 35 USC 112 are to be accorded full statutory equivalents under 35 USC 112. The invention can be better visualized by turning now to the following drawings wherein like elements are referenced by like numerals.
BRIEF DESCRIPTION OF THE DRAWINGS
[0036] FIG. 1 is a symbolic diagram of the prior art problem of how to relate individual pulsed photothermal radiometric (PPTR) measurements to individual maximum safe radiant exposure (IMSRE).
[0037] FIG. 2 is a symbolic diagram illustrating the conventional prior art approach of using biological models to solve the problem of FIG. 1 .
[0038] FIG. 3 is a symbolic diagram of how the illustrated embodiment of the invention relates individual pulsed photothermal radiometric (PPTR) measurements to individual maximum safe radiant exposure (IMSRE).
[0039] FIG. 4 shows in an upper graph each of the 304 data points plotted on axes representing the individual maximum safe radiant exposure (IMSRE) and the radiant exposures (RE) used for the test spots. The lower graph of FIG. 4 illustrates the histographic distribution of the data points in the upper graph into four categories of acceptable or unacceptable injury.
[0040] FIG. 5 is a graph of the change in temperature of skin as a function of time for two different thicknesses of epidermins.
[0041] FIG. 6 shows results of the simulation/feasibility exercise where calculated IMSREs are compared against predicted IMSREs.
[0042] FIG. 7 is a pair of graphs in which the upper graph show the feasibility of using partial linear regression to obtain a separation of the data set of points and in which the lower graph shows the corresponding distribution into the four injury categories of FIG. 4 .
[0043] The invention and its various embodiments can now be better understood by turning to the following detailed description of the preferred embodiments which are presented as illustrated examples of the invention defined in the claims. It is expressly understood that the invention as defined by the claims may be broader than the illustrated embodiments described below.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0044] The illustrated embodiment of the invention addresses the question of FIG. 1 of how can an individual pulsed photothermal radiometric measurement be used to determine individual maximum safe radiant exposure. The illustrated embodiments contemplate irradiation of skin by a laser pulse in combination with use of a spurt of cryogenic cooling in a heating/cooling protocol, but it must be expressly understood that the details of the protocol can be widely varied in any given application and in fact the cooling step may be omitted. The irradiation need not be pulsed or from a laser and the cooling need not be cryogenic or even practiced. The concepts of the invention are adaptable to an arbitrary heating and/or cooling methodology of any type of tissue.
[0045] The illustrated method of the invention avoids all the modeling steps of the approach of FIG. 2 and does not require assumption of any values. Instead, it requires calibration with an experimentally determined data set as symbolized by the diagram of FIG. 3 .
[0046] Two simple embodiments of the method to calibrate illustrate the invention, which are identified below as method #1, and method #2.
[0047] Analysis Method #1
[0048] The embodiment of method #1 begins with the premise:
[0000]
IMSRE
i
=
K
RE
D
Δ
T
i
,
(
1
)
[0049] where RE D is the radiant exposure of the diagnostic laser pulse, ΔT i is the measured temperature increase at 20 ms after the laser pulse and K is a calibration constant (units ° C.). In the illustrated embodiment K was determined empirically on the basis of the data set for 13 volunteers. K is assumed to be a universal constant valid for all skin types involved in the calibration data set and for the laser used, which in this embodiment was a 755 nm laser with 3 ms pulse duration, 50 ms pre cooling spurt duration, and a 30 ms subsequent delay before irradiation. It is to be expressly understood that the wavelength, irradiation period, cooling period and delay interval may be varied among other parameters of the calibration sample population with possible dependency of K thereon. It is expressly to be understood that the illustrated data set in this disclosure is exemplary only and that in any given application that the sample population will be much larger and randomly or representatively selected from the selected target population in order to obtain a valid IMSRE that will be optimally suited for the population to which it is to be applied.
[0050] Equation 1 expresses the premise that the individual maximum safe radiant exposure is higher when the temperature increase, which is induced by a sub-therapeutic laser pulse, is lower i.e. IMSRE and temperature are inversely proportional. We chose the ΔT at 20 ms because at this time the contribution of remaining hair follicles on the infra-red signal is negligible while the contribution of the epidermal layer, where the melanin is located, is still dominant over contributions from the deeper chromophores.
[0051] On each of the volunteers, test spots were applied with varying radiant exposure (RE), but was intended to be above and beyond the individual maximum safe radiant exposure which we defined as causing visible injury lasting at least 24 hrs.
[0052] To determine the K value, we categorize the data points in four categories. Categories 1 and 2 are observed acceptable injuries and categories 3 and 4 are observed unacceptable injuries. Again it must be understood that the definition of “acceptable” and “unacceptable” injury may be modified from that illustrated here without departing from the scope and spirit of the invention. Categories 2 and 4 are at radiant energies in excess of the individual maximum safe radiant exposure and categories 1 and 3 are at radiant energies less than the individual maximum safe radiant exposure. Using this categorization we can determine the optimal K value by minimizing the number of data points in category 2 (acceptable injury, above IMSRE) while the number of data points in category 3 (unacceptable injury, below IMSRE) does not exceed 3% of the total data points. It is also to be understood that the categories definitions can be modified without departing from the spirit and scope of the invention, for example the 3% limitation can be raised or lowered according to desired medical safety limits.
[0000]
TABLE 1
Categorization of prediction results.
Category
Injury level
over/under treated
1
acceptable injury
RE_used < individual maximum
safe radiant exposure
2
acceptable injury
RE_used > individual maximum
safe radiant exposure
3
unacceptable
RE_used < individual maximum
injury found
safe radiant exposure
4
unacceptable
RE_used > individual maximum
injury found
safe radiant exposure
[0053] The value K is determined such that the number of points at which damage occurs at a radiant exposure (RE) lower than the predicted individual maximum safe radiant exposure (IMSRE) is not more than 3% of the total test spots in the data set, while the individual maximum safe radiant exposure (IMSRE) is maximized at the same time. It followed that for the current data set (in which we used two laser spot sizes: 8 mm and 12 mm) K values of 35 and 27 provided the best prediction. Accuracy of these values can be increased with an expanded calibration data set.
[0054] FIG. 4 shows in the upper graph each of the 304 data points plotted on axes representing the individual maximum safe radiant exposure (IMSRE) and the RE used for the test spots. The data points in category 2 and 3 are incorrectly predicted with this method, but in general there is a good separation of points. The lower graph in FIG. 4 shows the fraction of the data points in each of the prediction categories. The majority of the points are correctly predicted.
[0055] Analysis Method #2
[0056] Whereas method #1 only uses one data point from the pulsed photothermal radiometric signal: ΔT (t=20 ms), the method based on partial least squares regression (PLS) uses the entire pulsed photo-thermal radiometric signal starting from the moment at which the diagnostic laser pulse is applied to about one second later. In other words a time profile or temporal signature of the photo-induced heat production in the skin to the laser pulse/cooling protocol is the measured and characterizing subset of points of the data set.
[0057] Method #2, however, is much less intuitive and strongly depends on a mathematical/statistical analysis method, known as partial least squares regression (PLS). Basically, it can quantify the relationship between two known data sets, assuming that there is some linear relationship between these data sets, and then use the resulting data to quantify an unknown value from a known related value.
[0058] In our case, the two data sets are the individual maximum safe radiant exposure IMSRE and the pulsed photo-thermal radiometric signals as schematically depicted in FIG. 1 . We are interested in determining individual maximum safe radiant exposure from the pulsed photo-thermal radiometric (PPTR) signal.
[0059] PLS assumes some degree of linearity between the datasets. The PLS calibration is able to improve the IMSRE prediction based on a PPTR signal, by using information regarding the epidermal thickness, embedded in the PPTR signal. This allows the calibration to account for both pigmentation surface density and pigmentation volumetric density. This condition is satisfied if we use the reciprocal of the pulsed photo-thermal radiometric (PPTR) signal:
[0060] Consider first a physical description of the PLS methodology. The pigmentation of skin is a simplification of what is relevant in the prediction of IMSRE because it may refer to the pigmentation surface density (the total amount of melanin per unit skin surface, including the underlying epidermis of that surface), or to the pigmentation volumetric density (melanin per unit volume within the epidermis). This difference would be irrelevant if all human epidermis were the same thickness. However, epidermal thickness can vary from approximately 50 micrometers to approximately 200 micrometers in different locations. Assume two skin areas with equal pigmentation surface density but with epidermal thicknesses of 50 and 100 micrometers, respectively, the melanin per unit volume would in the latter epidermis would be only half that in the former epidermis. In other words, the concentration of melanin is different by a factor of two. It follows that the absorption of laser light by melanin and subsequent heat production per unit volume is also different by a factor of two. If the heat production per unit volume is different by a factor of two, it follows that peak temperatures are also different. Thermal heat diffusion, during the laser pulse, will cause the peak temperatures to differ by a factor less than two, although a difference in (peak) temperature will still be affected. The above example is to illustrate that the total melanin content per unit skin surface may not be as relevant for the prediction of the IMSRE as the melanin content per unit volume.
[0061] Existing apparatus quantify individual pigmentation as a single number, the so called “melanin index” (e.g. the Mexameter by Courage-Khazaka Electronic, Cologne, Germany). It is our understanding that these devices provide a quantification for the pigmentation surface density and disregard the effect of epidermal thickness. Our data as well as our understanding of the thermally induced skin injury suggests that a more precise prediction of the IMSRE should involve a quantification of the epidermal thickness as well. A PPTR measurement contains information regarding the thickness of the epidermis, and can thus provide a measure for not only the pigmentation surface density but the volumetric density as well.
[0062] If a PPTR measurement is performed on a relatively thick epidermis, the temperature signal will drop less fast than if it were on a relatively thin epidermis due to the larger thermal relaxation time for the thicker epidermis.
[0063] Examples of measured PPTR signals with probably different epidermal thicknesses are shown in the graph of FIG. 5 . The PPTR signal A shows a relatively rapid decline with time, indicating a relatively thin epidermis with a small thermal relaxation time. PPTR signal B shows a slower decline with time, indicating a thicker epidermis with a larger thermal relaxation time. The larger temperature increase of the PPTR signal B for times >50 ms indicates a
[0064] A prior art model approach as illustrated in FIG. 2 would attempt to quantify the epidermal thickness and then apply a damage model to calculate the expected injuries for these different epidermal geometries.
[0065] In contrast, a calibration with PLS uses these signals and lets the mathematical, statistical algorithm determine how the shapes of these PPTR signals correlate with the IMSRE. A more statistically oriented explanation of the PLS methodology is as follows. The analysis method #1 (using a single k value and the PPTR signal at 20 ms) uses only one point of the PPTR signal, and basically uses linear regression to calibrate the IMSRE prediction. We could now expand this method to also use the PPTR signal at 30 ms and improve the prediction by performing multiple linear regression, using the 20 ms and 30 ms as data points. Expanding this even further would use each time point in the PPTR signal and use multiple linear regression to find the best constants for each of these time points. PLS is doing essentially exactly that. An important difference with multiple linear regression, however, is that PLS uses a factor based approach to perform a quantitative calibration. This or similar techniques are also often referred to as principal component regression.
[0066] If each of the individually measured pulsed photothermal radiometric signals Δ(t) are written as vectors T_, their reciprocal can be written as
[0000] T= 1/ T _. (2)
[0067] The length of the vector T is for example 1000 if we sampled the pulsed photo-thermal radiometric signal at 1000 Hz and acquired the signal for one second.
[0068] In terms of linear algebra we can now write:
[0000] IMSRE I =KT I (3),
[0069] where K is a vector of the same length as T such that the matrix product KT i equals IMSRE i
[0070] The problem now is to find the vector K which is needed to use equation 3 in order to predict the individual maximum safe radiant exposure IMSRE with a measured pulsed photothermal radiometric signal. This is briefly described below
[0071] PLS provides K in a calibration step. We first identify all test spots in which we just reached the damage threshold. We use the RE values that caused this threshold as the individual maximum safe radiant exposure IMSRE, forming a vector I. The associated reciprocal pulsed photothermal radiometric signals T (defined in equation 2) form a matrix T.
[0072] The calibration step in PLS, which is a conventional well known algorithm, uses I and T to produce K.
[0073] In the prediction step PLS essentially uses equation 3 to determine the unknown IMSRE i for any measured signal T i .
[0074] We tested PLS for our application using simulated pulsed photothermal radiometric signals to investigate the feasibility of PLS. Determining feasibility was necessary because using PLS for temporal data instead of spectral data is highly unusual and the results could not be assumed to be correct. We tested the PLS algorithm for our purpose because this technique is typically used to extract concentrations of a chemical from a measured (absorption or reflectance) spectrum. The application of PLS for temporal signals has not been previously done. Simulation confirmed that PLS was a feasible approach and later validation with experimental data as well confirmed it.
[0075] Although PLS is specifically used in the illustrated embodiment, it must be understood that any statistical regression technique may be applied that gives satisfactory results. We have thus far only used PLS, but other statistical regression methods may work just as well or better. The relevant point is that the approach of the invention is model free. No assumptions need to be made, nor additional modeling or reconstructions are necessary. This is the underlying mechanism for the robustness of the method.
[0076] FIG. 6 shows results of the simulation/feasibility exercise where calculated IMSREs are compared against predicted IMSREs. Simulated use of PLS to predict individual maximum safe radiant exposure from a pulsed photothermal radiometric signal is shown in FIG. 6 . Pulsed photothermal radiometric signals were simulated for a variety of skin pigmentations and epidermal thicknesses. For these same skin geometries, laser treatment was modeled with and without cooling. The individual maximum safe radiant exposure was calculated by assuming a critical threshold temperature for damage at the basal layer. PLS was used to predict the individual maximum safe radiant exposures (vertical axis of FIG. 6 ) from the pulsed photothermal radiometric signals and was then compared with those calculated. The results indicate the feasibility of PLS for this application.
[0077] We have used the experimentally acquired data to perform our first PLS calibration and then used the result to apply on the entire set of experimentally obtained data to verify the feasibility of PLS as shown in FIG. 7 . The same data points of all 13 volunteers (403 data points in total) are plotted on the same axes as in FIG. 4 . The PLS predicted individual maximum safe radiant exposure (method #2) are clearly different than those with the simpler method #1. Note that the prediction seems to be inaccurate for higher individual maximum safe radiant exposure values. However, we are confident this is only due to the fact that the calibration data set is relatively underrepresented for this region. What is important to notice in the upper graph of FIG. 7 is that the points are much better separated than in the upper graph in FIG. 4 . This is what is important for an accurate individual maximum safe radiant exposure prediction. We are confident that with an extended calibration data set, the category 2 points would be drastically reduced while the category 3 points would be the same or reduced as well.
[0078] Even without an extended calibration set, a pragmatic user of FIG. 7 would simply draw an empirical line (other than the straight line) between the data points which would already improve the prediction quality.
[0079] Many alterations and modifications may be made by those having ordinary skill in the art without departing from the spirit and scope of the invention. Therefore, it must be understood that the illustrated embodiment has been set forth only for the purposes of example and that it should not be taken as limiting the invention as defined by the following invention and its various embodiments.
[0080] Therefore, it must be understood that the illustrated embodiment has been set forth only for the purposes of example and that it should not be taken as limiting the invention as defined by the following claims. For example, notwithstanding the fact that the elements of a claim are set forth below in a certain combination, it must be expressly understood that the invention includes other combinations of fewer, more or different elements, which are disclosed in above even when not initially claimed in such combinations. A teaching that two elements are combined in a claimed combination is further to be understood as also allowing for a claimed combination in which the two elements are not combined with each other, but may be used alone or combined in other combinations. The excision of any disclosed element of the invention is explicitly contemplated as within the scope of the invention.
[0081] The words used in this specification to describe the invention and its various embodiments are to be understood not only in the sense of their commonly defined meanings, but to include by special definition in this specification structure, material or acts beyond the scope of the commonly defined meanings. Thus if an element can be understood in the context of this specification as including more than one meaning, then its use in a claim must be understood as being generic to all possible meanings supported by the specification and by the word itself.
[0082] The definitions of the words or elements of the following claims are, therefore, defined in this specification to include not only the combination of elements which are literally set forth, but all equivalent structure, material or acts for performing substantially the same function in substantially the same way to obtain substantially the same result. In this sense it is therefore contemplated that an equivalent substitution of two or more elements may be made for any one of the elements in the claims below or that a single element may be substituted for two or more elements in a claim. Although elements may be described above as acting in certain combinations and even initially claimed as such, it is to be expressly understood that one or more elements from a claimed combination can in some cases be excised from the combination and that the claimed combination may be directed to a subcombination or variation of a subcombination.
[0083] Insubstantial changes from the claimed subject matter as viewed by a person with ordinary skill in the art, now known or later devised, are expressly contemplated as being equivalently within the scope of the claims. Therefore, obvious substitutions now or later known to one with ordinary skill in the art are defined to be within the scope of the defined elements.
[0084] The claims are thus to be understood to include what is specifically illustrated and described above, what is conceptionally equivalent, what can be obviously substituted and also what essentially incorporates the essential idea of the invention.
|
A method for making pulsed photothermal radiometric measurements to determine individual maximum safe radiant exposure (IMSRE) of biological subjects corresponding to radiant energy exposure (RE) without any use of a biological model includes a calibration procedure, including the steps of applying a statistical regression to an empirical data set of IMSRE and temporal REs applied to a sample population of the subjects to determine a IMSRE corresponding to each temporal RE. The IMSRE is set so that using the statistical regression separation of the data set into an acceptable injury grouping and an unacceptable injury grouping is obtained with a predetermined limitation of the proportion of subjects having unacceptable injury at a temporal RE below the corresponding IMSRE. The separation of the data set is thus used to predict an IMSRE for a corresponding temporal RE to a biological subject not included in the sample population.
| 0
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This Appln. claims the benefit of U.S. Provisional Appln. No. 60/049,706 filed Jun. 16, 1997.
FIELD OF THE INVENTION
The present invention is directed to a wireless communication pole system and a method of use and, in particular, to a pole system that is fully integrated for rapid installation and includes systems to ease antenna maintenance.
BACKGROUND ART
In the field of cellular or other wireless communication devices, cell sites are required to handle wireless communication traffic. With the popularity of cellular phones and the development of an increased number of radio-based communication services, the number of cell sites presently available are inadequate to meet the needs of the future. Moreover, cell sites can no longer be limited to building tops or 150 foot towers to provide the pinpoint, error free, quality radio coverage demanded by customers. Sites are required to be lower in height and spaced even closer together, encroaching even into neighborhoods, parks and environmentally sensitive areas.
Many cell site poles have integral antenna assemblies which are self contained in a structure that is not accessible. With this construction, some disassembly is required for maintenance and/or repair. Often times, the antennas are enclosed in a plastic cylinder which is flexible if compressed. While the plastic cylinders can be painted, the durability of the paint coating is not guaranteed and the aesthetic appearance of these types of poles could deteriorate over time.
Accordingly, a need has developed to provide wireless communication cell sites or pole systems that are aesthetic, easy to install, and easy to maintain. The invention solves this need by providing a wireless communication pole system with a fully integrated design permitting rapid installation, easy maintenance of the pole antenna system, an aesthetic design, and a modular construction permitting the use of different ornamental structures in combination with the pole to fit different settings.
SUMMARY OF THE INVENTION
Accordingly, it is a first object of the invention to provide a cell site pole assembly integrating all of the antenna, transmission cable, connectors, grounding, lightning protection, vertical support, and foundation components for rapid installation.
Another object of the invention is a cell site pole assembly that adds aesthetic customization to enhance acceptance for community siting.
A further object of the invention is a cell site pole assembly that facilitates antenna access for field repairs of the antenna components.
A still further object of the invention is a cell site pole assembly that accommodates various types of antennas without the need for pole modification.
One other object of the invention is a method of installing the cell site pole that requires a minimum amount of time.
Other objects and advantages of the present invention will become apparent as a description proceeds.
In satisfaction of the foregoing objects and advantages, the present invention comprises a cell site pole assembly that has many of the components pre-installed so that field installation requires little assembly time prior to pole erection. The cell site pole assembly includes a foundation which is attachable to a cell site pole. The pole itself is preferably made of galvanized steel of a predetermined length depending on the pole application. An antenna spool assembly is connected to the top of the pole. The antenna spool assembly is shrouded by a pod that is vertically movable to provide easy access to the antenna components.
The pole assembly is designed with prefabricated features to receive different ornamental or functional features to enhance the pole's utility or aesthetic appearance. For example, the pole could support light fixtures to function as a street light as well as a cell site. The pole assembly could also include a base enclosure which is merely decorative or has functional features such as storage space. Similarly, the pole top can include features to enhance the pole's appearance such as a weathervane or the like. The pole assembly can be fabricated in different colors to blend in with its environment.
The pole itself can include internal connectors, preferably made of copper, at one or both ends. The connectors permit pre-installation of transmission cables along the length of the pole. With this arrangement, cables do not have to be run through the pole at the installation site. Rather, installers merely have to connect incoming cables to the connector at the pole base. Likewise, the cables of the antenna spool assembly need only to be connected to the connector positioned near the top of the pole. The connectors can also include lightning arrestors for safety purposes. The connectors are accessible by doors in the pole.
The antenna spool assembly has several features that contribute to the overall effectiveness of the pole assembly. First, the fit between a base of the antenna spool and a top of the pole allows for easy routing of cables between the spool assembly and the connector in the pole.
Second, the spool assembly employs a fiberglass housing that permits the RF transmission signal to pass through the housing without adversely affecting the antenna pattern loss. The housing can have a cylindrical shape to permit a 360° orientation of the antennas without any physical obstruction. Thus, the antenna azimuth can be oriented in any vertical configuration. The housing can be sized to accommodate a variety of different types of antennas as wells as antenna downtilting, thereby avoiding the necessity of reengineering the spool assembly. By the antenna spool and pole design, the housing can function without a significant structural bracing. Since the housing is made of fiberglass, the housing is light in weight which makes it easy to be moved when it is desired to access the antenna components.
Third, the antenna spool assembly employs a unique mechanism to raise and/or lower the housing to expose the antenna for repair, maintenance or the like. The housing is slightly larger than the connection between the spool and the top of the pole so that it can be lowered past this point. A counterbalance system is arranged as part of the spool assembly which allows a worker to apply a force to the housing in either an upward or downward direction. Application of the force in conjunction with the counterbalance system moves the housing in the direction of the applied force. If a worker needs to access the antenna, the worker would merely push or pull down on the housing, either by hand or with a tool, and the housing would slide down the antenna spool to expose the antenna components. Once the worker is finished, the housing would be pushed or pulled upward to again enclose the antenna.
In use, the pole assembly is delivered to a particular site. A hole is dug to receive the foundation, either before, after or during pole delivery. The foundation, preferably a pre-cast concrete cylindrical footer of sufficient diameter and length to support the pole, is installed in the hole and the pole assembly is erected and attached to the foundation, including making all the necessary cable connections. The antenna spool assembly can be attached to the pole prior to pole delivery to the site, at the site and prior to pole attachment to the foundation or after pole attachment to the foundation. Preferably, the spool is attached prior to pole delivery or at the site prior to pole erection. Any decorative or functional features of the pole assembly can be attached prior to pole delivery or at the site. For lighting fixtures, attachment may be required at the site due to the difficulty in transporting the pole if the lighting fixtures extend outwardly in a manner that may disrupt traffic during pole transport. Multiple antennas can also be employed.
BRIEF DESCRIPTION OF THE DRAWINGS
Reference is now made to the drawings of the invention wherein:
FIG. 1 is an elevational view of one embodiment of the invention;
FIG. 2 is an exploded elevational view of the base assembly of the pole of FIG. 1;
FIG. 3 is a sectional view along the line III--III of FIG. 2;
FIG. 4 is an exploded elevational view of the antenna assembly of the pole of FIG. 1;
FIG. 5 is an elevational view of the spool of the antenna assembly of FIG. 4;
FIG. 6 is an end view along the line VI--VI of FIG. 5;
FIG. 7 is an end view along the line VII--VII of FIG. 5;
FIG. 8A is an end view along the line VIIIA--VIIIA of FIG. 5;
FIG. 8B is an end view along the line VIIIB--VIIIB of FIG. 5;
FIG. 9 is an elevational view of the radome of the antenna assembly of FIG. 4;
FIGS. 10 and 11 are partial sectional views of the radome of FIG. 9;
FIG. 12 is and end view of the lower shroud depicted in FIG. 4;
FIG. 13 is a top view of the counterbalance system of the antenna assembly of the pole of FIG. 1;
FIG. 14A is an exploded view of one of the counterbalance arrangements of FIG. 13,
FIG. 14B shows the arrangement of FIG. 14 assembled;
FIG. 15 is an alternative spring end for the arrangement of FIGS. 14A and 14B;
FIG. 16 is a top view of the arrangement of FIG. 14B;
FIG. 17 is a sectional view along the line XVII--XVII of FIG. 16;
FIG. 18 is an elevational view of the pole alone shown in FIG. 1;
FIG. 19 is a sectional view along the line XIX--XIX of FIG. 18;
FIG. 20 is a sectional view along the line XX--XX of FIG. 19;
FIG. 21 shows an exemplary lightning arrestor
FIG. 22 is a sectional view along the line XXI--XXI of FIG. 18; and
FIGS. 23 and 24 detail comparative testwork with and without the inventive radome.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an elevational view of one embodiment of the pole assembly of the invention wherein the pole doubles as a banner-carrying light pole. The embodiment, designated by the reference numeral 10, includes a pole 1, a base assembly 3 and an antenna assembly 5.
Referring to FIG. 2, the base assembly 3 includes a foundation designated by the reference numeral 6 which further comprises a concrete footer 7 and a plurality of anchor bolts 9 extending therefrom.
The pole 1 has a bottom flange 11 with throughopenings 13. The through openings 13 are sized to receive the anchor bolts 9 for flange securement. In this embodiment, four anchor bolts are arranged in a circular pattern, the anchor bolts secured to the flange 11 via the nuts 15. Other ways or means to attach the foundation to the pole can be used as would be within the skill of the art.
Referring to FIGS. 2 and 3, the connection between the pole 1 and the foundation 6 is enclosed by base enclosure halves 17 and 19, the halves fastened together at respective ends 21 and 23. Set screws 25 are used to secure the halves 17 and 19 to the pole 1. Although a lap joint 35 is illustrated in FIG. 3 to facilitate connection between the ends 21 and 23, other modes of connection can be employed as part of the base assembly 5.
Each of the halves 17 and 19 have covers 27 and 29. The covers 27 and 29 permit access to the pole access covers 33, which in turn allow access to the pole interior 31. Preferably, the base assembly enclosure halves 17 and 19 are fiberglass and the pole 1 and covers 33 are galvanized steel. Of course, other materials of construction can be utilized as would be within the skill of the art.
Referring back to FIG. 1, the pole assembly 10 also illustrates a light/banner assembly 37. This assembly includes a light fixture 39 supported by arms 41 and 42, each arm mounted to the pole 1. The assembly 37 also includes a lower arm 45 and a banner 47 mounted between arms 42 and 45. It should be understood that the light/banner assembly 37 is optional and the pole assembly 10 could be installed without any such decorative or functional accessory. Alternatively, other styles of light fixtures and/or banner arrangements could be utilized, depending on the desired look and environment of installation. The various connections between the components can be any conventional type.
FIG. 4 more clearly illustrates the antenna assembly 5. The assembly 5 includes a spool 47 and a housing or radome 49. The radome 49 is typically cylindrical in cross sectional shape. Perched atop the spool 47 and radome 49 is a cap assembly 51. A lower shroud assembly 53 is positioned beneath the spool 47 and radome 49.
The spool 47 is shown in more detail in FIGS. 4-8B. The spool 47 has a base flange 55, a radome support base 57, the flange 55 and base 57 separated by the shaft 58. Extending above the radome support base 57 is a cap assembly support base 59. The cap assembly support base 59 supports the cap 61 via the fasteners 63 and threaded rods 65.
Still with reference to FIG. 4, the cap assembly 51 also includes a ball cap 67 affixed to the spool shaft end 69 via the threaded rod 71, coupling 73, lightning rod 75 and nut/washer combination 77. The threaded rod 71 attaches to the tapped hole 79 in the shaft end 69. The shaft end 69 also has a hoisting opening 81 for lifting of the pole assembly 10. Preferred materials of construction include fiberglass for the ball cap 67, bronze for the lightning rod and steel for the connecting fasteners. It should be understood that the cap assembly 51 is exemplary and other cap constructions and/or designs could be used as part of the inventive pole assembly.
The radome 49 is illustrated in FIG. 9 with its wall construction shown in FIG. 10. More specifically, the radome 49 is generally cylindrical in nature and composed of a laminate construction. The laminate construction comprises a foam core 85 and fiberglass layers 83. The thickness of the various layers can vary but are preferably 5/32 inches for the inner foam layer 85 and 1/16 inch for the fiberglass layers 83.
FIG. 11 shows a sectional view of the upper end 90 of the radome 49 that utilizes a steel band, preferably spaced 1-1/2 inches below the radome upper edge, to aid in radome support. FIG. 11 illustrates the band construction in combination with the fiberglass layers. The band 87, preferably 3 inches wide by 3/16 inch thick, is shown disposed between the layers 83.
The upper end 90 of the radome 49 is linked to the spool 47 via the fasteners 89 interfacing with the flanges 91 found on the radome support base 57, see FIGS. 4 and 5. The lower portion of the radome also uses fasteners 89 for attachment to the flanges 94 on the spool base flange 55.
The radome 49 also includes an enlarged diameter section 93 at the lower portion thereof which provides symmetry with the similarly shaped lower section of the cap 61, see FIG. 5.
The spoof base flange 55 is attached to the pole via pole flange 95. More specifically, threaded studs 97 extending from the lower surface of the base flange 55 interface with throughopenings in the pole top flange 95 and nut/washer combinations 98. The connection of the spool base 55 to the pole top flange 95 is enclosed by the radome section 93.
The lower shroud assembly 53 comprises two halves 101 and 103, the halves attached together via fasteners 105. The assembled shroud halves are then secured to the pole using the shroud cups 106 and fastening nuts 108. The shroud assembly 53 is exemplary and other designs and/or configurations can be utilized as part of the antenna assembly 5.
The radome 49 is movable about its longitudinal axis by means of a counterbalance assembly 110 which is depicted in FIG. 13. The assembly 110 allows for lowering and/or raising of the radome with minimal effort on the part of a person servicing the antenna components. The radome 49 is linked to the counter-balance assembly 110 via cables 111 that are guided via the roller guides 113. The cables can be affixed to the radome in any conventional manner.
The counterbalance assembly 110 is preferably designed with three spring/pulley systems, each system mounted to the upper radome support plate 57 of the spool. Each system has a cluster of three springs with a dual pulley or drum 115 centered within the cluster. The dual level of the drum 115 allows the three springs to attach to the drum at the lower level and also allows for the supporting cable for the radome 49 to attach to the upper level of the drum 115. The three spring/pulley systems are preferably set 120° apart within the radome diameter (other spacings or numbers of systems could be used). The cabling 111 of each system is attached to the radome at 120° segments as well. In use, the fiberglass radome 49 can be lowered using the counterbalance assembly as described below once the lower shroud 53 is removed. The radome is sized to be slightly larger, for example, 1/8 inch, than the mating surfaces of the spool base flange 55 and the pole top plate 95 to permit it to lower down the pole.
Referring to FIGS. 13-17, the drum 115 of the counter-balance assembly 110 has a cable storage reel 117. The drum 115, also having a spring take-up reel 118, is mounted for rotation on a pin 119 extending upwardly from a mounting plate 121, the plate 121 secured to the plate 57, see FIG. 14A. The mounting plate 121 has pins 123 extending upwardly therefrom, the pins receiving the take-up drums 125. Each drum 125 holds a spring 126 coiled thereon. One end 127 of each spring 126 is secured to the take-up reel 118. More specifically, the take-up reel 118 has a triangularly sectioned portion 131, the portion 131 having faces 132 to facilitate attachment of the respective spring ends 127. Each spring end 127 can be secured to the face 132 by a fastener engaging the threaded port 129 associated with each face.
In use, when the radome is in the uppermost position, the springs 126 that are wound around the drums 125 are at rest. Applying a downward force to the radome 49 unwinds the cable 111 from the drum 115, thereby rotating the drum 115. Rotation of the drum 115 retracts the springs 126 from the drums 125, the springs 126 accumulating on the take-up reel 118. The springs 126 are appropriately tensioned so that the radome 49 can be lowered in a controlled fashion, e.g., lowered to a point of rest to expose the antenna mounted on the spool 47. Lowering of the radome 49 permits a technician or other individual to access the antenna 1171, see FIG. 4, mounted to the antenna spool 47. Once service on the antenna is complete, the radome 49 can be raised or pushed upwardly, the raising causing the springs 126 to coil around the drums 125 and accumulate the cables 111 around the drums 115.
As part of the radome lowering, the lower shroud assembly 53 should be removed and then reinstalled once the radome is back in its uppermost position. It should be understood that the counterbalance assembly shown in FIGS. 13-17 is exemplary and other designs can be employed which perform the same function as that disclosed, i.e., a mechanism which allows an individual either alone or with a tool to vertically move the radome to expose one or more of the antenna components. Of course, the radome 49 could also be secured in place with fasteners or the like so as to be removed without the benefit of a counterbalance system rather than be used with a system that permits radome raising or lowering. For example, the radome could be merely separated from the spool and lowered using a cable hooked to a crane.
FIG. 15 shows an alternative spring end attachment configuration 127 . In this embodiment, the spring end has an enlarged end portion as compared to the spring end shown in FIG. 14B.
The inventive pole assembly 10 also includes an improved means or way to connect in-ground antenna cabling to the cabling associated with the pole assembly. This base connection is designated by the reference numeral 150 in FIG. 1 and more clearly illustrated in FIGS. 18-22. The base connector 150 comprises a rectangularly shaped copper plate 151 which is supported by the pole via the insulator 157 and insulator bracket 159. The insulator bracket 159 can be welded to the pole, the insulator providing electrical separation between the copper plate 151 and the pole 1.
Mounted to the copper plate 151 are connectors 158. One end of the connector, e.g., 162, is attached to the copper plate 151. This end is designed to receive the incoming antenna cables. The other end of the connector can be attached to the appropriate antenna cable so that the cable can be pre-installed within the pole interior 31 prior to its delivery to an installation site. In this way, at the base, the only connection required to be made when installing the pole is connecting the inground or incoming cables to the connectors 158. Preferably, the connectors incorporate lightning arresting properties, e.g., Huber+Suhner connectors. Alternatively, other modes of lightning arresting as part of the cable connections or other pole components can be employed.
At the other end of the pole 1 is an upper plate 161 mounted within the pole interior 31. The plate 161 has through holes 163 to permit cables to pass therethrough and provide cable alignment. The plate 161 is annular in nature to provide an opening 165 therethrough. J-hooks 167 are provided as a means of stress relief for the coaxial cable running through the pole 1.
The pole 1 includes access covers 169 as spaced intervals along its length to access the interior 31 of the pole. The access cover at the base allows the connection to be made between inground cables and the connectors 158. The access cover at the other end of the pole permits access to the plate 161.
Referring again to FIGS. 8A and 8B, the base plate 55 of the spool has through holes 171 to receive the antenna cables running up through the pole 1 from plate 161. U-shaped lifting handles 173 are provided as are busses 175, the busses facilitating antenna hookup. The cables 160, see FIG. 1, running through the pole and plate 161 can be hooked directly to at least one antenna or can be linked with jumpers for antenna connection.
The materials of construction and dimensions for the pole assembly 10 can vary depending upon the desired application. For example, the pole overall height could range from 50 to 100 feet with a 14 inch OD and the antenna module could have a ten foot height. The pole could be made from ASTM-A572 steel with the antenna radome being fiberglass reinforced plastic. Various finishes can be applied to any or all components of the pole assembly, paints, spray coatings or the like. Further, any conventional antennas can be employed as part of the pole construction. An EMS wireless dualpole antenna is but one example, but others may be employed.
FIGS. 23 and 24 show tests relating transmission and reflectivity for antennas with and without a radome. As can be seen these two figures, the fiberglass radome, being a RF semitransparent material has a minimal effect on antenna performance.
The spool design for containing the antenna offers several advantages. First, the spool lower plate 55 eases connection to the top 95 of the pole and connection to transmission cables within the pole. Second, the spool upper plate 57 provides a support surface for a mechanism to raise and/or lower the housing. The spool upper and lower plates, by reason of their increased diameter over the spool tube therebetween, form a space to mount and/or arrange an antenna. By specifying the proper dimensions for the spool assembly, a wide variety of different configurations of antennas can be employed.
The pole design in FIGS. 18-22 is exemplary and other types of connectors, flanges, plates, etc., can be used. Moreover, different mounting locations for the various components can also be selected.
As stated above, a wide variety of pole configurations can be used depending on the environment of use. The pole can be made in different colors, e.g., green, gray burgundy, white or any another color, tone or combination thereof. The surface of the pole can have different textures, e.g., smooth, fluted, spiraled or the like. The pole can utilize different types of lighting fixtures and the ornamental features can be located on the pole, at the base or at or near the top of the pole assembly, e.g., flag poles. Of course, the pole can be devoid of other features so that it functions as a cell site only and blends in with its environment.
When the housing, cap and shroud are fiberglass, the pole color can be incorporated into the fiberglass manufacturing process, e.g., gel coating of the part surface. This feature provides longevity to the pole color and reduced maintenance. The radome can be any RF transparent or semitransparent material. Fiberglass or a fiberglass reinforced material such as a plastic or polymer are just examples of preferred materials. Other materials may include polymeric or fabric materials or other materials exhibiting the desired RF transparency. The radome construction may also be related to the antenna operation such that a particular degree of RF transparency is required.
The embodiment depicted in FIG. 1 illustrates a single antenna mounted on the spool. However, a plurality of antennas, the same or different, can be mounted in the pod created by the radome and the spool. A group of antennas may require the appropriate separation, e.g., isolation baffles or the like, so that one antenna does not impede the performance of other antennas. In addition, the spool may require other structural members or supports to facilitate mounting more than one antenna. When using a number of antennas, the spool base flange, plate 161 and base connection 150 may require modification to handle the increased number of cables, additional connectors, throughholes, j-hooks, additional plates or the like. Other pole components can be modified as needed to accommodate additional antennas.
Another advantage of the invention is the modular nature of the pole assembly. The pole assembly can be brought to a site where the foundation has been installed and easily and quickly erected. The antenna and cabling can be installed as part of the pole assembly prior to erection such that the only connection required is at the base connection once the pole assembly is erected. The components of the pole assembly can be assembled at the erection site or beforehand at a remote site.
In use, it is preferred to first install the concrete footer at a desired site. Once the footer is installed, the assembled pole assembly can be shipped to the site and installed with a crane. The in-ground cable connection can then be made as can the necessary adjustments to the antenna. The entire installation can be done in a day since the pole components are pre-assembled.
Accordingly, an invention has been disclosed in terms of preferred embodiments thereof which fulfill each and every one of the objects of the present invention as set forth above and provides a new and improved cell site pole assembly and method of use.
Various changes, modifications and alterations from the teachings of the present invention may be contemplated by those skilled in the art without departing from the intended spirit and scope thereof. Accordingly, it is intended that the present invention only be limited by the terms of the appended claims.
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A cell site pole assembly is integrated with various antennas and pole components so that the pole assembly can be readily installed at a cell site without the need for extensive wiring, pole component assembly or the like. The pole assembly also includes a lightweight fiberglass housing which surrounds the antenna but does not interfere with antenna functioning. The pole assembly can have a counterbalance system to easily raise or lower the housing for access to the antenna. The pole assembly is designed to employ other features such as lighting or decorative/symbolic components to enhance the aesthetic appearance of the pole when situated in a community environment.
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FIELD OF THE INVENTION
[0001] This invention relates generally to bumper rails, and more particularly to shock absorbers for bumper rails.
BACKGROUND OF THE INVENTION
[0002] FIG. 1 illustrates a go cart track 5 with two bumper rails 6 extending around both sides of the full length of the track 5 . A common bumper rail 6 is configured to deflect when impacted by a cart and comprises a steel band, or suitable material, with an approximate 5-inch by 0.625-inch cross section. The bumper rails 6 are commonly backed by used automobile tires 3 or other rubber devices that serve as shock absorbers for the rails 6 .
[0003] Tires perform their function reasonably well, as long as the impact load on the rail system is low or moderate. But in areas of the track that receive frequent high-load impacts, the tires often become permanently deformed, particularly when the impact loads exceed the elastic limit of the tires. Eventually, the elasticity of many tires decay so much that the tires are rendered crumpled and useless. FIG. 2 illustrates some tires in the early stages of this deformation process.
[0004] After a tire is spent, it is common to remove the tire, re-straighten the bumper rail, and install a new tire. This type of maintenance may have to be performed many times depending on the track design and usage.
[0005] Despite these inconveniences, used tires are relatively cheap and easy to obtain and relatively easy to install. These and other factors have served to suppress prior art motivation to replace the tires with a different shock absorbing system.
[0006] One of the Applicants owns a small amusement park that includes a go cart track. Applicants, moreover, enjoy making innovations even in areas where a person of ordinary skill, content with conventional techniques, might lack any motivation to innovate. This drive led Applicants to explore replacing tires with leaf springs similar to auto leaf springs.
[0007] Applicants' investigations made them aware of one prior art leaf-spring-based shock absorbing system installed at a track in Florida. The system, which is herein referred to as the “Shaller design,” is illustrated in FIG. 3 . The Shaller design replaces each tire 3 with an arch-shaped leaf spring 90 installed lying on its side—that is, with its radial cross-section in a horizontal (non-upright) position. One end of the arch-shaped leaf spring 90 is welded to a sleeve 99 which is secured to the concrete base 2 by an anchor bolt 91 .
[0008] Although Applicants were informed that the Shaller design performed well, Applicants also realized that it was relatively expensive to fabricate. So Applicants conceived, tested, and refined alternative systems. Applicants tried different leaf spring sizes, configurations (including a “V” shaped design), and fastening alternatives. Many of Applicants' experimental designs resulted in failures where the spring was anchored to the concrete base, due to the intense side bending loads imposed on the concrete anchor. After repeated refinements, Applicants developed a design that is both economical and robust.
SUMMARY OF THE INVENTION
[0009] A spring is provided as a shock absorber for a bumper rail system. The spring—preferably but not necessarily taking the form of a four-inch by one-quarter-inch bar of 5160 spring steel—is shaped into an arch configuration and mounted in a standing arch configuration. An end portion of the spring bar is shaped into a saddle so that the spring bar can be secured indirectly, by means of a metal plate or bracket, to the concrete base.
[0010] The current invention has proven not only to be more effective and robust than used tires, but also competitive in price. The invention is easy to fabricate and easy to install.
[0011] Additional advantages of the present invention—which were not apparent when conceptualizing the design but which became apparent after testing of the invention—included (1) the ability to add more springs between existing ones in high impact areas and (2) the practicality of re-straightening the springs when they become over-stressed. Other environmental, maintenance, and financial benefits include (3) potential savings on new track installations, (4) the ability to retrofit existing tracks while using the same bolt that was used to secure the tire to the rail to secure the spring to the rail; (5) the avoidance of having rainwater and debris collect inside the tires, (6) the fact that it is more feasible to recycle spent steel than spent tires, and (7) the fact that spent steel can be sold at a small profit for scrap, whereas spent tires require a disposal fee.
[0012] Part of what makes the present invention so innovative and remarkable is its simplicity and economy. It comprises only a few different parts and is easy to use. But despite its simplicity, the present invention provides numerous advantages over conventional approaches. Those of ordinary skill in the art will appreciate these and other improvements described further below in the detailed description and the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 illustrates a go-cart track with used tires employed as shock absorbers for the rails.
[0014] FIG. 2 illustrates a portion of a go-cart track with used tires employed as shock absorbers for the rails.
[0015] FIG. 3 illustrates a portion of a go-cart track with shock-absorbing leaf springs lying on their sides and secured to the concrete base of the track by an anchor-bolt sleeve welded to the spring.
[0016] FIGS. 4-6 illustrate a portion of a go-cart track with one embodiment of a bumper rail assembly according to the present invention, including shock-absorbing springs mounted in a standing arch configuration and a saddle for anchoring the springs to the concrete base.
[0017] FIG. 7 is a side view of one embodiment of an arch-shaped spring configured in accordance with the present invention.
[0018] FIG. 8 is a perspective view of one embodiment of an arch-shaped spring configured in accordance with the present invention.
[0019] FIG. 9 is a top view of a bar of spring steel before it is formed into the arch-shaped spring of FIG. 8 .
[0020] FIG. 10 is a top view of the bar of FIG. 10 , showing a drilled hole location and lines along which the bar is bent to form the saddle portion and the opposite end portion.
[0021] FIG. 11 is a side view of the bar of FIG. 9 .
[0022] FIG. 12 is a side view of the bar of FIG. 10 , after the saddle and opposite end portions have been bent.
[0023] FIG. 13 is a perspective view of one embodiment of an anchor bracket.
[0024] FIG. 14 is a perspective view of one embodiment of the arch-shaped spring and bracket assembly.
DETAILED DESCRIPTION
[0025] FIGS. 4-6 illustrate one embodiment of a bumper rail assembly 9 for a go cart track 5 . The bumper rail assembly 9 comprises a track rail 6 in the form of a metal band extending along and near an edge of the track 5 . The track rail 6 has an outer side 7 facing away from the track 5 and an inner side 8 facing the track 5 . The bumper rail assembly 9 is configured to resiliently deflect impacts from go carts. A plurality of bumper rail springs 10 , each taking the form of an arch- or arcuate-shaped leaf spring, back up the track rail 6 . Each bumper rail spring 10 is coupled to and positioned in a standing arch configuration on the outside 7 of the track rail 6 .
[0026] Each arch-shaped spring 10 is fastened to the track rail 6 by means of a fastener 11 that secures a first end of the spring 10 to the track rail 6 . The fastener 11 will often be a bolt 12 ( FIG. 14 ) that is welded to the track rail 6 , which penetrates a hole 55 ( FIG. 10 ) in the first end of the spring 10 . The bolt 12 is secured to the spring 10 by a nut 13 ( FIG. 14 ). In retrofitting situations, the fastener 11 is preferably the same bolt 12 that had been used to secure a tire 3 or other shock absorber.
[0027] An anchor 15 indirectly secures the second end, opposite the first end, of the spring 10 to a concrete base 2 that extends alongside the perimeter of the track 5 . In preferred embodiments, the second end of each arch-shaped spring 10 is formed in the shape of a saddle 30 ( FIG. 8 ), including a bracket or saddle seat 35 and an upturned section 36 ( FIG. 7 ). An anchor bracket 70 ( FIGS. 13-14 ) straddles the saddle 30 to secure the spring 10 to the concrete base 2 . In its simplest form, the anchor bracket 70 comprises a rectangular, planar metal plate ( FIG. 13 ) with a thickness N of about one-half an inch, sides 73 and 74 each having a length L of about six and three-eighths inches, and sides 71 and 72 each having a width M of about two inches. The anchor bracket 70 also includes two nine-sixteenth-of-an-inch-diameter holes 78 and 79 spaced about 4.25 inches apart and otherwise centered in the bracket 70 . The anchor bracket 70 is secured to the concrete base 2 by two concrete anchor bolts 80 and nuts 81 .
[0028] In stating that the anchor 15 indirectly secures the spring 10 to the concrete base 2 , Applicants mean to contrast the anchor 15 from systems that would incorporate a bolt that is inserted through a hole in the spring 10 or through a sleeve or other device welded to the spring 10 .
[0029] The saddle 30 and bracket 70 configuration gives the second end of the spring 10 some play to move laterally with respect to bracket 70 as the spring 10 receives strong compressive forces. The upturned section 36 also accommodates upward deflection of the first end of the spring 10 .
[0030] The saddle 30 and bracket 70 configuration also converts some of the spring compressive force that would otherwise tend to shear the bolts 80 into a tensile force against the bolts 80 . Applicants' experimentation has shown this configuration, on the whole, significantly reduces the problem of anchor bolts 80 being sheared.
[0031] FIGS. 7-12 illustrate the dimensions and formation process of one preferred embodiment of the bumper rail spring 10 .
[0032] To form the bumper rail spring 10 , an elongate flat rectangular bar 50 ( FIGS. 9 , 11 ) of steel is obtained. In a preferred embodiment, the bar 50 is made of spring steel, and more particularly, 5160 carbon-chromium spring steel. Spring steel is a low alloy, medium carbon steel with a very high yield strength. Objects made of spring steel can return to their original shape despite significant bending and twisting. The bar 50 has a top face 57 , a bottom face 56 , a rail-proximate end 53 , a rail-distal end 54 , and opposing sides 51 and 52 . The bar 50 has a length G of between 2 and 4 feet—in one embodiment approximately 33.5 inches—a width F of approximately four inches, and a thickness E of approximately one-quarter of an inch. The dimensions may be varied somewhat, but Applicants have found through experimentation that the bar 50 should have a cross-sectional surface area substantially greater than 0.5 square inches. As shown in FIG. 10 , a single hole 55 having a diameter H of about five-eighths of an inch is drilled about one inch from the rail-proximate end 53 , centered between sides 51 and 52 . The hole 55 is meant to accommodate a pre-existing anchor bolt 12 ( FIG. 14 ) welded onto the steel band of a go-cart track.
[0033] As illustrated in FIG. 12 , a rail-proximate end portion 25 of the bar 50 , having a length D of about 2 inches, is bent along line 61 downward at an angle I of between about 3 and 10 degrees. A short section of the opposite end of the bar 50 , having a length C of about 1.25 inches, is bent upward along line 63 at an angle K of about 20-45 degrees to form the upturned section 36 . An adjoining section, having a length B of about 2 inches, is bent upward along line 62 at an angle J of about 75 to 90 degrees, to form the saddle seat section 35 .
[0034] Finally, a long intermediate section 59 spanning about 28 inches between lines 61 and 62 is bent convexly—from the perspective facing the front face 57 —into an arch 20 having a radius A of approximately 9 inches. The arch does not have to be entirely circular or elliptical. Indeed, it may be skewed so that the portion of the arch 20 closest to the saddle 30 has a flatter curve.
[0035] The present invention also contemplates the following method of improving a go-cart track 5 having a track rail 6 braced with tires 3 or other shock absorber to absorb shock. The method comprises the steps of removing one of the tires 3 or other shock absorbers and replacing it with an arch-shaped spring 10 . The arch-shaped spring 10 is formed from a bar 50 of spring steel, a section of which has been shaped into an arch 20 , and another section of which has been shaped into a saddle 30 . The spring 10 is mounted in a standing arch configuration to the bumper rail 6 and a concrete base 2 . The bar 50 is indirectly anchored to the concrete base 2 by an anchor bracket 70 that straddles the saddle 50 and which is secured to the concrete base 2 by bolts 80 .
[0036] Although the foregoing specific details describe various embodiments of the invention, persons reasonably skilled in the art will recognize that various changes may be made in the details of the apparatus or method of this invention without departing from the spirit and scope of the invention as defined in the appended claims.
[0037] The present invention includes several independently meritorious inventive aspects and advantages. Unless compelled by the claim language itself, the claims should not be construed to be limited to structures that incorporate all of the inventive aspects, or enjoy all of the advantages, disclosed herein.
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A bumper rail assembly is provided that uses bars of arch-shaped spring steel, mounted in a standing-arch configuration, as shock absorbers for the bumper rails. An end portion of the spring steel bar is shaped into a saddle so that the spring steel bar can be secured indirectly, by means of a metal plate or bracket, to the concrete base. The assembly minimizes shear forces on the anchor bolts, offers performance advantages over conventional shock absorbers such as used tires, and is economically competitive with conventional shock absorbers.
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BACKGROUND OF THE INVENTION
The invention relates to an apparatus for measuring the thickness and/or irregularities of a running sliver in a spinning preparation machine, particularly a draw frame. The apparatus is of the type which has a biased sensor element which mechanically scans (contacts) the sliver and a tongue-and-groove roll pair which defines a closed nip of generally rectangular cross section through which the sliver passes. The groove roll of the roll pair has a radially fixed rotary axis.
Published PCT Application WO-A-91 16595 discloses an apparatus for guiding the slivers at the inlet end of the drawing unit of a draw frame. The apparatus includes a conically converging sheet metal support body having laterally upwardly bent wall faces and, downstream thereof (as viewed in the direction of sliver advance), a sliver guide having a rectangular inlet cross section, parallel-extending top and bottom walls and converging, upstanding lateral walls. The side-by-side arranged slivers glide on the supporting surface formed of the supporting body and the bottom wall of the sliver guide. Between the slivers and the side walls an intermediate space is provided at the sliver intake zone. The sliver guide is situated immediately in front of a pull-off roll pair whose parallel axes are vertically oriented. The roll pair also serves for measuring the sliver thickness within a predetermined tolerance range and, for such a purpose, the distance between the two cooperating rolls of the roll pair is variable. The radially movable, spring-loaded roll forms a biased, movable sensor element and is horizontally displaceable relative to the stationary roll. The stationary roll is a “groove roll” and is composed of a middle disk and two flanking disks. The middle disk has a smaller diameter than the two flanking disks whereby the circumferential peripheral face of the roll forms a circumferential groove. The radially movable roll is a “tongue roll” and is formed of a single disk which projects, with a peripheral portion, into the groove of the groove roll. The circumferential surface of the middle disk of the groove roll forms a rotary, radially stationary counterface for the circumferential surface of the radially movable tongue roll. By means of the tongue-and-groove construction an essentially rectangular constriction (nip) is formed between which a sliver bundle formed of a plurality of slivers passes in a compressed state for measuring purposes. In operation, the individual slivers run into the sliver guide at the drawing unit inlet with a speed of, for example, 150 m/min. The converging walls of the sliver guide gather the slivers without any clamping into a single plane so that they assume a side-by-side relationship. The slivers exiting the sliver guide are first densified by being pulled into the nip of the two downstream arranged rolls, that is, they are compressed to their solid material cross section and thus, in particular, enclosed air is expelled therefrom so that a measurement may take place. The circumferential speed of the rolls and the running speed of the slivers are identical so that no slippage takes place between the rolls, on the one hand, and the slivers, on the other hand. The clamping effect of the rolls required for exerting a pulling force is simultaneously used for the densification needed for the measuring step. After the slivers exit the roll nip they diverge laterally and enter the downstream-arranged drawing unit.
It is a disadvantage of the above-outlined apparatus that it involves substantial structural and operational outlay. It is a particular drawback that the drive of the two rolls is structurally complex and also, that a rotary drive has to be used for the radially displaceable roll. It is a further disadvantage that both rolls have to be driven. The drive for the radially movable roll includes a spur gear pair; one of the gears is mounted on the shaft of the roll while the other gear is arranged coaxially with the pivot axis of the pivotal arm carrying the radially displaceable roll. This arrangement ensures that the meshing relationship of the gears of the gear pair remains unchanged independently of a pivotal motion of the pivot arm. To obtain the required, opposite rotation of the rolls, a further, intermediate gear has to be provided which has the additional disadvantage that, apart from its complex structure, clearances between the individual gear teeth lead to accumulated inaccuracies.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved apparatus of the above-outlined type from which the earlier-described disadvantages are eliminated, which is structurally particularly simple and which makes possible an improved measurement of the running sliver.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the apparatus for advancing a sliver and sensing thickness variations thereof in a fiber processing machine includes a tongue-and-groove roll pair composed of a tongue roll and a groove roll. The groove roll is radially fixedly supported and has a circumferentially extending groove including a groove bottom. The tongue roll projects into the groove and defines, with the groove roll, a nip through which the sliver passes for being compressed and advanced by the tongue-and-groove roll pair. The apparatus further has a sensing device including a biased, movably supported sensor element projecting into the groove of the groove roll and cooperating with the groove bottom upstream of the nip as viewed in a direction of sliver advance for pressing the sliver against the groove bottom and for undergoing excursions in response to thickness variations of the sliver passing between the sensor element and the groove bottom.
According to the invention, for the measuring process the groove bottom of the groove roll is used as a counter supporting element which cooperates with the sensor element. The apparatus according to the invention ensures that the slivers are densified and scanned by the sensor element upstream of the nip defined by the tongue-and-groove roll pair (pull-off rolls), so that the latter merely needs to pull through the earlier-sensed running sliver. These measures permit a separation of function by providing that the sensor element arranged upstream of the pull-off rolls simultaneously densifies and scans the running sliver in a simple manner. The after-connected pull-off rolls may be of simplified structure and, as far as their installation is concerned, may be significantly simpler since they function exclusively as a pulling mechanism. Particularly by eliminating the measuring function of the pull-off roll pair, the significant difficulties and complexities experienced in the measuring process performed by the conventional apparatus are avoided. Thus, the slivers are submitted to a separate handling as concerns a densification which is required for the mechanical scanning step and a densification required for the sliver-advancing (sliver-pulling) step. Accordingly, the apparatus according to the invention provides an improved measuring of the sliver bundle at the inlet of the drawing unit and further, the side walls of the groove roller ensure that the lateral guidance and support of the slivers is preserved.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic side elevational view of a regulated draw frame incorporating the apparatus according to the invention.
FIG. 2 is a schematic side elevational view of a preferred embodiment of the invention.
FIG. 2 a is an exploded fragmentary front elevational view of two components of the structure shown in FIG. 2 .
FIG. 3 a is an enlarged side elevational view of a detail of the construction shown in FIG. 2 .
FIG. 3 b is a schematic front elevational view of a ganged construction, composed of units illustrated in FIGS. 2 and 3 a , for sensing and advancing individual slivers.
FIG. 4 a is a schematic top plan view of a further preferred embodiment including a tongue-and-groove roll pair for sensing and advancing a sliver bundle formed of a plurality of slivers.
FIG. 4 b is a side elevational view of the construction shown in FIG. 4 a.
FIG. 4 c is a view similar to FIG. 4 a shown without the presence of fiber material.
FIG. 4 d is a sectional view taken along line IVd—IVd of FIG. 4 c.
FIG. 4 e is a sectional view taken along line IVe—IVe of FIG. 4 c.
FIG. 5 is a schematic side elevational view illustrating a variant of the structure shown in FIG. 2 .
FIG. 6 is a schematic side elevational view illustrating yet another variant of the structure shown in FIG. 2 .
FIG. 7 is a schematic perspective view of a guide trough assembly for the slivers, adapted to be arranged upstream of the apparatus shown in FIG. 3 b as viewed in the direction of sliver run.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a draw frame generally designated at 1 which may be an HSR model manufactured by Trützschler GmbH & Co. KG, Monchengladbach, Germany. The draw frame 1 includes a drawing unit 2 , a drawing unit inlet 3 and a drawing unit outlet 4 . Slivers 5 simultaneously treated by the draw frame are pulled through a measuring device 9 by cooperating pull-off rolls 7 and 8 . The drawing unit is a 4 -over- 3 structure, that is, it is composed of three lower rolls I, II and III (that is, a lower output roll I, a lower mid roll II and a lower input roll III) and four upper rolls 11 , 12 , 13 and 14 . The drawing unit 2 draws the sliver bundle 5 composed of a plurality of slivers. The drawing operation is composed of a preliminary and a principal drawing operation. The roll pairs 14 ,III and 13 ,II constitute the preliminary drawing field whereas the roll pairs 13 ,II and the three rolls 11 , 12 and I constitute the principal drawing field. The drawn slivers are admitted at the drawing unit outlet 4 to a sliver guide 10 and are, by means of pull-off rolls 15 and 16 , pulled through a sliver trumpet 17 in which the slivers are gathered to form a single sliver bundle 18 which is subsequently deposited in coiler cans.
The pull-off rolls 7 , 8 , the lower input roll III and the lower mid roll II which are mechanically coupled to one another, for example, by drive belts, are driven by a regulating motor 19 as a function of an inputted desired rpm. The associated upper rolls 14 and 13 are driven by friction. The lower output roll I and the pull-off rolls 15 and 16 are driven by a main motor 20 . The regulating motor 19 and the main motor 20 each have a respective regulator 21 and 22 . The rpm regulation is effected via a closed regulating circuit in which a tachogenerator 23 is associated with the regulating motor 19 and a tachogenerator 24 is associated with the main motor 20 . At the drawing unit inlet 3 a dimension of the slivers that is proportionate to the fiber mass, such as the sliver cross section is measured by the intake measuring device 9 . At the drawing unit outlet 4 the cross section of the exiting sliver bundle 18 is determined by an outlet measuring device 25 associated with the sliver trumpet 17 .
A central computer unit 26 (control and regulating device), for example, a microcomputer with microprocessor, applies, to the regulator 21 , a setting signal representing a desired magnitude for the regulating motor 19 . The measuring magnitudes of the measuring device 9 are applied to the central computer unit 26 during the drawing process. The setting value for the regulating motor 19 is determined in the central computer unit 26 from the measuring magnitudes of the measuring device 9 and from the desired value for the cross section of the exiting sliver bundle 18 . The measuring magnitudes of the outlet measuring device 25 serve for monitoring the exiting sliver bundle 18 . With the aid of the regulating system, fluctuations in the cross section of the inputted slivers may be compensated for by corresponding regulations in the preliminary drawing process to thus achieve an evening of the outputted, drawn sliver bundle 18 .
FIG. 2 illustrates a driven tongue-and-groove roll pair composed of a groove roll 8 and a tongue roll 7 . The rolls 7 and 8 rotate in the direction of the arrows B and C, respectively. The groove of the groove roll 8 and the tongue of the tongue roll 7 together define a gap (nip) through which the sliver may pass. While the rolls 7 , 8 are both radially stationarily supported during operation, the distance between their respective rotary axes may be adjusted.
A measuring device 9 , arranged upstream of the roll clearance formed by the rolls 7 and 8 , as viewed in the sliver advancing direction A, has a longitudinal, biasable sensor element 30 , such as a pivotal sensor lever, which is movable in the direction of the arrows D and E. The sensor element 30 has, at one end, a holding member, such as a support shaft 31 which is supported in a bearing 32 . The other end of the sensor element 30 which projects into the groove of the roll 8 is arranged immediately upstream of the roll clearance (nip) which is formed by the rolls 7 , 8 and through which the sliver 5 passes.
Also referring to FIG. 2 a , the tongue of the roll 7 has a cylindrical peripheral edge face 7 ′ and two opposite radial lateral faces 7 ″ and 7 ′″. The tongue roll 7 has an axially measured thickness a. The groove of the roll 8 is composed of a center disk 8 1 and two flanking disks 8 2 and 8 3 . The peripheral surface of the center disk 8 1 forms a cylindrical groove bottom 8 ′ of the groove roll 8 , whereas the inner radial faces of the flanking disks 8 2 and 8 3 form two opposite radial lateral groove wall faces 8 ″, 8 ′″ spaced at a distance b from one another. The distance b is so dimensioned relative to the distance a that the tongue roll 7 may penetrate with a minimum clearance into the space defined between the groove wall faces 8 ′ and 8 ′″.
In operation, the outer free end of the sensor element 30 presses the sliver 5 against the groove bottom 8 ′ moving in the direction C. Thus, the groove bottom 8 ′ forms a supporting counter face cooperating with the sensor element 30 . The sliver 5 glides under the sensor element 30 while it is being scanned and densified. The lateral groove walls 8 ″, 8 ′″ form a lateral support and guide for the sliver 5 and thus prevent it from spreading towards either lateral side.
As illustrated in FIG. 3 a , the peripheral surface 7 ′ of the tongue roll 7 and the groove bottom surface 8 ′ of the groove roll 8 have a distance c from one another. The diameter d 1 of the tongue roll 7 and the diameter d 2 of the middle disk 8 1 of the groove roll 8 are identical to one another, while the diameter d 3 of the outer (flanking) disks 8 2 and 8 3 is greater than the diameter d 2 . The width (thickness) of the sensor element 30 measured parallel to the rotary axes of rolls 7 , 8 essentially corresponds to the dimension a to ensure that it fits between the two flanking disks 8 2 and 8 3 of the groove roll 8 .
In operation, the running sliver is densified between the sensor element 30 and the groove bottom 8 ′ of the groove roller 8 only to such an extent as necessary for the sensing of the thickness and/or irregularities (thickness variations) without adversely affecting the advancing of the sliver in the direction A. In the nip between the tongue roll 7 and the groove roll 8 the fiber material is densified only to an extent as necessary for its conveyance by the roll pair 7 , 8 . Thus, the fiber material need not be densified to such an extent that a solid cross section is obtained.
The embodiment illustrated in FIG. 3 b is composed of a plurality of tongue-and-groove roll pairs 7 , 8 , wherein the tongue rolls 7 are mounted on a joint shaft 32 and the groove rolls 8 are mounted on a joint shaft 33 , spaced from and parallel to the shaft 32 . The sensing device 9 is provided with a plurality of sensor elements 30 , so that with each tongue-and-groove roll pair 7 , 8 a respective sensor element 30 is associated, as described in connection with FIGS. 2 and 3 a . The FIG. 3 b embodiment is designed for treating (densifying, measuring and advancing) individual running slivers 5 a - 5 f . Accordingly, in the ganged roll structure of FIG. 3 b , the signals derived from the excursions of the individual sensor elements 30 are added. The embodiment shown in FIG. 3 b makes possible a substantially parallel, spaced guidance of the individual slivers 5 a - 5 f from the drawing unit inlet 3 through the drawing unit 2 up to the sliver guide 10 of the drawing unit outlet 10 . This structure thus prevents the slivers 5 a - 5 f from converging, diverging or from being exposed to any irregular guidance.
FIGS. 4 a - 4 e show a further embodiment in which, as shown in FIG. 4 a , a sliver bundle 5 formed, for example, of six individual slivers 5 a - 5 f is jointly scanned and jointly pulled through the tongue-and-groove roll pair 7 , 8 which may be essentially of a construction described in conjunction with FIGS. 2, 2 a and 3 a . The sliver bundle 5 is, in a known manner, caused to laterally converge in the advancing direction A and is thereafter scanned by the sensor element 30 . Thereafter, the sliver bundle 5 passes through the clearance (nip) formed between the rolls 7 and 8 and is then caused to diverge. In this structure, a single tongue-and-groove roll pair 7 , 8 and a single sensor element 30 are provided. As also shown in FIG. 4 a , the flanking disks 8 2 and 8 3 of the groove roll 8 have at the radially outer end of the respective groove side walls 8 ″, 8 ′″ a circumferential chamfered region 8 IV and 8 V , so that the groove side walls 8 ″, 8 ′″, as viewed radially outwardly, continue as a widening surface which facilitates a satisfactory introduction of the sliver bundle 5 into the groove-and-roll pair 7 , 8 .
As shown in FIG. 4 c , the tongue roll 7 extends into the groove roll 8 . The sensor element 30 which extends with its free end into the groove of the groove roll 8 is supported at its other end by a support shaft 31 which is rotatably held in bearing elements 32 a , 32 b . As shown in FIG. 4 d , at one end 31 a of the pivot shaft 31 an end of a biasing lever 34 is secured which, with its other end, is charged by a spring 37 supported on the machine frame. At the other end 31 b of the shaft 31 , as shown in FIG. 4 e , an end of a biasing lever 34 is attached which, in turn, is charged at its other end by a spring 37 also supported in the machine frame. At the other end 31 b a lever 36 is secured which cooperates with a lever arm 39 a of a rotatably supported dual lever 39 whose other lever arm 39 b is exposed to the force of a tension spring 38 which is countersupported on the machine frame. A transducer 35 , such as an inductive path sensor, is connected with the other end of the lever arm 39 b for converting excursions into electric pulses. The machine frame components are designated at 40 and 41 .
Turning to FIG. 5, between the outer, free end of the sensor element 30 and the groove bottom 8 ′ the end of a stationarily held counter support element 42 , such as a plate or the like is provided which also projects into the groove of the roll 8 . The fiber material 5 is pulled through between the two adjacent ends of the counterelement 42 and the sensor element 30 by the roll pair 7 , 8 .
According to FIG. 6, the outer end of the sensor element 30 carries a rotatable roller 43 and the fiber material 5 is pulled by the roll pair 7 , 8 between the peripheral surface of the roller 43 and the groove bottom 8 ′. In such a construction the fiber material is surrounded during sensing by four movable surfaces, that is, the peripheral surface of the roller 43 , the groove bottom 8 ′ and the lateral groove faces 8 ″, 8 ′″
FIG. 7 shows a guide trough 45 which is provided with a plurality of longitudinally extending parallel grooves (troughs) each accommodating a separate sliver 5 a - 5 f . The trough 45 is arranged upstream of the construction illustrated in FIG. 3 b . By the motion of the slivers 5 a - 5 f the longitudinal grooves are self cleaned and thus dust and fiber fly and the like are removed. By means of the guidance within the guide grooves a fluttering, sagging or lateral excursion of the slivers 5 a - 5 f is prevented.
It will be understood that the above description of the present invention is susceptible to various modifications, changes and adaptations, and the same are intended to be comprehended within the meaning and range of equivalents of the appended claims.
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An apparatus for advancing a sliver and sensing thickness variations thereof in a fiber processing machine includes a tongue-and-groove roll pair composed of a tongue roll and a groove roll. The groove roll is radially fixedly supported and has a circumferentially extending groove including a groove bottom. The tongue roll projects into the groove and defines, with the groove roll, a nip through which the sliver passes for being compressed and advanced by the tongue-and-groove roll pair. The apparatus further has a sensing device including a biased, movably supported sensor element projecting into the groove of the groove roll and cooperating with the groove bottom upstream of the nip as viewed in a direction of sliver advance for pressing the sliver against the groove bottom and for undergoing excursions in response to thickness variations of the sliver passing between the sensor element and the groove bottom.
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CROSS-REFERENCE TO RELATED APPLICATION
The invention described and claimed hereinbelow is also described in Spanish Patent Application ES 2008 00702 filed on Mar. 11, 2008. This Spanish Patent Application, whose subject matter is incorporated here by reference, provides the basis for a claim of priority of invention under 35 U.S.C. 119(a)-(d).
BACKGROUND OF THE INVENTION
The present patent relates to a security splicing system of aligned pipes, against the expansion and/or contraction thereof.
More particularly, the present patent relates to a system devised to carry out the splicing of piping with identical diameters and situated aligned one with respect to the other, featuring as its essential characteristic that the watertightness achieved by means of the splice with suitable flanges will not be altered by expansions and/or contractions that the aforementioned piping may suffer due to changes in temperature. The elements which constitute the system are described below.
The use of prefabricated piping is generalized for the construction or installation of fluid pipes, both liquid and gas, at various pressures, often high, for requirements of the type of pipe or transport to be carried out and for the characteristics of the fluid to conduct or transport.
This piping can be supplied in factory-produced sections, of several dozen metres, so that the time necessary to lay the piping is relatively short. This piping is preferably manufactured in polyethylene, a material of optimal characteristics for the transport of different fluids, and especially aggressive liquids and/or gases, including the United Nation's list of hazardous materials.
However, a basic and characteristic element of these installations are flanges and fastenings that are used for the joining or splicing of two pipes, aligned and of equal diameter, flanges and fastenings of various types that grip both ends of the pipes to splice and which must guarantee the watertightness of that splice, especially if the phenomenon of expansion/contraction due to changes in temperature and the drawbacks that can arise in that spliced area are taken into consideration, since the movements caused by the expansion/contraction will directly affect the position of the flange/fastening device, and can bring about leaks due to the loss of watertightness in that place, with the ensuing danger.
The system being disclosed and which is object of the present invention completely eliminates the possibility of the excessive movement of the flange/fastening placed on the two aligned ends of the piping that has been joined, guaranteeing the stability of that area and the impossibility that any leak due to an improbable movement of said flange/fastening occurs.
Patent ES200202246 (M. J. Pires) discloses flanges for the splicing of piping with smooth ends which achieve watertightness with help from metal rings which support and drive into the piping surface, providing that most of them increase the number of fixed vertices and, therefore, improve the watertightness.
If the function desired is obviously correct, the difficulty arises when the piping to be spliced expands or contracts, given that especially those made of propylene increase in length with heat and shrink in cold.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a security splicing system of aligned pipes, against the expansion and/or contraction thereof which avoids the disadvantages of the prior art.
The system to be protected with the present invention consists of the incorporation of a double flange, formed by two fastening elements, solidly joined by means of rods, parallel to each other and to the common axis of both pipes to be spliced, elements which will be strongly fastened on the outer surface of said pipes, slightly behind the classic and known flange/fastening position, which hereinafter will be called “watertight connecting flange”, of the ends of the two abovementioned pipes.
The purpose of this double flange is to always keep the distance of the piping areas whereupon each one of the two fastening elements which compose it are fastened the same, and in this manner maintain the end edges of said piping at the same distance.
This action will guarantee and allow that, in the case that a longitudinal variation of the facing ends of the pipes already spliced is produced due to expansion, which would possibly cause a movement of the watertight connecting flange, at no time can this watertight connecting flange be moved beyond a pre-established limit because of the solid connection rods of both fastening elements, and which will specifically be the limit of the movement which would cause the removal of this watertight connecting flange and, consequently, the loss of the watertightness of the connection and the dangerous and inadmissible leakage of fluid in that place. This situation must be considered both if the changes in temperature cause expansion or contraction of the piping.
The characteristics of the double flange, as well as of its two fastening elements and of the connection rods, are described below.
The novel features which are considered as characteristic for the present invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side view of the fastening assembly which constitutes the splicing system described wherein, by way of illustration, the correct position of the upper half of the watertight connecting flange has been drawn, while the lower half thereof has been drawn displaced until running into the fastening element of the double flange situated in that area.
FIG. 2 is an AA sectional view of one of the spliced pipes, corresponding to one of the two fastening elements which constitute the double flange.
FIG. 3 is a close-up, on a larger scale and duly sectioned, of the placement of one of the two fastening elements which compose the double flange, showing the fastening and attachment thereof on the outer face of the pipe.
FIG. 4 is a close-up, also on a larger scale and sectioned, of the fastening profile located inside each one of the two fastening elements which constitute the double flange.
FIG. 5 is an illustrative view of one of the connecting rods of the two component elements of the double flange.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the drawings, the security splicing system of piping - 1 - and - 1 a -, aligned and of equal diameter, against the expansion and/or contraction thereof that they may suffer from due to changes in temperature, is based on the application of a double flange constituted by two identical fastening elements - 2 - and - 2 a - which will grip the outer face of both pipes - 1 - and - 1 a -, already spliced in a completely correctly manner, with total guarantee of watertightness, by means of the watertight connecting flange - 3 - positioned on both ends - 4 - and - 4 a - of those already spliced pipes, a watertight connecting flange - 3 - of known characteristics and application.
Each one of the two fastening elements - 2 - and - 2 a - is constituted by an exterior clasp - 5 - by means of pressure screws - 6 - which actuate on the corresponding closures - 7 -, one or more, according to the diameter of the pipes, said exterior clasp - 5 - being provided with hollow cylinders - 8 -, situated longitudinally, parallel to each other and to the common axis of the pipes - 1 - and - 1 a -, and of variable number, through whose interior are disposed the connecting rods - 9 -, of variable number, but four in the example represented in FIG. 2 , all of that identical in both elements - 2 - and - 2 a - whose cylinders - 8 - are positioned in identical angular branching.
The connecting rods - 9 - are cylindrical and smooth, except their ends - 9 a -, which are threaded and which will remain situated outside of the corresponding hollow cylinders, - 8 - which position them, so that the hold-down nuts - 10 - can be situated on these threaded ends, nuts which, locked against the hollow cylinders - 8 -, will fix the relative position between the two fastening elements, - 2 - and - 2 a -, of the double flange, so that they cannot separate or move.
In the event that, due to a phenomenon of expansion/contraction, the watertight connecting flange - 3 - will move, as represented in FIG. 1 , in the position indicated of the lower part of said flange, the movement thereof would be limited by the running into the fastening element - 2 a - of the double flange, which, joined to the other element - 2 - by the connecting rods - 9 -, has remained and will remain immobile, without being displaced.
The watertight connecting flange - 3 -, displaced due to expansion, as observed in the lower part of FIG. 1 , will not leave the spliced area uncovered at any time between the ends - 4 - and - 4 a - of the pipes, thereby eliminating any danger of loss of watertightness and, consequently, risk of leakage.
In the event of a contraction due to decrease in temperature, neither will the watertight connecting flange - 3 - be displaced excessively thanks to the limiting action of the connecting rods - 9 -, which keep the fastening elements - 2 - and - 2 a - immobile.
Finally, the exterior clasp - 5 - of each one of the elements - 2 - and - 2 a - which compose the double flange, basic assembly of the system object of this invention, positions in its interior and around the external face of the corresponding pipe the fastening profile - 11 - constituted by a rectangular metal sheet, which can be coiled as indicated around the pipe, provided with a series of projections of truncated conical appearance - 12 -, achieved by means of a simultaneous punching and deep drawing action, which will be situated on the internal face of the fastening profile - 11 -, against the external face of the piping, so that upon tightening the pressure screws - 6 - of the exterior clasp - 5 - this fastening profile - 11 - remains completely pressed against the piping and the projections - 12 - practically driven into the surface thereof, featuring a suitable and sufficient fastening in order to avoid any displacement.
This fastening profile - 11 - remains, in turn, perfectly positioned under the entire exterior clasp - 5 -, once coiled around the corresponding pipe, thanks to the action of the edges in a right angle - 13 - which have and outline said exterior clasp - 5 - on both sides and all around it.
Having sufficiently described the basic characteristics of the system object of the present invention, it must be stated that its application, always in piping of equal diameter to be spliced can be performed with two polyethylene pipes, as well as if one of them is metal or of another material suitable for the conducting of the abovementioned fluids. Any variation in materials, shapes, sizes, and external appearance of the double flange and its components will not alter the essential nature of the invention, or the types of material used in its construction. Said essential characteristics will be summarised in the claims below.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
While the invention has been illustrated and described as embodied in a security splicing system of aligned pipes, against the expansion and/or contraction thereof, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
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A security splicing system of aligned pipes against an expansion and/or contraction thereof due to variations in temperatures, has a flange unit providing a stability and watertightness of a splice, and including a double flange with two identical fastening elements gripping an outer face of an end area of two previously spliced pipes with a watertight connecting flange, so that an accidental displacement of the watertight connecting flange is prevented in an event that dimensions of the end area of the pipes vary due to an expansion or contraction.
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FIELD OF THE INVENTION
[0001] This invention concerns an autonomous energy-saving device allowing automatic programming of a dumb electrical device like an electric water heater, continuously connected to the grid or operating on rate periods using a switch or timer.
BACKGROUND OF THE INVENTION
[0002] In general, a dumb electric water heater comprises a thermostat provided with a temperature sensor which is integrated in the water heater and that makes it possible to measure the temperature of the water in the water heater tank.
[0003] The so-called “smart” electronic thermostats for water heaters are known which include learning functions and that run heating programs at various times and at different heating temperatures.
[0004] These so-called “smart” electronic thermostats always include a temperature sensor that must be mounted on the dumb electric water heater to replace the one provided by the manufacturer. These so-called “smart” electronic thermostats can alter the water heater's technical characteristics and cause malfunctions which are not guaranteed by the manufacturer.
[0005] Mechanical or electronic programmers are also known that allow the customer to set fixed times for turning on the dumb electric water heater. These mechanical or electronic programmers are installed on the main power source to the water heater, but do not save the household consumption patterns in order to reduce electricity consumption.
SUMMARY OF THE INVENTION
[0006] The object of this invention is an autonomous energy saving device which is positioned on the supply line of a dumb water heater making it possible to automatically program it to learn the home routines, and which is installed upon the water heater to make it smart without having to change the water heater and therefore eliminate the risk of damaging or changing the characteristics of the safety controls of said water heater equipped with the energy saving device.
[0007] The autonomous energy saving device of this invention makes it possible to take control of an electric heater connected to the grid with a phase P, a neutral N and a protective conductor T that operate with a permanent power supply or during rate periods using a switch or timer. The autonomous energy saving device according to this invention includes inputs E 1 , E 2 , E 3 and outputs S 1 , S 2 , S 3 and between the inputs E 1 and E 2 and the outputs S 1 and S 2 at least one electronic component to remove or reduce the water heater's heating times without changing the technical characteristics of the water heater, in order to adapt its operation to the actual needs of the user.
[0008] The autonomous energy saving device making it possible to control a water heater according to this invention comprising at least one temperature sensor mounted on the water inlet or outlet of the water heater.
[0009] The autonomous energy saving electronic component making it possible to control a water heater according to this invention comprising at least one current sensor making it possible to identify the operating state of the water heater's thermostat.
[0010] The autonomous energy saving electronic component making it possible to control a water heater according to this invention comprising at least one controlled relay to reduce the heating times of the water heater.
[0011] The autonomous energy saving device making it possible to control a water heater according to this invention comprising at least one flow rate sensor mounted on the inlet or outlet of the water heater.
[0012] The autonomous energy saving device making it possible to control a water heater according to this invention comprising at least one means of communication with external management supports connected to the internet by means of an internal or external network.
[0013] The autonomous energy saving device making it possible to control a water heater according to this invention comprising at least one electronic component comprising a microcontroller for storing measurement logs.
[0014] The autonomous energy saving device making it possible to control a water heater according to this invention comprising at least one electronic component comprising a microcontroller connected to a component for storing measurement logs.
[0015] The autonomous energy saving device making it possible to control a water heater according to this invention constituted of a housing linked to the main power supply of the water heater, with a means to connect to attach the primary circuit board comprising at least one electronic component and a control algorithm to remove or reduce the duration of the water heater's heating periods and a protective conductor that is attached to said housing.
[0016] The autonomous energy saving device making it possible to control a water heater according to this invention comprises a housing, the protective cover of which includes a window for passage of an indicator light placed on the primary circuit board.
[0017] The autonomous energy saving device making it possible to control a water heater according to this invention comprises a housing provided with a first side opening for connection to the primary circuit board by means of a wire connecting the latter to at least one temperature sensor mounted on the cold water inlet or on the hot water outlet of the water heater.
[0018] The autonomous energy saving device making it possible to control a water heater according to this invention comprises a housing provided with a second side opening for connection to the primary circuit board of the power cable, connecting the latter to the water heater.
[0019] The autonomous energy saving device making it possible to control a water heater according to this invention comprises a housing provided with a third side opening for connection to the primary circuit board by means of a wire connecting the latter to at least one flow rate sensor mounted on the cold water inlet or on the hot water outlet of the water heater.
BRIEF DESCRIPTION OF DRAWINGS
[0020] The description that follows with regard to the attached drawings, given as non-limiting examples, will make it possible to better understand the invention, the characteristics which it presents and the advantages which are likely to be obtained:
[0021] FIGS. 1 and 2 are views showing the installation of the autonomous energy saving device according to this invention on a per se known water heater.
[0022] FIG. 3 is an exploded view in perspective depicting the housing of the autonomous energy saving device according to this invention.
[0023] FIG. 4 is a schematic view depicting the electrical connection of the autonomous energy saving device according to this invention.
[0024] FIG. 5 is a schematic view depicting the electrical connection of the autonomous energy saving device according to this invention on the electrical circuit of a water heater.
DETAILED DESCRIPTION OF THE INVENTION
[0025] FIGS. 1 and 2 show a water heater 1 that is known is per se connected to a cold water supply pipe 1 a and a hot water outlet pipe 1 b. The water heater 1 comprises a control thermostat 1 c which is connected via an electrical cable 1 d to the general power supply.
[0026] The thermostat 1 c makes it possible to control and regulate the temperature of the water inside the tank of the water heater 1 . The regulating thermostat 1 c controls the power of the electrical resistance, cutting it off when the water in the tank has reached the desired temperature, or powering it up if the hot water has been extracted from the tank and/or if the tank water has become cold.
[0027] The autonomous energy saving device 2 according to this invention is mounted directly on the main power supply upstream of the thermostat 1 c of the water heater 1 .
[0028] The autonomous energy saving device 2 includes connections consisting of screw type or spring connectors or “plug connectors” forming the inputs E 1 , E 2 , E 3 and the outputs S 1 , S 2 , S 3 of said energy saving device ( FIG. 4 ).
[0029] The autonomous energy saving device 2 includes inputs E 1 , E 2 , E 3 and outputs S 1 , S 2 , S 3 and between at least one of inputs E 1 or E 2 and outputs S 1 or S 2 to at least one primary circuit board 7 comprising at least one electronic component 3 , 4 and a control algorithm for controlling the power supply to the water heater 1 connected downstream of the device.
[0030] An example of an electrical connection of the autonomous energy saving device 2 between the power supply of the housing installation E 1 , E 2 , E 3 and the outputs S 1 , S 2 , S 3 of the water heater 1 is illustrated in FIG. 5 .
[0031] In this case, the autonomous energy saving device 2 comprises between the input E 1 and the output S 1 , the first electronic component 3 of the primary circuit board 7 ensuring a function type switch or relay which is connected via the input E 1 to phase P of electrical supply and through the output S 1 to the water heater 1 .
[0032] The first electronic switch or relay type component 3 provides electrical current to the water heater 1 according to the power periods controlled by the algorithm of the primary circuit board 7 of the autonomous energy saving device 2
[0033] The second input E 2 is connected directly to the second output S 2 of the water heater 1 but upon which the second electronic component 4 of the primary circuit board 7 is connected to the autonomous energy saving device 2 in order to detect the current circulating in the connection depending upon the state of the thermostat 1 c and thus making it possible to inform the algorithm (of the primary circuit board 7 of the autonomous energy saving device 2 ) of the power supply periods in the water heater 1 .
[0034] The third input E 3 is directly connected to the output S 3 of the autonomous energy saving device 2 .
[0035] Other solutions may be provided for the electric connections and positioning of the electronic components 3 and 4 between the inputs E 1 , E 2 and the outputs S 1 , S 2 without that changing the operation of the autonomous energy saving device 2 .
[0036] The second electronic component 4 is constituted by at least one current sensor making it possible to identify the operating state of the thermostat 1 c of the water heater 1 . The current sensor 4 makes it possible to identify the heating periods of the thermostat 1 c and the power consumption of the water heater 1 . The current sensor 4 may also allow the detection or presence of calcium carbonate deposits in the water heater 1 .
[0037] The current sensor 4 makes it possible to send, based on the readings from the current circulating in the connection, and save such information to the control algorithm of the primary circuit board 7 of the autonomous energy saving device 2 to analyze the water heater 1 user consumption profiles and also to measure and record electrical consumption of said water heater.
[0038] The autonomous energy saving device 2 may include at least one temperature sensor 5 which is placed either on the cold water inlet pipe 1 a or on the hot water outlet pipe 1 b of the water heater 1 . The temperature sensor 5 can be mounted in any area of the installation. Either close to the water heater 1 or remotely without changing the operation of the autonomous energy saving device 2 .
[0039] The temperature sensor 5 makes it possible to identify the schedules of water extraction by the user and the detection of a presence makes it possible to determine the schedules of cold or hot water consumption by the user.
[0040] The temperature sensor 5 is connected by a wire 8 to the primary circuit board 7 of the autonomous energy saving device 2 to record the times when water is extracted and the consumption schedules of cold or hot water used by the user to compare them to the information from the current sensor 4 to refine the water heater user consumption profiles 1 .
[0041] The autonomous energy saving device 2 may include at least one flow rate sensor 6 that is positioned on the cold water inlet 1 a or on the hot water outlet 1 b of the water heater 1 . The flow rate sensor 6 makes it possible to identify the amount of cold water feeding the water heater 1 or the amount of hot water extracted from said water heater.
[0042] The flow rate sensor 6 is connected by a wire 9 to the primary circuit board 7 of the autonomous energy saving device 2 to record the amounts of cold water or hot water consumed by the user to compare them to the information from the current sensor 4 and/or from the temperature sensor 5 to refine the water heater user consumption profiles 1 .
[0043] The primary circuit board 7 of the autonomous energy saving device 2 comprises at least one electronic component consisting of a microcontroller or of a microprocessor connected to a component allowing for storage of measurement logs coming from the switch 3 , of the current sensor 4 , and/or from the temperature sensor 5 and/or from the flow rate sensor 6 .
[0044] The control algorithm of primary circuit board 7 of the autonomous energy saving device 2 can also be set by the user depending upon the characteristics of the water heater 1 , the dimensions of the tank, and the level of comfort sought.
[0045] The control algorithm of the primary circuit board 7 allows using one part of the information obtained by the current sensor 4 , and/or from the temperature sensor 5 and/or from the flow rate sensor 6 and from the other settings from the technical characteristics of the water heater 1 to control the switch or relay 3 to reduce the heating times of said water heater.
[0046] The autonomous energy saving device 2 may comprise a second circuit board or a second component allowing communication with external management supports connected to the internet by means of an internal or external network.
[0047] The means of communication may be constituted by an electronic circuit for communicating through different protocols and communication media known to date such as WIFI, Bluetooth, Powerline, UNB (Ultra Narrow Band), LoRaWAN (Long Range Wide-area network which may be translated as “long-range WAN”).
[0048] In FIG. 3 the autonomous power saving device 2 is shown which consists of a housing 2 a which is fixed and connected to the recessed housing 11 of the main power supply of the water heater 1 . The housing 2 a may alternatively be wall mounted and not directly mounted upon the recessed housing 11 .
[0049] The housing 2 a comprises a means of connection, not shown, allowing the attachment of the primary circuit board 7 provided with at least one electronic component 3 , 4 and a control algorithm which makes it possible to remove or reduce the heating times of the water heater 1 .
[0050] The housing 2 a is closed with a protective cover 2 c. The protective cover 2 c includes a window 2 d which allows for passage of an indicator light 10 placed on the primary circuit board 7 .
[0051] The housing 2 a has a first side opening 2 e making it possible to connect the primary circuit board 7 with a wire 8 connecting the latter to at least one temperature sensor 5 mounted on either the cold water inlet 1 a or on the hot water outlet 1 b of the water heater 1 .
[0052] The housing 2 a has a second side opening 2 f making it possible to connect the primary circuit board 7 with the power cable 1 d, connecting the latter to the water heater 1 .
[0053] The housing 2 a has a third side opening 2 g making it possible to connect the primary circuit board 7 with another wire 9 connecting the latter to at least one flow rate sensor 6 mounted on either the cold water inlet 1 a or on the hot water outlet 1 b of the water heater 1 .
[0054] The bottom of the housing 2 a comprises a window 2 h allowing the passage of electrical supply cables from the recessed housing 11 .
[0055] Note that the autonomous energy saving device 2 according to this invention supplies power to the water heater 1 only if heating water is required from a user's consumption history or according to an operating stage selected by the user.
[0056] It should be understood that the above description was given only as an example and by no means limits the field of the invention, nor will it be outside the field of the invention, if implementation details described are replaced with any other equivalent.
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The autonomous energy saving device ( 2 ) enabling the control of a water heater ( 1 ) connected to a power grid comprising a phase P, a neutral N and a protective conductor T operating on a permanent power supply or during rate periods using a switch or timer, said energy saving device ( 2 ) comprises inputs E 1, E 2, E 3 and the outputs S 1, S 2, S 3 and between inputs E 1 and E 2 and the outputs S 1 and S 2 at least one primary circuit board ( 7 ) comprising at least one electronic component ( 3, 4 ) and a control algorithm to remove or reduce the heating times of the water heater ( 1 ) without changing the technical characteristics of the water heater, and in order to adapt its operation to the needs of the user.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a retractable handle for a locking device for a retractable handle of wheeled luggage and more particularly to such a locking device with improved characteristics.
2. Description of Related Art
Typically, a single locking device is provided in the retractable handle for controlling the handle in a retracted position and an extended position. That is, the retractable handle may be extended to a maximum length when towing on the ground by traveler as well as retracted into a minimum length (i.e., rested on the top of luggage) appropriate for stowage or transport. It is known that luggage equipped with a retractable handle is very popular among travelers. Thus many types of luggage with retractable handle are commercially available in which each type of luggage mounted with a unique locking device. For example, the single locking device comprises wedge members, springs, lock blocks (or pins), supporting members, detents, and connecting wires.
Various designs of locking devices have been found in a search as follows: U.S. Pat. No. 5,581,846 entitled “Controlling Handle Structure for Full Rods of a Luggage”, and U.S. Pat. No. 5,628,088 entitled “Multistage Adjustable Device for Trunk Bracket”. As to the complex retractable handle with multiple retaining slots, various designs thereof also have been found in a search as follows: Taiwanese Patent Published No. 337,100 entitled “Improved Retractable Handle of Luggage”; No. 362,404 entitled “Activation Mechanism for Retractable Handle with Multiple Retaining Slots of Luggage”; and No. 368,815 entitled “Improved Activation Mechanism for Retractable Handle with Multiple Retaining Slots of Luggage”. But these are unsatisfactory for the purpose for which the invention is concerned for the following reasons:
1. Complex in structure.
2. Susceptible to breakdown.
3. Time consuming in assembly.
4. A horizontal component force is applied on the slope because connecting wires, detents, and wedges interact with one another when user presses on the push button to activate the locking mechanism through the connecting wires. This horizontal component force may control the activation of lock blocks (or pins) and detents. However, an undesirable gap still exists between a fully retracted handle and the bezel. This is a significant drawback.
5. A horizontal component force is applied on the slope when lock blocks (or pins) are activated by slanted guide groove. This causes additional drawbacks in addition to those described above. In detail, the ratio of extendible maximum length to retractable minimum length is significantly lowered due to the implementation of multiple-segment longitudinal slanted guide groove. This limits the effective length of extended handle. Further, it has the disadvantages of complex in structure, difficult to adjust the assembly, low yield of finished product, and higher manufacturing cost. Thus improvement is desirable.
SUMMARY OF THE INVENTION
It is therefore an object of the present invention to provide a locking device for handle assembly for significantly increasing the ratio of extendible maximum length to retractable minimum length of handle such that a predetermined extendible length is achievable.
It is another object of the present invention to provide a locking device for handle assembly wherein second locking device secures to the bottom of the second sliding tube. The second locking device has three members at most. Further, only a snapping is required to finish the assembly of second locking device and second sliding tube without any fastener. This second locking device has the advantages of simple in structure, quick assembly, and durable.
It is still another object of the present invention to provide a locking device for handle assembly wherein lock member of first locking device is provided at the bottom of first housing of the first locking device capable of directly moving into the lock hole of the second locking device so as to cause lock pin of the second locking device to become disengaged. There is no horizontal component force created on the slope as occurred in the prior art because the lock member of the first locking device directly inserts into the lock hole of second locking device as well as first locking device and second locking device are engaged in a planar surface. This ensures that there is no gap between the first and second locking devices such that the handle grip of the fully retracted handle may rest on the bezel.
To achieve the above and other objects, the present invention provides a locking device for handle assembly comprising: a first sliding tube; a first locking device detachably attached to the bottom of the first sliding tube; a second sliding tube for allowing the first sliding tube to slidingly move therein having a hole; a second locking device detachably attached to the bottom of the second sliding tube; a support tube for allowing the second sliding tube to slidingly move therein having a hole; and a first connecting means connected between a push button and the first locking device.
Whereby the handle is retracted when the push button is not pressed, the first sliding tube is received in the second sliding tube and the second sliding tube is received in the support tube, the projection of the first locking device is engaged with the lower hole of the second sliding tube, the bottom of the first locking device is biased against the top of the sliding block of the second locking device so as to move the lock member of the first locking device into the lock hole of the second locking device to cause the lock pin of the second locking device to retract into the support tube, whereby the handle is locked in a retracted position.
The push button is pressed. Then handle is pulled upward to cause the first locking device to move up so as to move the lock pin of the first locking means into lower hole of the second sliding tube. Grasp handle grip to pull first sliding tube upward for separating the lock member on the bottom of first locking device from lock hole of the second locking device. Then second locking device moves up as the second sliding tube and first sliding tube move up together until the second lock pin comes into contact with upper hole of the support tube and locks therein. Now handle is in a fully extended position for allowing luggage to be towed along the ground.
The above and other objects, features and advantages of the present invention will become apparent from the following detailed description taken with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded view of a locking device for handle assembly of wheeled luggage of the invention;
FIG. 2 is a greatly enlarged fragmentary view showing the first and second locking devices of FIG. 1;
FIG. 3 is similar to FIG. 2 showing the lock block of first locking device;
FIG. 4 is similar to FIG. 2 showing the lock block of second locking device;
FIGS. 5A and 5B are first and second sectional views of first and second locking devices where handle is fully extended;
FIGS. 6A and 6B are first and second sectional views of first and second locking devices where second locking device is pressed by first locking device and handle is being retracted; and
FIGS. 7A and 7B are first and second sectional views of first and second locking devices where handle is retracted to its lowest position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1-4, there is shown a locking device for handle assembly of wheeled luggage constructed in accordance with the invention wherein handle assembly is provided on the back of luggage with a handle grip (not shown) received in a bezel on top of luggage.
Note that because the handle system is bilaterally symmetrical so that description of one side serves to describe the entirety. Thus the handle system of the invention comprises: a first sliding tube 10 having a lower hole 13 and an upper hole 12 attached to one end of handle grip by a known fastener; a first locking device 20 detachably attached to the bottom of first sliding tube 10 ; a second sliding tube 40 for allowing first sliding tube 10 to slidingly move therein having a top and lower holes 43 and 44 on a first side, an apertures 42 on first side, and a pin hole 45 on a second side; a first sleeve member 30 provided on the top of second sliding tube 40 having two detents 32 provided on two opposing sides matingly engaged with apertures 42 of second sliding tube 40 ; a second locking device 50 detachably attached to pin hole 45 of the second sliding tube 40 by a projection 513 ; a support tube 70 for allowing second sliding tube 40 to slidingly move therein having a top and lower holes 73 and 74 on a first and third sides, two apertures 72 on a second and third sides; and a second sleeve member 60 provided on the top of support tube 70 having two detents 62 provided on two opposing sides matingly engaged with apertures 72 of support tube 70 .
The first locking device 20 comprises a first housing 21 having an upper portion 210 with a guide groove 212 and a pin hole 213 such that pin 14 may insert through lower hole 13 of first sliding tube 10 and pin hole 213 to secure first locking device 20 and first sliding tube 10 together; and a lower portion 214 with a cavity 215 (FIG. 2 ); a spring 23 provided in the cavity 215 of first housing 21 ; a lock block 24 provided in the cavity 215 of first housing 21 having a projection 240 on a first side, an aperture 241 on a second side, and an opening 245 in communication with the aperture 241 ; a lock member 217 provided on the bottom of first housing 21 ; and a flexible steel cable 22 having an enlargement on one end (not shown) being secured to handle grip and an enlargement 221 on the other end being secured in the opening 245 through the guide groove 212 , cavity 215 (FIG. 2 ), and aperture 241 such that a pressing of the push button may be transmitted to first locking device 20 through the movement of flexible steel cable 22 .
The second locking device 50 comprises a second housing 51 , spring 52 , and second lock block 53 wherein the upper portion of the second housing 51 having a plurality of slots 516 , two opposing recesses 511 , and a lock hole 515 wherein a projection 513 is protruded inwardly on two opposite inner surfaces of flexible member 512 formed therebetween slots 516 , the projection 513 may engage with pin hole 45 of second sliding tube 40 ; the lower portion of the second housing 51 having a cavity 514 for receiving the second lock block 53 being in communication with lock hole 515 in the recess 511 ; and a projection 533 is protruded on one end of second lock block 53 for putting spring 52 thereon and a lock pin 531 is protruded on the other end of second lock block 53 .
The following is a description of the operation of handle assembly.
Referring to FIGS. 1-7, handle is retracted when push button (not shown) is not pressed (FIGS. 7 A and 7 B). First sliding tube 10 is received in second sliding tube 40 and second sliding tube 40 is received in support tube 70 . Projection 240 is biased by spring 23 to engage with lower hole 44 of second sliding tube 40 and lower hole 74 of the support tube 70 . The lock member 217 at the bottom of the first locking device 20 is biased against the lock hole 515 of the second locking device 50 so as to retract the lock block 53 of the second locking device 50 into the support tube 70 , whereby the handle is locked in a retracted position.
The push button is pressed (FIGS. 6 A and 6 B). Then handle is pulled upward. That is, flexible steel cable 22 of the first locking device 20 is moved up so as to bias spring 23 of the first locking device 20 . Further, lower hole 44 of projection 240 of lock block 24 clears lower hole 44 of second sliding tube 40 and lower hole 74 of support tube 70 (FIG. 6 A). As such, grasp handle grip to pull first sliding tube 10 upward for separating the lock member 217 at the bottom of first locking device 20 from lock hole 515 of the second locking device 50 . Then lock block 53 of the second locking device 50 retract into the upper hole 73 of support tube 70 and secured therein (FIGS. 7 A and 7 B). Once first sliding tube 10 is pulled up to cause projection 240 of lock block 24 of first locking device 20 to come into upper hole 43 of the second sliding tube 40 to lock therein (FIGS. 5 A and 5 B). Now handle is in a fully extended position for allowing luggage to be towed along the ground. To the contrary, press push button to retract handle which in turn causes pin 240 of lock block 24 attached to cable 22 to escape engagement with upper hole 43 of second sliding tube 40 . Whereby first sliding tube 10 may receive within second sliding tube 40 until lock member 217 at the bottom of first locking device 20 comes into contact with the lock hole 515 of the second locking device 50 . This causes lock pin 53 of second locking device 50 to clear upper hole 73 of support tube 70 (FIGS. 6 A and 6 B). Pin 240 of the lock block 24 of the first locking device 20 clears upper hole 43 of second sliding tube 40 when push button is pressed again. Then first sliding tube 10 may receive in second sliding tube 40 and second sliding tube 40 may receive in support tube 70 . Now the handle is fully retracted (FIGS. 7 A and 7 B).
Note that the first locking device 20 is a master device and second locking device 50 is a slave one. As such, the number of second locking device 50 may be added in other embodiments. Further, the number of second sliding tube 40 with a number of second locking device 50 having a lock member 217 at the bottom of second locking device 50 (except the lowest one) may be added too. As a result, a handle assembly with multiple locking devices and a plurality of constituent tubes are carried out, thereby enabling handle to extend and lock in one of a plurality of selective positions thereof.
While the invention herein disclosed has been described by means of specific embodiments, numerous modifications and variations could be made thereto by those skilled in the art without departing from the scope of the invention set forth in the claims.
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A handle assembly of luggage comprises a handle grip with a push button, two first sliding tubes, at least one pair of second sliding tubes, two support tubes, two first locking means each provided below each first sliding tube, at least one pair of second locking means each provided below each second sliding tube, and a flexible steel cable attached between handle grip and first locking means. This ensures a fully extended handle, a significant increase of the ratio of extendible maximum length to retractable minimum length of handle, and the retracted handle grip rested on the bezel without any gap.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an automobile seat belt system with an automatic unlocking function.
2. Description of the Prior Art
Seat belt systems are used in automobiles for protecting the driver and passengers. A conventional seat belt system comprises a seat belt retractor anchored to the automobile frame, a seat belt consisting of a shoulder belt connected to the retractor and a lap belt directly anchored to the automobile frame, a tongue plate secured at an intermediate position of the seat belt, i.e., at a position between the shoulder belt and the lap belt, and a buckle anchored to the automobile. This buckle has a mechanism for locking the tongue plate and a mechanism for unlocking the tongue plate.
In the prior art, the unlocking mechanism has had to be manually operated. This has aggravated the drivers' and passengers' dislike of using the seat belt system. In addition, if an accident occurs, manual operation may significantly delay the exit of drivers and passengers from the automobiles.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an automobile seat belt system in which an unlocking function is automatically performed, thereby making it easier to use the seat belt system and, in addition, to make it easier to exit an automobile if an accident occurs.
According to the present invention, an actuator and its controller are added for providing an automatic unlocking function.
BRIEF DESCRIPTION OF THE DRAWINGS
The present invention will be more clearly understood from the description as set forth below with reference to the accompanying drawings, wherein
FIG. 1 is a schematic view of an embodiment of the seat belt system according to the present invention;
FIG. 2 is a cross-sectional view of the buckle of FIG. 1;
FIG. 3 is a diagram of the control circuit of FIG. 1;
FIG. 4 is a schematic view of another embodiment of the seat belt system according to the present invention; and
FIG. 5 is a cross-sectional view of the buckle of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1, a seat belt 1 is divided into a shoulder belt 1a and a lap belt 1b. The shoulder belt 1a holds the upper part of the driver and passengers, while the lap belt 1b holds the lower part of the driver and passengers. Note that, however, the shoulder belt 1a and the lap belt 1b form a single seat belt.
One end of the seat belt 1 is secured to a seat belt retractor 2 anchored to the automobile frame, while the other end of the belt 1 is anchored directly to the automobile frame. A slip joint 3 anchored to the automobile frame is provided for guiding the belt 1.
A tongue plate 4 is secured at an intermediate position of the seat belt 1. The tongue plate 4 can be connected to a buckle 5 anchored to the automobile frame on the opposite side of the seat. For this purpose, the buckle 5 has a mechanism for locking the tongue plate 4 and a mechanism for unlocking the tongue plate 4.
According to the present invention, the unlocking mechanism of the buckle 5 is controlled by a control circuit 6 which receives various sense signals S 1 , S 2 , . . . , S 5 . These signals are generated from a key switch 7, a door switch 8, a brake lever switch 9, a deceleration sensor (G sensor) 10, and a vehicle velocity sensor 11.
The door switch 8 is located at a door (not shown). When the door is open, the sense signal S 2 has a high potential (=+5 V), while when the door is closed, the sense signal S 2 has a low potential (=0 V). The brake lever switch 8 is located at a brake lever (not shown). When the brake is applied with the brake lever, the sense signal S 3 has a high potential (=5 V), while when the brake is released by the brake lever, the sense signal S 3 has a low potential (=0 V). The G sensor 10, located at a portion of the automobile, detects whether the deceleration of the automobile exceeds a predetermined value. For example, if the automobile collides with another automobile, the G sensor 10 operates so that the sense signal S 4 has a high potential (=5 V). The vehicle velocity sensor 11 is comprised of a lead switch 11a and a permanent magnet 11b coupled to a speedometer cable (not shown). When the speedometer cable is rotated, the lead switch 11a performs an on/off operation so as to generate a pulse-shaped signal which has a frequency proportional to the velocity.
The buckle 5 will be explained with reference to FIG. 2. In FIG. 2, reference numeral 51 designates a case, 52 a solenoid, and 53 an operating shaft fixed to a slide button 54. The slide button 54 has a tapered face 54a contacting a lever 55. The slide button 54, associated with the operating shaft 53, is capable of moving within the case 51.
The lever 55 has a salient portion 55a which penetrates through a hole 4a of the tongue plate 4 and is contact with a face 4b of the tongue plate 4.
A spring 56 is provided between the case 51 and the lever 55 for pushing the lever 55 and is rotatably fixed to a curled portion 51a of the case 51.
A hole 51b is provided for anchoring the buckle 5 to the automobile frame by a bolt.
The control circuit 6 will be explained with reference to FIG. 3. In FIG. 3, reference numerals 601 through 604 are resistor-capacitor (RC) delay circuits (filters) for receiving the signals S 1 through S 4 , respectively. A frequency/voltage converter 605 receives the pulse-shaped signal S 5 and generates a signal S 5 ' having a voltage proportional to the velocity. This signal S 5 is supplied to a NOR circuit 606, which also receives a ground level signal. That is, the NOR circuit 606 serves as a comparator for comparing the velocity with zero. The NOR circuit generates a high potential (=5 V) only when the velocity equals zero. In addition, an AND circuit 607 is connected to the outputs of the delay circuit 604 and the NOR circuit 606. Therefore, the AND circuit 607 generates a high potential (=5 V) only when the signal S 4 has a high potential and the velocity equals zero.
Reference numeral 608 designates an OR circuit, 609 a monostable multivibrator, 610 a diode, and 611 a solenoid driving circuit. The monostable multivibrator 609 is triggered by a positive-rising edge of an input signal thereof and generates an output signal having a constant time duration, which is determined by a resistor 609a and a capacitor 609b. That is, when one or more of the signals S 1 , S 2 , S 3 , and S 4 ' rises, the monostable multivibrator 609 generates an output signal and transmits it via the diode 610 to the solenoid driving circuit 611.
The solenoid driving circuit 611 comprises resistors 612, 613, a transistor 614, resistors 615, 616, a transistor 617, and a diode 618. In the solenoid driving circuit 611, when the output of the monostable multivibrator 609, i.e., the output of the diode 610, is high (=5 V), the transistor 614 is turned on. Accordingly, the transistor 615 is turned on so as to energize a solenoid 52.
Note that the emitter of the transistor 617 receives a higher potential (=12 V) directly from a battery (not shown).
Returning to FIG. 1, the seat belt retractor 2 usually includes a spiral spring or a motor for imparting a winding force to the seat belt 1. Therefore, the seat belt 1 always is under tension.
Now assume that the seat belt 1 binds the driver (or passenger). Accordingly, the seat belt 1 (the tongue plate 4) is locked in the buckle 5. When leaving the automobile, the driver usually first turns off the engine with the key switch 7, whereby the monostable multivibrator 609 (FIG. 3) is operated. Therefore, the solenoid 52 is energized for the predetermined time period.
In FIG. 2, when the solenoid 52 is energized, the solenoid 52 generates an electromotive force which attracts the operating shaft 53. As a result, the operating shaft 53 is moved to the right direction. Accordingly, the slide button 54 is also moved to the right direction. Simultaneously, the slide button 54 pushes down the lever 55 by the tapered face 54a. Accordingly, the salient portion 55a is also pushed down and is released from the hole 4a of the tongue plate 4. In this state, the spring 56 is depressed. On the other hand, since the seat belt 1 is under tension from the retractor 2, it pulls the tongue plate 4 out from the buckle 5. Thus, the driver is released from the seat belt 1.
Similarly, when the driver opens the door, door switch 8 is activated. When operating the brake lever, the brake lever switch 9 is activated. In both these cases, the seat belt 1 is automatically released. Further, if the automobile collides with another automobile or obstacle, the G sensor 10 is activated. In this case, after automobile is stopped, the seat belt 1 is released, and the driver can easily leave the automobile.
Note that the switches 8 and 9 can be connected between the battery (12 V) and the solenoid 52. In this case, the open/close characteristics of the switches would be opposite to those of the above-mentioned embodiment. In addition, when the switch 8 or 9 is closed, the solenoid 52 would remain in an energized state.
In addition, a hydraulic actuator or a pneumatic actuator can be used instead of the solenoid 52.
Of course, the unlocking mechanism of the buckle 5 can be manually operated. In this case, the slide button 54 is pushed by the hand as indicated by the arrow in FIG. 2.
In FIG. 4, which illustrates another embodiment of the present invention, a buckle 5' is controlled mechanically by a door lock/open handle lever 12. A cable 13 is provided between the buckle 5' and the door lock/open handle lever 12. In this embodiment too, the unlocking operation of the buckle 5' can be automatically performed.
The structure of the buckle 5' will be explained with reference to FIG. 5. In FIG. 5, elements the same as those of FIG. 2 are denoted by the same reference numerals. The elements 52 and 53 of FIG. 2 are absent in FIG. 5, and, instead of this, the elements 57 and 58 are provided in FIG. 5.
In FIG. 5, when the slide button 54 is moved to the right direction, the lever 55 associated with the salient portion 55a is pushed down. As a result, the tongue plate 4 is released from the buckle 5' due to the presence of the spring 57. The slide button 54 is connected to an end of the cable 13. The other end of the cable 13 is connected to a portion 12a of the lever 12. The lever 12 is rotatably secured by a shaft 12b to a door frame 14.
A spring 58 is provided for pushing the slide button 54 to the left direction.
The buckle 5' of FIG. 5 operates as follows. The driver rotates the lever 12 as indicated by the arrows to release the locked state of the door. Simultaneously, since the cable 13 is connected to the lever 12 at the portion 12a, the cable 13 moves the slide button 54 to the right direction. As a result, the lever 55 and the salient portion 55a are pushed down. Accordingly, the tongue plate 4 is pushed out of the buckle 5' by the spring 57.
Of course, in this embodiment, the unlocking operation of the buckle 5' can also be manually performed. In this case, since a space 54b is provided at the connection between the slide button 54 and the cable 13, a manual unlocking operation will not conversely operate the door lock/open lever 12.
The cable 13 can be connected to the brake lever instead of the door lock/open lever.
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A seat belt system comprising a seat belt retractor, a seat belt, a tongue plate secured at an intermediate position of the seat belt, and a buckle which has a locking function and an unlocking function for the tongue plate. An actuator and its controller are provided for automatically actuating the unlocking function of the buckle.
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BACKGROUND OF THE INVENTION
Field of the Invention
[0001] The invention relates to a method for controlling call diversion.
[0002] Many switching devices in present-day communications systems allow call diversions to be set up for terminals which are connected to the switching devices. The setting up and activation of a call diversion for a terminal has the effect that incoming calls for this terminal are transferred by the switching device for this terminal to another terminal which can be defined by the user. The term call diversion is also used in the following text to cover so-called call transfer, in which an incoming call for one terminal is first of all signaled to this terminal and is transferred to a transfer destination only if it is not answered.
[0003] Call diversion is often used to divert calls which are intended for a fixed terminal located at a user's workplace to another terminal when the user leaves his workplace. To do this, where a user leaves his workplace, he must activate an appropriate call diversion process in the switching device. In this case, for example, the user can define as the transfer destination a mobile or cordless terminal which he carries with him, a mailbox, or a work colleague's terminal. When call diversion is activated, the switching device then signals the incoming calls for the fixed terminal at the workplace on the terminal defined as the transfer destination. When the user returns to his workplace, he must once again explicitly deactivate call diversion, so that incoming calls are once again switched to the fixed terminal at his workplace.
[0004] The user inputs which need to be carried out on activation or deactivation of call diversion when leaving and when returning to the workplace are time-consuming and complex. Furthermore, there is a risk, for example, that, when he leaves his workplace, the user will forget to activate call diversion and, in consequence, will be temporarily unavailable for incoming calls.
SUMMARY OF THE INVENTION
[0005] It is accordingly an object of the invention to provide a method for activating call diversion that overcomes the above-mentioned disadvantageous of the prior art methods of this general type and that allows for automatic control of call diversion on an as-required basis.
[0006] With the foregoing and other objects in view there is provided, in accordance with the invention a method for controlling call diversion that includes coupling a first terminal, for which call diversion is to be activated, to a switching device; determining a measure indicating a position of a mobile terminal relative to at least one base station using radio signals that are transmitted between the mobile terminal and the at least one base station; and using a switching device to control the call diversion as a function of the determined measure.
[0007] The method allows automatic control of call diversion for a first terminal to any desired second terminal as a function of a position or the capability to access a mobile terminal. To a certain extent, the mobile terminal may in this case be regarded as an indicator as to where a user who is carrying the mobile terminal with him is located and/or whether this user can be accessed for connection requests. In this context, the term mobile terminal also covers the so-called cordless terminal.
[0008] The process of controlling call diversion may include, for example, setting up, configuration, activation or deactivation of call diversion. For example, call diversion for a landline terminal at a user's desk can be activated when the user, together with his mobile terminal, leaves a predetermined area around his desk. The call diversion to be activated may be to any desired second terminal, such as to the mobile terminal itself, to a mailbox, to a work colleague's terminal, to the user's home connection, or to another mobile terminal of the user. In the case of the last-mentioned example, a call diversion process controlled by the method according to the invention can be used to provide so-called roaming to another mobile terminal, which may also belong to a different radio network than that of the mobile terminal being used as an indicator.
[0009] The method is essentially independent of the wire-free communication method used by the mobile terminal and the base station. For example, it is possible to use a mobile terminal to the Bluetooth, DECT and/or GSM Standard.
[0010] In accordance with an added feature of the invention, a distance measure for the distance between the mobile terminal and a base station can be determined as a measure for the position of the mobile terminal. Such a distance measure can be determined particularly easily from the received field strength or from the signal delay time of radio signals interchanged between the base station and the mobile terminal, either by the base station or by the mobile terminal.
[0011] The radio signals transmitted between the mobile terminal and a number of base stations can be evaluated in order to determine the position of the mobile terminal more precisely. For example, the distance between the mobile terminal and each of a number of base stations can be determined for this purpose, in order to use this to determine a measure for the position of the mobile terminal on the basis of geometric relationships. Furthermore, direction-finding can also be carried out from a number of base stations in order to determine the position of the mobile terminal. The mobile terminal position determined relative to the base stations can also be used, if the position of the first terminal is known, to determine a measure for the distance between the mobile terminal and this first terminal.
[0012] The measure for the position of the mobile terminal can be determined not only by the mobile terminal itself but also by a base station. Using the base station to determine this position has the advantage that the method according to the invention can be carried out with conventional mobile terminals, which do not require any modification for this purpose.
[0013] Once it has been determined, the measure for the position of the mobile terminal can be transmitted as such to the base station and/or to the switching device. As an alternative to this, the mobile terminal or the base station can also check the position measure which has been determined to find out whether the mobile terminal has gone outside a predetermined value frame, for example, a predetermined maximum distance from the base station, and a message can be transmitted to the base station and/or to the switching device only when this situation occurs. One advantage of transmitting a message is that the switching device need not itself evaluate the position of the mobile terminal. In this case, a control message, which is normally used or is standardized for direct control of call diversion processes, is preferably used as the message. There is thus no need for any intervention in the existing switching devices to carry out the method according to the invention.
[0014] The position of the mobile terminal can be checked particularly easily if the predetermined value frame is governed by the range of the wire-free link between the mobile terminal and the base station. In this case, a message is transmitted to the base station and/or to the switching device when the mobile terminal leaves the radio area of the base station.
[0015] In the situation when there are various base stations located within radio range with which the mobile terminal is authorized to set up a connection, a prioritization list can additionally be predetermined, for example in the mobile terminal, which indicates which of these base stations it is preferable for the mobile terminal to register with, in order to control the call diversion process. In this case, a base station can preferably be allocated a higher priority the closer it is to the first terminal. Base stations specified in the prioritization list may in this case also belong to different radio networks. The prioritization list also allows different priorities to be allocated to different radio networks.
[0016] With the foregoing and other objects in view there is also provided, in accordance with the invention a method for controlling call diversion that includes: coupling a first terminal, for which call diversion is to be activated, to a switching device; registering, with a base station that is coupled to the switching device, whether a mobile terminal other than the first terminal can be accessed for connection requests; and controlling the call diversion process, with the switching device, as a function of the registration.
[0017] Other features which are considered as characteristic for the invention are set forth in the appended claims.
[0018] Although the invention is illustrated and described herein as embodied in a method for position-dependent call diversion, it is nevertheless not intended to be limited to the details shown, since various modifications and structural changes may be made therein without departing from the spirit of the invention and within the scope and range of equivalents of the claims.
[0019] The construction and method of operation of the invention, however, together with additional objects and advantages thereof will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0020] [0020]FIG. 1 shows a communications system having a switching device with call diversion that has been set up but has not been activated; and
[0021] [0021]FIG. 2 shows the same communications system with call diversion activated.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] [0022]FIGS. 1 and 2 each schematically show a communications system having a switching device V, for example a so-called PBX system (PBX: private branch exchange) connected to a communications network KN. A fixed tabletop terminal TEG as well as base stations BS 1 and BS 2 are coupled to the switching device V. The radio cell FZ 1 of the base station BS 1 and the radio cell FZ 2 of the base station BS 2 are each indicated as dotted ellipses. The communications system also includes a mobile terminal MEG, which is authorized to set up connections both via the base station BS 1 and via the base station BS 2 .
[0023] For the present exemplary embodiment, it is assumed that the base station BS 1 is located in the immediate vicinity of the tabletop terminal TEG and that base station BS 1 is a home base station or a base station prioritized in some other way for the mobile terminal MEG. The user of the tabletop terminal TEG is also assumed to be the user of the mobile terminal MEG, which he carries with him.
[0024] The base stations BS 1 and BS 2 may, for example, be in the form of DECT base stations (DECT: Digital Enhanced Cordless Telephony), which belong to the same or to different radio networks. In this case, the mobile terminal MEG is in the form of a cordless DECT terminal which is registered as being authorized to accept connections in both the joint and the different radio networks of the respective base stations BS 1 , BS 2 . As an alternative to this, the base station BS 1 may also be in the form of a so-called Bluetooth module, which allows the mobile terminal MEG to be coupled over short distances to the switching device V via a Bluetooth module in the mobile terminal MEG.
[0025] The base stations BS 1 and BS 2 are each coupled to a radio switching assembly RC of the switching device V. The radio switching assembly RC is used to control the setting up of connections and the routing of connections to mobile terminals automatically via base stations which are connected to it. The switching device V also contains a call diversion table TAB in which call diversions to any desired terminals can be entered, for example by user inputs, for those terminals which are registered with the switching device V, in this case the fixed tabletop terminal TEG and the mobile terminal MEG. In the present exemplary embodiment, a call diversion to the mobile terminal MEG has been entered for the tabletop terminal TEG. No call diversion has been entered for the mobile terminal MEG itself.
[0026] In the call diversion table TAB, each terminal for which call diversion has been set up, in this case the tabletop terminal TEG, is allocated a respective destination terminal, in this case the mobile terminal MEG. For each terminal set up for call diversion, the call diversion table TAB contains an activation status, in this case A for Activated or D for Deactivated, and initiation information, in this case BS 1 . The initiation information in this case identifies those terminals, base stations, assemblies and/or events which can initiate control of the associated call diversion process. In the present exemplary embodiment, the initiation information identifies the base station BS 1 . This means that the call diversion process for the tabletop terminal TEG can be controlled by messages from the base station BS 1 .
[0027] [0027]FIG. 1 shows a situation in which the user is located, together with his mobile terminal MEG, in the immediate vicinity of the tabletop terminal TEG and of the base station BS 1 . The mobile terminal MEG is located within the radio cell FZ 1 , and within radio range of the base station BS 1 . The base station BS 1 confirms that the mobile terminal MEG can be accessed by interchanging radio signals, as indicated by means of a stylized lightning symbol, and reports this to the radio switching assembly RC.
[0028] In the switching device, an appropriate entry in the call diversion table TAB causes call diversion to be set up for the tabletop terminal TEG to the mobile terminal MEG but this is initially identified as being deactivated by virtue of the activation status D allocated to the tabletop terminal TEG.
[0029] Since the call diversion which has been set up for the tabletop terminal TEG is still deactivated, connection requests VA 1 arriving at the switching device V and whose destination is the tabletop terminal TEG are switched from the communications network KN to the tabletop terminal TEG. Since, as confirmed by the base station BS 1 , the user together with his mobile terminal MEG is located in the vicinity of the tabletop terminal TEG, the incoming connection requests VA 1 can be received by the user on the tabletop terminal TEG.
[0030] [0030]FIG. 2 shows a situation in which the user, together with his mobile terminal MEG leaves the radio cell FZ 1 of the base station BS 1 , and thus leaves a predetermined area around his tabletop terminal TEG. As soon as the base station BS 1 finds that the mobile terminal MEG has left the radio cell FZ 1 , it sends a message M to the switching station V. The base station BS 1 confirms that the terminal has left the radio cell FZ 1 by comparing the received field strength of radio signals from the mobile terminal MEG with a predetermined limit value, which defines the range of the radio link.
[0031] The switching station V identifies the message M as coming from the base station BS 1 , and an entry with initiation information which identifies this base station BS 1 is then determined in the call diversion table TAB. In the present exemplary embodiment, the entry which is determined relates to the previously deactivated call diversion for the tabletop terminal TEG to the mobile terminal MEG. This call diversion is then activated by the switching device V, and is identified as being active by entering an activation status A in the call diversion table TAB. Subsequent connection requests VA 2 which are directed from the communications network KN to the tabletop terminal TEG are in consequence diverted by the switching device V to the mobile terminal MEG. The switching device V to this end passes on the connection requests VA 2 to the radio switching assembly RC, which controls the rest of the process of setting up a wire-free connection to the mobile terminal MEG. In the present exemplary embodiment, it is assumed that, on leaving the radio cell FZ 1 , the mobile terminal MEG is located in the radio cell FZ 2 of the base station BS 2 and has registered with the radio switching assembly RC via the base station BS 2 , by interchanging radio signals with the base station BS 2 . This registration process causes the radio switching assembly RC to switch all incoming connection requests VA 2 for the tabletop terminal TEG to the mobile terminal MEG via the base station BS 2 .
[0032] Thus, even when the user is away from his tabletop terminal TEG, he is accessible for calls directed to his tabletop terminal TEG.
[0033] Instead of call diversion to the mobile terminal MEG, the method according to the invention also makes it possible to control call diversions to any other desired terminals, which may also belong to a different communications system than that of the switching device V. Thus, for example, an appropriate entry for the tabletop terminal TEG in the call diversion table TAB allows call diversion to be activated to a mailbox, to a work colleague's tabletop terminal, to the user's home terminal or to another of the user's mobile terminals, whenever he leaves the radio cell FZ 1 . Call diversion to one of the user's mobile terminals other than the mobile terminal MEG is advantageous, for example, if the mobile terminal MEG is a cordless DECT terminal which has only a relatively short radio range (in the order of magnitude of 100 meters). In this case, call diversion to a GSM terminal (Global System for Mobile Communication), which can be accessed over a large area, can be activated as soon as the cordless DECT terminal MEG leaves the radio cell FZ 1 . This method is particularly advantageous when the DECT terminal MEG which initiates the activation of the call diversion process is integrated in the same mobile terminal as the GSM terminal.
[0034] Apart from the message M which is sent by the base station BS 1 when the mobile terminal MEG leaves the radio cell FZ 1 , the base station BS 1 may also transmit one or more other messages to the switching device V, depending on the position of the mobile terminal MEG found from the received field strength, and/or depending on its operating status. For example, if the received field strength rises, that is to say the mobile terminal MEG moves toward the base station BS 1 , a specific message which initiates deactivation of a previously activated call diversion can be transmitted to the switching device V.
[0035] In general, specific messages, which can be transmitted to the switching device V and which are used to control one or more call diversion processes in a predetermined manner, can in each case be provided for different position changes of the mobile terminal MEG, which can be detected by the base station BS 1 . For example, the base station BS 1 can check the received field strength periodically in order to detect a change in the position of the mobile terminal MEG.
[0036] Furthermore, a message can be provided for the situation where the base station BS 1 detects a change in the operating status of the mobile terminal, for example when the mobile terminal is switched on or is busy. For example, when the user takes a call on the mobile terminal MEG, a specific message can be transmitted to the switching device V, activating call diversion to the user's mailbox for the tabletop terminal TEG.
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A method providing automatic control of call diversion from a first terminal (TEG), which is coupled to a switching device (V), to any desired second terminal (MEG). The call diversion process is controlled as a function of the position of a mobile terminal (MEG) relative to a base station (BS 1 ) which is coupled to the switching device (V). A measure for the relative position of the mobile terminal (MEG) is in this case determined on the basis of radio signals which are transmitted between the base station (BS 1 ) and the mobile terminal (MEG).
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TECHNICAL FIELD OF THE INVENTION
The present disclosure relates generally to the field of photolithography and more specifically to selective imaging.
BACKGROUND OF THE INVENTION
Photolithography is the transfer of a pattern to a photosensitive material by selective exposure to a radiation source such as, for example, light. A photosensitive material generally experiences a change in its material property when exposed to a radiation source. Typically, a photosensitive material includes a photoresist polymer or resist. After a resist is exposed to a radiation source of a specified wavelength and a developer solution, the chemical resistance of the resist changes and the resist will etch away either the exposed or unexposed regions, depending on the chemical properties of the resist and the developer solution. For example, if the exposed material is etched away by the developer and the unexposed region is resilient, the material is considered a positive resist. On the other hand, if the exposed material is resilient to the developer and the unexposed region is etched away, the material is considered a negative resist. Using the properties of the resist and the developer, patterns may be etched onto the surface of a wafer. Moreover, patterns may be used as a template for depositing materials after lithography. At the end of the process, the resist is typically etched away and any materials deposited on the resist is also etched away. Resists, however, cannot withstand high temperatures and may act as a source of contamination. Often times, etching near the edge of the wafer is simply not possible or not etched adequately within system parameters.
In most applications, the lithography process typically follows several standard steps to ensure that a wafer is etched accurately. For example, the lithography process typically includes preparing the surface of the wafer by baking the wafer to ensure that the resist will adhere properly. Some applications require that the wafer surface be prepared with an adhesion promoter. The wafer is spinned or sprayed uniformly with the resist and then soft baked to remove some of the solvent in the resist, making the resist more viscous. The wafer is typically aligned with a mask, selectively exposed to a radiation source and then baked again. Then, the wafer is exposed to a developer to selectively remove the resist. Finally, the wafer is typically hard baked to drive off more of the solvent in the resists and any resist residue is removed.
Prior art systems and methods, however, have failed to employ systems to enhance performance on the edge of the wafer. Even after selective imaging, prior systems often waste valuable wafer surface space (i.e., wafer edges) and are tedious and time consuming. Accordingly, the images were, at best, placed without taking into account most imaging practices, especially near the edge of the wafer. In addition, selective hard masking is currently accomplished by performing a photo process, an etch process, an ash or strip process. Often times, prior practices led to incomplete nodes and thus, the percentage of operational devices manufactured, or “yield”, is relatively low or simply unacceptable.
What is needed therefore is an improved, low cost method for hard masking wafers, including wafer edges.
SUMMARY OF THE INVENTION
The present disclosure provides an improved, low cost method for hard masking wafers including wafer edges, and in particular, system and method for selective imaging through dual photoresist layers.
In one embodiment, a method of selectively hard masking a semiconductor wafer is disclosed. The method includes coating a surface of the wafer with a first resist and baking the wafer to sufficiently drive out solvents in the first resist. The method also includes exposing the first resist to a first radiation source and exposing an edge of the wafer having the first resist disposed thereon to the first radiation source. The method further includes hard baking the first resist to the wafer and coating the first resist with a second resist. The method still further includes baking the wafer to sufficiently drive out solvents in the second resist and exposing the second resist to a second radiation source. The method still further includes exposing select portions of the edge of the wafer having the second resist disposed thereon to the second radiation source and hard baking the second resist to the wafer.
In another embodiment, a method of selective imaging through a dual photoresist layer for use in a semiconductor wafer is disclosed. The method includes coating a surface of the wafer with a resist and baking the wafer to sufficiently drive out solvents in the resist. The method also includes exposing the resist to a first radiation source and hard baking the resist to the wafer. The method further includes exposing the wafer to a high hot plate and coating the resist with a photosensitive polymer. The method still further includes baking the wafer to sufficiently drive out solvents in the photosensitive polymer and exposing the photosensitive polymer to an ultraviolet radiation source. The method also includes hard baking the photosensitive polymer to the wafer.
In still another embodiment, a semiconductor wafer is disclosed. The semiconductor wafer includes a surface and a first resist selectively disposed on the surface. The semiconductor wafer also includes a second resist selectively disposed and hard baked onto the first resist.
Other features and advantages of the present disclosure will be apparent to those of ordinary skill in the art upon reference to the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
For a better understanding of the disclosure, and to show by way of example how the same may be carried into effect, reference is now made to the detailed description of the disclosure along with the accompanying figures in which corresponding numerals in the different figures refer to corresponding parts and in which:
FIG. 1 depicts a coated wafer with a mask image in accordance with one embodiment of the present disclosure;
FIG. 2A depicts a coated wafer with mask image in accordance with one embodiment of the present disclosure;
FIG. 2B is a simplified cross-sectional view of a photoresist layer remaining after the wafer is developed.
FIG. 3 is a somewhat simplified flow chart illustrating a first phase of a method for coating a wafer in accordance with one embodiment of the present disclosure; and
FIG. 4 is a somewhat simplified flow chart illustrating a second phase of a method for coating a wafer with a second photoresist layer in accordance with one embodiment of the present disclosure.
DETAILED DESCRIPTION OF THE INVENTION
While the making and using of various embodiments of the present disclosure are discussed in detail below, it should be appreciated that the present disclosure provides many applicable inventive concepts, which can be embodied in a wide variety of specific contexts. Although described in relation to such apparatus and methods, the teachings and embodiments of the present disclosure may be beneficially implemented with a variety of manufacturing and applications. The specific embodiments discussed herein are, therefore, merely demonstrative of specific ways to make and use the disclosure, and do not limit the scope of the disclosure.
FIG. 1 depicts a coated wafer 100 with a mask image in accordance with one embodiment of the present disclosure, and specifically a wafer 100 resulting from the first phase of the method disclosed later herein. Wafer 100 includes multiple reticles 101 . The reticles 101 are transferred to wafer 100 by exposing wafer 100 to an ultraviolet light source through a mask (not shown). After performing a full field exposure of the entire wafer through a mask, positional offsets 102 are performed. The positional offsets 102 aid exposing corner edges 103 of the die after first exposing the entire wafer 100 . Each positional offset 102 exposes, for example, a two-by-two section of reticles 101 at a time, as illustrated on the right-hand side of FIG. 1 . It should be understood, however, that any section of reticles 101 may be exposed at a given time.
FIG. 2A depicts a coated wafer 200 with a mask image in accordance with one embodiment of the present disclosure. In contrast with prior art systems, wafer 200 includes a double photoresist layer. Wafer 200 experiences increased yields, especially on edge 103 of wafer 200 , by employing a baked photoresist as a hard mask in accordance with an embodiment of the present disclosure. Wafer 200 preferably includes a dual photoresist layer formed by method 300 described below.
FIG. 2B is a simplified cross-sectional view of an exemplary photoresist layer 201 remaining after wafer 200 is developed. Wafer 200 includes a wafer edge exposure (WEE) end 202 , a non-yielding area 203 and yielding edge die 204 . Photoresist layer 201 includes a “hard masking” photoresist layer 205 and “patterning” photoresist layer 206 .
FIGS. 3 and 4 are somewhat simplified flow charts illustrating methods 300 a and 300 b (collectively sometimes referred to herein as method 300 ) of baking a dual photoresist layer or hard mask during lithography on a wafer, such as wafer 200 .
In accordance with one embodiment of the present disclosure, a wafer is coated with an adhesion promoter to aid in adhering a resist, photosensitive polymer or photoresist to the wafer in step 301 . Preferably, the wafer is coated with the adhesion promoter in an ambient temperature of 150 degrees Celcius for about 50 seconds. In step 302 , the wafer is coated with the photoresist. Preferably, the photoresist is uniformly coated onto the wafer by a spinning or spraying process known in the art. The photoresist preferably protects the underlying material during processing or etching. According to one embodiment of the present disclosure, the photoresist may be, for example, an i-line resistance coating. Although the description primarily describes a photoresist, any suitable resist material may be used in accordance with the present disclosure.
Method 300 a continues in step 303 by driving off some of the solvent in the photoresist by soft baking the wafer. Preferably, after coating the areas with a resistance coating, the wafer is baked in a high temperature sufficient to drive out any solvent from the resistance coating on the wafer. Preferably, the wafer is soft baked at about 90 degrees Celsius for about 80 seconds. According to one embodiment of the present disclosure, the wafer may be soft baked on a vacuum hot plate to optimize the light absorbance characteristics of the photoresist. Although the photoresist may lose mass or experience decreased thickness on the wafer surface, the photoresist preferably becomes more viscous.
In step 304 , the wafer is aligned with the mask and prepared for exposure to ultraviolet light in step 305 . Preferably, the exposure to ultraviolet light in step 305 is sufficient to cause selective chemical property changes on the surface of the resistance coating using a standard process such as an I7010 12K process. For example, method 300 preferably activates the photo-sensitive components of the resistance coating resulting in adequate line-width resolution and overlay accuracy, while maintaining a surface relatively free of particles and defects.
The wafer is preferably moved in the X- and Y-directions so that patterns or “shots” may be exposed onto the reticle. After performing a full field exposure of the entire wafer through a mask in step 305 , positional offsets aid in filling in corner edges of the die. Each positional offset preferably exposes, for example, certain sections of reticles at a given time (preferably 7 mm at a time).
After exposure to ultraviolet light, the photoresist surface is then baked in step 306 . Preferably, the photoresist surface is baked immediately after exposure to the ultraviolet light and at a temperature between about 110 degrees Celsius for about 60 seconds. A photoresist developer dissolves soluble areas of the photoresist and visible pattern begin to appear on the wafer in step 307 . The developer may be either a positive resist or a negative resist photoresist polymer and may be a wet or dry process. Preferably, the visible pattern exhibits adequate quality measures such as, sufficient line resolution and uniformity, while maintaining a surface relatively free of particles and defects.
Method 300 a continues in step 308 , the wafer is subjected to a post-development thermal bake or hard bake. The hard bake preferably evaporates the remaining solvent in the photoresist and improves the resist-to-wafer adhesion. Preferably, the hard bake occurs at about 100 degrees Celsius for about 50 seconds. Finally, the wafer is placed on a transition chill plate. Preferably, the wafer is placed onto a chill plate at a temperature of about 23 degrees Celsius for about 20 seconds. Method 300 a continues method 300 b.
Now referring to FIG. 4 , method 300 b begins by exposing the wafer resulting in step 320 to a high hot plate in step 401 to dehydrate the wafer to later aid in adhering a photoresist to the wafer and to ensure that the surface of the wafer is dry and clean. Preferably, the wafer is exposed to a high hot plate set at about 225 degrees Celsius for about 52 seconds. In one embodiment of the present disclosure, a hexamethyldisilazane or HMDS hot plate may be used.
In step 402 , the wafer is coated with an adhesion promoter to further aid in adhering the photoresist to the wafer. Preferably, the wafer is coated with an adhesion in an ambient of about 180 degrees Celsius for about 57 seconds. Then, in step 403 , the wafer is coated with the photoresist. Preferably, the photoresist is uniformly coated onto the wafer by a spinning or spraying process known in the art. The photoresist preferably protects the underlying material during processing or etching. According to one embodiment of the present disclosure, the photoresist is preferably an i-line resistance coating. Although the description primarily describes a photoresist, any suitable resist material may be used.
Method 300 b continues in step 404 by driving off some of the solvent in the photoresist, the wafer is then soft baked. Preferably, after coating the areas with an i-line resistance coating, the wafer is baked in a high temperature sufficient to drive out any solvent from the i-line resistance coating on the wafer. Preferably, the wafer is baked in an ambient temperature of 105 degrees for about 60 seconds. According to one embodiment of the present disclosure, the wafer may be soft baked on a vacuum hot plate to optimize the light absorbance characteristics of the photoresist. Although the photoresist may lose mass or decreased thickness on the wafer surface, the photoresist preferably becomes more viscous. At this stage of method 300 b , the wafer is now coated with two layers of photoresist material in accordance with one embodiment of the present disclosure.
In step 405 , the wafer is aligned with the mask and prepared for exposure to ultraviolet light in step 406 . Once aligned, the wafer is preferably moved in the X- and Y-directions so that patterns or “shots” may be exposed onto the reticle. Preferably, the exposure to ultraviolet light in step 406 is sufficient to cause selective chemical property changes on the surface of the i-line resistance coating using a standard deep ultraviolet (DUV) process such as 12.0 DUV. In accordance with the present disclosure, the DUV process is preferably conducted without leveling over areas of the wafer 200 which contain double resist coatings. For example, method 300 b preferably activates the photo-sensitive components of the i-line resistance coating resulting in adequate line-width resolution and overlay accuracy, while maintaining a surface relatively free of particles and defects. In addition, the wafer edges are exposed to ultraviolet light.
After exposure to ultraviolet light, the photoresist surface is then baked in step 407 . Preferably, the photoresist surface is baked immediately after exposure to the ultraviolet light and at a temperature between about 100 degrees Celsius for about 60 seconds. A photoresist developer dissolves soluble areas of the photoresist and visible pattern begin to appear on the wafer in step 408 . The developer may be either a positive resist or a negative resist photoresist polymer and may be a wet or dry process. Preferably, the visible pattern exhibits adequate quality measures such as, sufficient line resolution and uniformity, while maintaining a surface relatively free of particles and defects.
Finally, in step 409 , the wafer is subjected to a post-development thermal bake or hard bake. The hard bake preferably evaporates the remaining solvent in the photoresist and improves the resist-to-wafer adhesion. Preferably, the hard bake in step 409 occurs at even higher temperatures than the soft bake in step 407 , or about 110 degrees Celsius for about 60 seconds. The wafer may be etched using contact printing, proximity printing or projection printing at any suitable time during method 300 . Accordingly, method 300 is a method of making a double resist coated or baked photoresist hard mask in accordance with one embodiment of the present disclosure. It should be understood that the dual layer hard mask may be made of two different types of resists or may have any number of layers of resists.
In accordance with an embodiment of the present disclosure, a standard DUV process is disclosed which contains a double resist coating or a baked photoresist hard mask. The cycle times and number of shots required are lower than that of the prior art, while still addressing other problems such as edge focus or photo throughput. Speed, yield, cost of manufacturing, cost of human resources and maintenance of critical layer imaging is improved without employing more expensive equipment, such as high-end scanners. The process of selective imaging in accordance with the present disclosure is useful for wafer edge imaging as well as patterning different layer formations onto the same substrate or on multiple layers with different photoresists on the same film stack without performing multiple etches.
The embodiments and examples set forth herein are presented to best explain the present disclosure and its practical application and to thereby enable those skilled in the art to make and utilize the invention. However, those skilled in the art will recognize that the foregoing description and examples have been presented for the purpose of illustration and example only. The description as set forth is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching without departing from the spirit and scope of the following claims.
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A system and method for selective imaging through dual photoresist layers. The system and method includes coating a surface of the wafer with a first resist and baking the wafer to sufficiently drive out solvents in the first resist. The first resist is exposed to a first radiation source and exposing an edge of the wafer having the first resist disposed thereon to the first radiation source. The method further includes hard baking the first resist to the wafer and coating the first resist with a second resist. The method also includes baking the wafer to sufficiently drive out solvents in the second resist and exposing the second resist to a second radiation source. The method also includes exposing select portions of the edge of the wafer having the second resist disposed thereon to the second radiation source and hard baking the second resist to the wafer.
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INCORPORATION BY REFERENCE
[0001] This application claims priority based on a Japanese patent application, No. 2008-242745 filed on Sep. 22, 2008, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] The present invention relates to a memory management method which dynamically secures and releases a memory of a computer, and a computer using the same.
[0003] It has been known that securing and releasing processing of a memory area used by a program when a computer program is developed is apt to cause a problem with a program such as a false area reference. Particularly, in a program development by plural persons or large-scale program development, it is becoming difficult to completely grasp securing and releasing processing of all memories.
[0004] To solve this problem, there is used a garbage collector for automating memory management in a program. Java (a registered trademark of Sun Microsystems, Inc. in the USA), which is one of language processors equipped with a memory management function using a garbage collector, prepares for an Application Program Interface (API, description for programming) but has no API for release. That is to say, a Java program developer needs to specify (describe) the securement of a memory area but does not need to describe the release processing of the memory area. The memory area secured in the process of executing a program is released by the garbage collector implemented in a Java virtual machine executing a program and the released area is reusable. A function executed by the garbage collector is garbage collection (hereinafter referred to as GC). In other words, the term GC refers to a function to collect (delete) unnecessary data out of the memory area dynamically secured by a program (during execution) and release the area where the unnecessary data is collected.
[0005] In a commonly used GC method, all Java program execution threads are stopped to collect unnecessary data. The Java virtual machine starts the garbage collector when the amount of use of a Java heap memory (hereinafter referred to as Java heap) which stores data (object) generated by a program exceeds a certain threshold.
[0006] In recent years, a Java system executing a program described by the Java language on a Java virtual machine has been used in an embedded system such as a server system, a cellular phone and a car navigation system. These systems have a problem in that the stoppage of the Java program execution thread by the GC lowers the response performance of the system.
[0007] A method of solving this problem is disclosed in Angelo Corsaro and Ron K. Cytron, Efficient Memory-Reference Checks for Real-time Java, Proceedings of the 2003 Conference on Languages, Compilers, and Tools for Embedded Systems, 2003 as well as in F. Pizlo, J. M. Fox, D. Holmes and J. Vitek, Real-Time Java Scoped Memory: Design Patterns and Semantics, Proceedings of the Seventh IEEE Internal Symposium on Object-Oriented Real-Time Distributed Computing, 2004. The methods disclosed in these documents have not only a heap memory (Java heap) subjected to the GC by the Java virtual machine, but also a heap memory (hereinafter referred to as external heap memory) not subjected to the GC. The term external heap memory refers to a memory area where a memory can be managed by a program. In other words, the securement of a memory area from the external heap memory, the generation of an object and the release of the memory area follow the description of a program into a source code by a programmer. In the release processing of memory area of the external heap memory, a referential relationship of an object generated in the secured memory area is restricted to release the memory area irrespective of an object generated in the memory area. The restriction ensures that, when an object generating thread is reduced to zero in a certain memory area in the external heap memory, the release of the memory area does not influence the execution of the program. Thus, the referential relationship of the object is restricted using an area where a memory area can be managed by a program, i.e., using the external heap memory not subjected to the GC by the Java virtual machine to minimize the occurrence of halt of the Java program execution thread for a long time.
[0008] The restrictive items on the referential relationship between the objects in the methods disclosed in the Angelo Corsaro and Ron K. Cytron as well as in the F. Pizlo, J. M. Fox, D. Holmes and J. Vitek significantly impair the convenience of this memory area. Specifically, one or more threads need to execute an interval generating an object on a memory area as a condition for the existence of the memory area of the external heap memory secured during the execution of the program; however, the condition imposes tight restrictions on the programming. Since the referential relationship between objects is restricted, the programmer needs to perform programming while always paying attention to the restriction; however, it is extremely difficult to grasp the referential relationship between objects because the program becomes large in scale and implicit data which is not described in a user program is generated. If the referential relationship against the restrictions is detected by a check at the time of executing the program, an exception occurs, which may not normally execute the program.
[0009] To solve such a problem, when a certain memory area in the external heap memory is released without imposing restrictions on the referential relationship between objects, a relationship between an object in the memory area to be released and an object in the other areas (the Java heap subjected to the GC and the memory area not subjected to the release of the external heap memory) is checked to confirm that the release of the memory area does not disturb the execution of the program, and then the memory area is released.
[0010] The check of the referential relationship between objects requires processing time depending on the number of objects included in the Java heap and the external heap memory. In general, the larger the capacity of the Java heap and the external heap memory, the greater the number of objects included therein, so that a system with a large capacity memory requires a long processing time to safely release a memory.
SUMMARY OF THE INVENTION
[0011] The present invention provides below a memory management method and a computer using the same. The memory management method includes the steps of: securing a memory area by a program executed by a computer; storing an object in the memory area in accordance with the execution of the program; bringing the memory area into a release reservation state in accordance with the program instructing the memory area to be released; moving the object to a memory area not to be released while another object in the memory area not to be released and not to be brought into the release reservation state refers to the object in the memory area to be released including the memory area to be brought into the release reservation state; and releasing the memory area to be released.
[0012] Another desirable aspect of the present invention is that the move of an object to a memory area not to be released and the release of the memory area to be released are executed at a predetermined moment.
[0013] According to the present invention, it is enabled to shorten the processing time required for releasing the memory area dynamically secured.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 is a block diagram illustrating a configuration of a computer according to the first embodiment;
[0015] FIG. 2 is a chart illustrating an example of description of a Java program;
[0016] FIG. 3 is a process flow chart for an external heap memory releasing routine;
[0017] FIGS. 4A to 4C are diagrams illustrating examples of an external heap memory release process;
[0018] FIG. 5 is a table illustrating an example of an external heap memory release reservation management table;
[0019] FIG. 6 is a process flow chart of an external heap memory release reservation section;
[0020] FIG. 7 is a process flow chart of an external heap memory releasing section;
[0021] FIGS. 8A and 8B are diagrams exemplifying states of objects and references between the objects;
[0022] FIGS. 9A and 9B are diagrams exemplifying states of objects and references between the objects;
[0023] FIGS. 10A and 10B are process flow charts illustrating an example of an external heap memory release timing determination routine;
[0024] FIG. 11 is a block diagram illustrating a configuration of a computer according to the second embodiment;
[0025] FIG. 12 is a table illustrating an example of an external heap memory release reservation management table;
[0026] FIG. 13 is a table illustrating an example of an external heap memory generating management table;
[0027] FIG. 14 is a process flow chart of an external heap memory generating section; and
[0028] FIG. 15 is a process flow chart illustrating an example of an external heap memory release timing determination routine.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] The best embodiments for carrying out the present invention are described below as first and second embodiments.
First Embodiment
[0030] The present embodiment is a method of releasing a memory and a computer using the same. In the present embodiment, although a Java system is described as an object, if there is a system which can determine whether data (object) stored in a memory to be released is required or not at the time of releasing the memory, such a memory may be taken as an object for description.
[0031] FIG. 1 is a block diagram illustrating a configuration of a computer 100 according to the present embodiment. The computer 100 includes a processor (CPU) 1 for executing each processing, a memory 2 and an external storage 4 . For the sake of easy understanding, FIG. 1 shows that a Java virtual machine (Java VM) 10 is mounted on the processor 1 and executed by the processor 1 . If the Java virtual machine (Java VM) 10 is constructed by software, the software is stored in the external storage 4 and loaded on the memory 2 along with the start of the computer 100 . The loaded software is executed by the processor 1 to construct the Java virtual machine 10 as a Java virtual machine.
[0032] The Java virtual machine 10 causes a program reading section 11 to read a Java program 20 and a program executing section 12 to execute the read Java program 20 . The program executing section 12 is an interpreter or a Just-In-Time (JIT) compiler.
[0033] The memory 2 includes the Java program 20 executed by the Java virtual machine 10 , a Java heap 21 (hereinafter referred to as Java heap) used by the Java virtual machine 10 and an external heap memory 30 (hereinafter referred to as external heap memory). The Java heap 21 is a memory subjected to garbage collection (GC) by the Java virtual machine 10 and a garbage collector 13 implemented in the Java virtual machine 10 performs memory management such as the GC. However, the memory area which the Java program 20 secures on the Java heap 21 cannot be released by the Java program 20 .
[0034] The external heap memory 30 is a memory which is not garbage collected by the garbage collector 13 of the Java virtual machine 10 and a memory area is formed in the external heap memory 30 according to the execution of external heap memory generating statement described in the Java program 20 . To form the memory area is actually to secure the memory area; however, it is viewed from the Java program 20 as if a usable memory area were formed, so that it is referred to as formation herein. In FIG. 1 , the memory area to be formed is denoted by an external heap memory “i,” specifically, an external heap memory 1 ( 31 ), an external heap memory 2 ( 32 ), an external heap memory 3 ( 33 ) . . . . The Java program 20 may be stored not on the memory 2 but in the external storage 4 .
[0035] The Java program 20 describes the generation of an external heap memory, the generation of an object on the external heap memory and the release of the external heap memory in order not only for required processing as an application program but for the execution of its processing. The Java virtual machine 10 executing the program generates, uses and releases the external heap memory “i.” An external heap memory processing section 14 is mounted on the Java virtual machine 10 to generate, use and release the external heap memory “i.” The external heap memory processing section 14 includes an external heap memory generating section 15 , a data generating section 16 to the external heap memory, an external heap memory releasing section 17 and an external heap memory release reservation section 18 .
[0036] FIG. 2 illustrates an example of description of the Java program 20 including the description for the generation of the external heap memory “i” (“em” in the description in FIG. 2 ), the generation of data into the external heap memory “i” and the release of the external heap memory “i.” A statement 201 on the second line is a description for generating the external heap memory “i” (the forgoing external heap memory generating statement). Data (object) generated in a process 202 from an enter method on the fourth line to an exit method on the sixth line (the process 202 is referred to as “data generation interval”) is generated on the external heap memory “i.” A statement 203 on the ninth line is a descriptive reclaim method for releasing the external heap memory “i.” The execution of the reclaim method reclaims (deletes) the data generated inside and releases the external heap memory “i.”
[0037] Simply releasing the external heap memory “i” subjected to a memory-area release by the reclaim method makes reference from another object false (or nonexistence of objects in a reference destination) if there exists another object referring to the data (object) included therein, causing a problem. The external heap memory releasing section 17 checks if another object which refers to an object included in the external heap memory “i” and is included in the memory area (Java heap or other external heap memories) which is not released before the external heap memory releasing section 17 releases the external heap memory “i” to be released. If there is such a reference, the object to which another object refers (referred to as target object) is moved to the memory area not to be released to correct the referential relationship between the objects, enabling continuing the execution of the Java program 20 even after the external heap memory “i” is released.
[0038] FIG. 3 is a process flow chart for an external heap memory releasing routine 19 adapted to continue a normal execution of the Java program 20 even after the external heap memory is released. If the process of the external heap memory release reservation section 18 described later is not taken into consideration, the process of the external heap memory releasing routine 19 illustrated in FIG. 3 is the process of the external heap memory releasing section 17 .
[0039] A check is made whether another object in the memory area not to be released refers to an object in the external heap memory “i” to be released (step 190 ). If yes (step 192 ), the target object is moved to the memory area not to be released (if there is plural memory areas not to be released, it is desirable to select a memory area not to be released in which an object referring to the target object is stored) and the reference of another object is corrected to the destination where the target object is moved (step 194 ). The process returns to the step 190 , and the step 194 is repeated until other objects in the memory area not to be released do not refer any longer to any object in the external heap memory “i” to be released. If another object in the memory area not to be released does not refer to an object in the external heap memory “i” to be released (step 192 ), the external heap memory “i” to be released is released.
[0040] The above release process is described using an example illustrated in FIGS. 4A to 4C . FIGS. 4A to 4C are examples illustrating the release of an external heap memory in FIG. 4A with the memory area to be released taken as an external heap memory and the memory area not to be released taken as the Java heap 21 . Objects (a) and (b) exist in the Java heap 21 being the memory area not to be released. Objects (c) and (d) exist in the external heap memory being the memory area to be released. There are a reference ac of the object (a) to the object (c), a reference cd of the object (c) to the object (d) and a reference db of the object (d) to the object (b). In the figure, a reference jk is indicated by an arrow from an object “j” (to be referred to) to an object “k” (to which the object “j” refers).
[0041] If the step 190 in FIG. 3 is executed, there is the reference ac of the object (a) in the memory area not to be released (the Java heap 21 ) to the object (c) in the memory area to be released (the external heap memory) (step 192 ), so that the step 194 is executed. At this point, the object (c) is the target object. If the step 194 is executed, the object (c) being the target object is moved to the memory area not to be released (the Java heap 21 ) and the reference ac of the object (a) to the object (c) is corrected to a reference N-ac to the moved object (c). The move of the object (c) to the memory area not to be released (the Java heap 21 ) newly creates a reference N-cd of the moved object (c) to the object (d). FIG. 4B illustrates the arrangement of the objects and the references therebetween as the result of the above process.
[0042] In the state shown in FIG. 4B , if the step 190 is executed again, there is the reference N-cd of the object (c) in the memory area not to be released (the Java heap 21 ) to the object (d) in the memory area to be released (the external heap memory) (step 192 ), so that the step 194 is executed. At this point, the object (d) is the target object. If the step 194 is executed, the object (d) being the target object is moved to the memory area not to be released (the Java heap 21 ) and the reference N-cd of the object (c) to the object (d) is corrected to a reference NN-cd to the moved object (d). The move of the object (d) to the memory area not to be released (the Java heap 21 ) newly creates a reference N-db of the moved object (d) to the object (b). FIG. 4C illustrates the arrangement of the objects and the references therebetween as the result of the above process.
[0043] In the state shown in FIG. 4C , if the step 190 is executed again, there does not exist an object in the memory area not to be released (the Java heap 21 ) which refers to an object in the memory area to be released (the external heap memory), that is to say, there is no reference to the object of the memory area to be released (the external heap memory), so that the external heap memory being the memory area to be released is released (step 196 ). As is clear from the above description, since there is no reference to the object on the external heap memory, the release of the external heap memory as the memory area does not cause a problem with the execution of the program.
[0044] Since the object (d) that refers to the object (b) is in the external heap memory being the memory area to be released and the object (d) does not refer to the object (b) after the external heap memory is released, the existence of the reference db of the object (d) to the object (b) does not influence the subsequent execution of the Java program.
[0045] As described with reference to FIGS. 3 to 4C , the larger the number of objects existing in the memory area to be released and the memory area not to be released, the longer the time required for processing related to checking if another object existing in the memory area not to be released refers to the target object existing in the memory area to be released, moving the target object if such a reference exists and correcting the reference to the moved target object. In other words, the larger the memory capacity of a system, the longer the time required for releasing the memory safely (without affecting the execution of a program).
[0046] Such a problem is solved in the following manner. In FIG. 4 , one external heap memory is taken as the memory area to be released. In addition, the memory area not to be released is taken as the Java heap 21 . Actually, if one external heap memory (for example, the external heap memory 1 ( 31 ) in FIG. 1 ) is taken as the memory area to be released, the memory area not to be released includes not only the Java heap 21 but also external heap memories not to be released (for example, the external heap memory 2 ( 32 ), the external heap memory 3 ( 33 ) . . . in FIG. 1 ) as illustrated in FIG. 1 . Therefore, control is performed so that some external heap memories are collectively released. Collectively releasing some external heap memories probably makes smaller the number of objects in relation to a check on the reference of the object in the memory area not to be released to the object in the memory area to be released, the move of the object and the correction of the reference than separately releasing external heap memories. This is because collected some external heap memories are taken as the memory area to be released to probably turn the reference of an object in the memory area not to be released to an object in the memory area to be released into the reference between objects in the memory area to be released. In other words, increasing the capacity of the memory area to be released brings about the same effect. However, increasing the capacity of each external heap memory leads to developing the Java program including functions for using them, which may lower the efficiency of development of the Java program. In the following, there is described in detail the collective release of external heap memories.
[0047] The program executing section 12 executing the statement ( 201 in FIG. 2 ) for generating the external heap memory “i” in the Java program 20 generates the external heap memory “i” in the external heap memory generating section 15 . In the data generation interval ( 202 in FIG. 2 ) described in the Java program 20 and in which data is generated in the external heap memory “i,” the data generating section 16 generates data (object) in the external heap memory “i.” If the Java program 20 explicitly instructs the release of the external heap memory “i” ( 203 in FIG. 2 ), the external heap memory release reservation section 18 renders the designated external heap memory “i” into a release reservation state and registers a value that can uniquely identify the designated external heap memory “i” (hereinafter referred to as external heap memory ID) in an external heap memory release reservation management table 22 . The term “release reservation state” refers to a state in which the external heap memory may be released.
[0048] The Java virtual machine 10 is an object (to which the object in the memory area not to be released refers) required for executing the Java program 20 at a certain moment (described in detail later) and the external heap memory releasing section 17 moves the target object in the external heap memory “i” in the release reservation state in the external heap memory release reservation management table 22 to the memory area not to be released, releasing the external heap memory “i” reserved to be released.
[0049] FIG. 5 is a table illustrating an example of the external heap memory release reservation management table 22 . In this example, an external heap memory ID and its heap size (memory capacity) are associated with each line and registered. FIG. 5 shows that the external heap memory IDs EH 1 , EH 2 , EH 3 . . . EHm and their respective heap sizes Eh 1 (Kbytes), Eh 2 (Kbytes), Eh 3 (Kbytes) . . . Ehm (Kbytes) associated with FIG. 1 are registered. The external heap memory ID may uniquely identify each external heap memory “i” and the heap size may be registered as required.
[0050] FIG. 6 is a process flow chart of the external heap memory release reservation section 18 executing process in response to the release instruction 203 of the external heap memory. A check is made whether the external heap memory ID in the external heap memory instructed to be released is registered in the external heap memory release reservation management table 22 (step 180 ). If Yes, the process is ended. If No (step 182 ), the external heap memory ID reserving release and its heap size are registered in the external heap memory release reservation management table 22 (step 184 ). The term “registered” refers to a state occurring because the same external heap memory may be instructed to be released at plural places in a complicated program.
[0051] FIG. 7 is a process flow chart of the external heap memory releasing section 17 for releasing the external heap memory reserved to be released. A check is made whether the external heap memory ID is registered in the external heap memory release reservation management table 22 (step 170 ). If the external heap memory ID is not registered in the external heap memory release reservation management table 22 , the process is ended (step 172 ). If the external heap memory ID is registered in the external heap memory release reservation management table 22 (step 172 ), external heap memories corresponding the external heap memory ID and existing in the external heap memory release reservation management table 22 are collected as the memory area to be released (step 174 ) and the external heap memory releasing routine 19 is executed. The external heap memory releasing routine 19 described using FIG. 3 executes process with the collected external heap memories as the memory area to be released. The external heap memory ID which exists in the external heap memory release reservation management table 22 and is released by executing the external heap memory releasing routine 19 is deleted (step 176 ).
[0052] FIGS. 8A to 9B exemplify states of each object and references between the objects with respect to the release of the memory area to be released by a difference between the number of external heap memories collected in step 174 in FIG. 7 . FIG. 8A shows that objects (a) and (b) exist in the Java heap 21 , an object (c) exists in the external heap memory 1 in the external heap memory 30 , objects (d) and (e) exist in the external heap memory 2 , an object (f) exists in the external heap memory “m”, a reference ac of the object (a) to the object (c), references db and dc of the object (d) to the objects (b) and (c) and a reference fe of the object (f) to the object (e). There is described below a state in a case where the memory area to be released is released according to the external heap memory ID registered in the external heap memory release reservation management table 22 based on a state of each object and references between the objects illustrated in FIG. 8A (or, in a case where the execution of the external heap memory releasing routine 19 is completed in FIG. 7 ).
[0053] FIG. 8B shows that the external heap memory 1 is registered as the external heap memory ID in the external heap memory release reservation management table 22 and released as the memory area to be released. In the figure, the external heap memory 1 being the memory area to be released is indicated by the broken line. In the state in FIG. 8A , there exist the references ac and dc of the object (a) of the Java heap 21 being the memory area not to be released and the object (d) of the external heap memory 2 to the object (c) of the external heap memory being the memory area to be released respectively, the object (c) is moved as the target object to the Java heap 21 being the memory area not to be released to correct the references ac and dc to new references N-ac and N-dc.
[0054] FIG. 9A shows that the external heap memories 1 and 2 are registered as external heap memory IDs in the external heap memory release reservation management table 22 based on the state in FIG. 8A , and the external heap memories 1 and 2 are collected and released as the memory area to be released. In the figure, the external heap memories 1 and 2 being the memory area to be released are indicated by the broken line. Since the external heap memories 1 and 2 are released based on the state in FIG. 8A , the objects (a) to (d) and the references between their objects are the same as those in FIG. 8B . Since there exists a reference fe of an object (f) in the external heap memory “m” being the memory area not to be released to an object (e) in the external heap memory 2 being the memory area to be released, the object (e) is moved as the target object to the external heap memory “m” being the memory area not to be released to correct the reference fe to a new reference N-fe.
[0055] FIG. 9B shows that the external heap memories 1 to m are registered as the external heap memory IDs in the external heap memory release reservation management table 22 based on the state in FIG. 8A (for the sake of simplicity of description, 1 to m are taken as serial numbers but may be discontinuous), and the external heap memories 1 to m are collected and released as the memory area to be released. In the figure, the external heap memories 1 to m being the memory area to be released are indicated by the broken line. Since the external heap memories 1 to m are released based on the state in FIG. 8A , the objects (a) to (d) and the references between their objects are the same as those in FIG. 8B . For the reference fe of the object (f) to the object (e) described in FIG. 9A , since the external heap memory 2 where the object (e) exists and the external heap memory “m” where the object (f) exists are the memory areas to be released, the objects are not moved and the reference is not corrected.
[0056] As can be seen from difference (reference fe) between FIGS. 9A and 9B , collecting some external heap memories reduces the number of objects in relation to a check on the reference of the object in the memory area not to be released to the object in the memory area to be released, the move of the object and the correction of the reference. As the system becomes large in size, the number of the external heap memories and capacity thereof are increased and the number of objects and references are also increased, enhancing the effect of reducing process time at the time of releasing the external heap memories.
[0057] When this idea is further developed, collectively releasing the external heap memory 30 after the execution of the Java program is completed is to minimize the process time. This loses the advantage that the memory area is dynamically secured while the Java program is executed and dynamically released to be reused after the use of the memory area is completed and the use efficiency of the memory area is increased to resultantly eliminate the need for increasing the capacity of the memory implemented in the computer 100 . In addition, the computer is continuously operated, so that timing of releasing the external heap memory 30 cannot be determined depending on applications. Therefore, it is necessary to balance the trade-off between the memory capacity of the external heap memory and the process time required for releasing the external heap memory. The trade-off depends on the number of objects and references, which depends on an application executing the Java program 20 .
[0058] There is described “certain moment” which means the timing of releasing the external heap memory 30 and is required for balancing the trade-off between the memory capacity of the external heap memory and the process time required for releasing the external heap memory. In other words, the term “certain moment” refers to execution timing of the external heap memory releasing section 17 . As described below, some methods of determining execution timing are selected based on applications.
[0059] (1) “Certain moment” is taken as the time of occurrence of GC. When the amount of use of the Java heap 21 exceeds a certain threshold, the Java virtual machine 10 operates the garbage collector 13 to execute GC on the Java heap 21 . The occurrence of GC is used as a target for timing of releasing the external heap memory 30 . For this reason, when the amount of use of the Java heap 21 exceeds a certain threshold, the Java virtual machine 10 performs control so as to execute the external heap memory releasing section 17 ( FIG. 7 ) and then execute the garbage collector 13 . The check on the reference of the memory area not to be released to the memory area to be released in the step 190 of the external heap memory releasing routine 19 ( FIG. 3 ) at the time of executing the external heap memory releasing section 17 is the same as the process following the reference of the objects in GC, so that the process of a part (check on reference) of the garbage collector 13 can be compensated with an external heap memory releasing process. This enables reduction of the sum of stoppage time for GC and stoppage time for external heap memory release (related to the execution of the external heap memory releasing routine 19 ).
[0060] (2) “Certain moment” is taken as the time of the number of external heap memory release reservations exceeding a certain threshold. With reference to FIG. 6 , there has been shown that the external heap memory release reservation section 18 starts execution in response to the release instruction 203 of the external heap memory. An external heap memory release timing determination routine is provided on the Java virtual machine 10 (not shown in FIG. 1 ) as a process for controlling the start of executing the external heap memory release reservation section 18 . FIG. 10A is a process flow chart illustrating an example of the external heap memory release timing determination routine. As is the case with FIG. 6 , the external heap memory release reservation section 18 is first executed in response to the release instruction 203 of the external heap memory. A check is made whether the number of external heap memories reserved to be released which are registered in the external heap memory release reservation management table 22 exceeds a predetermined threshold along with the execution of the external heap memory release reservation section 18 (step 140 ). If yes (step 142 ), the external heap memory releasing section 17 is executed. The predetermined threshold is determined based on applications or a rule of thumb in design. Incidentally, if the external heap memory ID is registered in the external heap memory release reservation management table 22 in step 182 of the external heap memory release reservation section 18 , the step 140 and the subsequent steps are not needed, but are optional design items which may be executed.
[0061] The use efficiency of the external heap memory 30 depends on the predetermined threshold determined based on applications or a rule of thumb in design, which is one method of balancing the trade-off between the use efficiency of the external heap memory 30 and the process time required for releasing the external heap memory.
[0062] (3) “Certain moment” is taken as the time when the total heap size (memory capacity) of the external heap memories reserved to be released exceeds a certain threshold. FIG. 10B is another example of the external heap memory release timing determination routine. The example in FIG. 10B is different from the example in FIG. 10A in that a determination is made whether the total of the external heap memory size (memory capacity) reserved to be released which is registered in the external heap memory release reservation management table 22 exceeds a predetermined threshold in steps 144 and 146 .
[0063] It is enabled to balance the trade-off between the use efficiency of the external heap memory 30 and the process time required for releasing the external heap memory even with a total heap size (memory capacity) as reference.
[0064] Although there are described above the three methods (1) to (3) of determining the predetermined timing (certain moment) in which the external heap memory is released, the external heap memory releasing section 17 may be periodically executed using a periodic timer, or, if the Java program 20 is a program for processing transaction, the external heap memory releasing section 17 may be executed depending on the number of the processed transactions or the number of times that data is committed to the database required for transaction process. Alternatively, a combination of these determination methods may be used.
[0065] According to the present embodiment, one or more external heap memories reserved to be released are collectively released at the predetermined timing, so that the process time required for releasing the external heap memory can be reduced while the use efficiency of the memory allocated to the external heap memory is being maintained.
Second Embodiment
[0066] FIG. 11 is a block diagram illustrating a configuration of a computer 101 according to the present embodiment. The configuration of the computer 101 is the same as that of the computer 100 except for an external heap memory generating section 45 , an external heap memory releasing section 47 and an external heap memory release reservation section 48 included in the Java virtual machine (Java VM) 10 and an external heap memory release reservation management table 23 and an external heap memory generating management table 24 on the Java heap 21 . Incidentally, the external heap memory generating management table 24 may be provided on the external heap memory 30 . The second embodiment is different from the first embodiment in that external heap memories are grouped and managed. The difference is described below.
[0067] FIG. 12 is a table illustrating an example of the external heap memory release reservation management table 23 . In this example, an external heap memory ID and group ID of the group to which external heap memory ID belongs are associated with each line and registered. FIG. 12 shows that, for example, an external heap memory in which the external heap memory ID is EH 1 belongs to a group in which the group ID is G 1 .
[0068] The group ID of the group to which each external heap memory belongs is determined as a design item and written in the external heap memory generating statement of the Java program 20 . For example, a group ID is provided by plural sub-programs forming an application program.
[0069] FIG. 13 is a table illustrating an example of the external heap memory generating management table 24 . The external heap memory generating management table 24 associates the group ID with the number of the external heap memories grouped and generated by the group ID (referred to as the number of generation) and stores them therein. As illustrated in the figure, the figure shows that twelve external heap memories in which the group ID is grouped to G- 1 are generated.
[0070] FIG. 14 is a process flow chart of the external heap memory generating section 45 . A check is made whether the group ID of the external heap memory to be generated is registered in the external heap memory generating management table 24 (step 450 ). If not (step 452 ), the group ID of the external heap memory to be generated is registered in the external heap memory generating management table 24 , the number of generation corresponding the group ID is taken as one (step 454 ). If the group ID is registered therein (step 452 ), the number of generation corresponding the group ID of the external heap memory to be generated is incremented by one (+1) (step 456 ).
[0071] FIG. 15 is a process flow chart illustrating an example of the external heap memory release timing determination routine executed by the Java virtual machine 10 . In the figure, steps 500 to 504 are processes of the external heap memory release reservation section 48 and steps 510 to 514 are processes of the external heap memory releasing section 47 .
[0072] A check is made whether the external heap memory ID of the external heap memory instructed to be released is registered in the external heap memory release reservation management table 23 in response to instructions for the release of the external heap memory (step 500 ). If yes (step 502 ), the process is ended. If no (step 502 ), the external heap memory ID reserving release and its group ID are registered in the external heap memory release reservation management table 23 (step 504 ).
[0073] There are checked the number of the registered group IDs registered in the external heap memory release reservation management table 23 (the number of release reservation external heap memories) and the number of the generated external heap memories corresponding to the group IDs in the external heap memory generating management table 24 (step 506 ). If the number of release reservation external heap memories is less than the number of the generated external heap memories (step 508 ), the process is ended. If the number of release reservation external heap memories is not less than the number of the generated external heap memories (step 508 ), which means that all external heap memories belonging to the group and generated are reserved to be released, the external heap memories having the group IDs and registered in the external heap memory release reservation management table 23 are collected as the memory area to be released (step 510 ). The external heap memory releasing routine 19 is executed to release the memory area to be released in which the external heap memories are collected. The external heap memory ID taken as the memory area to be released is deleted from the external heap memory release reservation management table 23 (step 512 ), and the group ID taken as the memory area to be released is deleted from the external heap memory generating management table 24 (step 514 ).
[0074] According to the present embodiment, since one or more grouped external heap memories are collectively released at the timing in which all of the generated external heap memories are regarded as being reserved to be released, the process time required for releasing the external heap memory can be reduced while the use efficiency of the memory allocated to the external heap memory is maintained.
[0075] Incidentally, the first embodiment is applicable to a group with an external heap memory in the present embodiment. Conversely, the first embodiment is implemented in a case where the number of groups in the external heap memory is one in the present embodiment. Consequently, the release timing described in the first embodiment as well as the release timing in the present embodiment can be used as the release timing of the external heap memory of a group in the present embodiment. It is advantageous in program design to apply the above double timings to a case where the number of external heap memories in a group and memory capacity are obliged to be increased.
[0076] According to the embodiments described above, it is possible to shorten the process time required for releasing dynamically secured memory area (external heap memory).
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The present invention provides a memory management method, including the steps of: securing a memory area by a program executed by a computer; storing an object in the memory area in accordance with the execution of the program; bringing the memory area into a release reservation state in accordance with the program instructing the memory area to be released; moving the object to a memory area not to be released while another object in the memory area not to be released and not to be brought into the release reservation state refers to the object in the memory area to be released including the memory area to be brought into the release reservation state; and releasing the memory area to be released.
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BACKGROUND OF THE INVENTION
1. Field of Invention.
This invention relates to improvements in methods and means for cleaning radiators and more particularly, but not by way of limitation, to an ultrasonic method and means for cleaning radiators.
2. Discription of Prior Disclosures.
Radiators of all sizes are in wide spread use today in many areas such as the conventional vehicle or truck radiators, industrial radiators and the like. During utilization of these radiators, the header members which normally support the outer ends of the heat exchange tubes of the radiator, frequently become encrusted with residue material from the fluids normally utilized in connection with the radiator. This accumulation of residue and the like hinders the efficient operations of the radiator and, as a result, it is common practice to clean the radiators for improving the operational performance thereof. A method for using ultrasonic transducers is described in U.S. Pat. No. 4,372,787 entitled "Method For Ultrasonic Cleaning Of Radiators", issued Feb. 8, 1983. The method described in that patent is being widely used, however, it is not without certain drawbacks. For example, the ultrasonic transducers are fixed and there is the problem of accumulation of sludge on the transducers.
SUMMARY OF THE INVENTION
The present invention contemplates a novel method and means for quickly and efficiently cleaning radiators in a manner for overcoming the foregoing disadvantages. The novel invention comprises an ultrasonic cleaning method which comprises a suitable housing which is preferably rectangular in shape. Along the bottom of the housing there is provided a sludge pit e.g., 4 inches deep and 7 inches wide for collecting sludge. A carriage supporting an ultrasonic transducer is movable above the sludge pit and along the bottom of the housing or tank. There is a radiator support rack above the ultrasonic transducer. Adjustable means are provided to control the length or width of movement of the transducer along the bottom of the tank. If only one radiator is being cleaned, the movement would be controlled by the width of the radiator. A suitable cleaning liquid, which is a technically compounded blend of the proper chemicals for performing the cleaning operations, is placed in the housing and surrounds the transducer means and the lower end of the radiator when placed in the tank. When cleaning the radiator a heating means is provided for heating the cleaning liquid to a preselected temperature. A (or radiators) radiator is then lowered, header down, onto the radiator rack. Stop means are adjusted to give the transducer means its desired or selected travel path. Then the transducer means is activated by the ultrasonic generator means for converting electrical energy into mechanical energy. At the same time the motor for moving the transducer means is activated and together with the stops and control means causes the transducer means to travel back and forth between the two stop means. As the sludge is cleaned from the radiator, it falls downwardly and a part of it may fall on the transducer means. However, inasmuch as the transducer is being moved while in the activated state, the vibrations causes the sludge to fall off the trailing end and into the sludge pit.
In another embodiment, two transducer means are involved. One is fixed near one end of the housing or tank in a vertical position and a second one is mounted on a traveling rack, also in a vertical position. The radiator to be cleaned is mounted on a rack between the two vertical transducer means. The movable transducer means is, of course, adjustable to accomodate different size radiators.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of an ultrasonic radiator cleaning apparatus embodying the invention.
FIG. 2 is plan view taken along the line 2--2 of FIG. 1 and is an elevation view.
FIG. 3 is a view taken along the line 3--3 of FIG. 2.
FIG. 4 is a view taken along the line 4--4 of FIG. 3.
FIG. 5 is a view taken along the line 5--5 of FIG. 4.
FIG. 6 is a side elevational view of a different embodiment showing two vertically erected ultrasonic transducers, one fixed and the other movable.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Attention is now directed to the drawings and particularly FIGS. 1 and 2. Shown therein is an ultrasonic radiator cleaning apparatus. This includes a double-wall tank or housing having an outer wall 14 and inner wall 16 with insulation 22 therebetween. The housing can be mounted on wheels 12 for easy movement from one location to another. The tank has a bottom plate 18 and a bottom 20. As can be seen in the drawings and especially FIG. 1, the configuration of the housing is preferably rectangular. As shown in FIG. 3, there is a sludge pit 25 which runs the length of the housing as shown in FIG. 1.
Means will now be discussed for moving the transducer 24 from one position to another. The transducer means 24 is activated by an ultrasonic generator means (not shown) for converting electrical energy into mechanical energy in a known manner. The transducer means 24 is preferably an immersible transducer of the type manufactured and sold by Branson Cleaning Equipment Company, Parrott Drive, Shelton, Conn. The ultra-sonic generator can be of a type also manufactured and sold by Branson Cleaning Equipment Company. The transducer means 24 is mounted on a carriage 26 having rollers 28 which move along track or path 30.
As shown in FIG. 3, a drive rod 32 is connected to carriage 26. The upper end of drive rod 32 is secured to traveling block 38 which has internal threads which are screwed onto the threads of lead screw 36 which is connected between reversable motor 34 and the end support 64.
A line 46 connects the ultrasonic generator to the transducer means 24 in a known manner. The upright portion of line 46 and the upright portion of drive rod 32 are in housing 52.
As shown in FIG. 2, transducer means 24 can be in the position shown in the solid lines on the left or it can be moved to a second advanced position indicated by dashed lines 22A and 52A and alternatively moved in different directions between the two portions.
A reversable motor 34 rotates screw 36 and in doing so, causes traveling block 38 to move either left or right and carry with it the drive rod 32 which drives the carriage 26 which moves the transducer means 24 alternately from one position to another. There are means provided to determine the travel of the transducer means. This includes a first limiting stop 40 and a second limiting stop 42 mounted on a rod 44 which is supported from end members 64 from the housing or tank of the cleaning portion of the device. These stops 40 and 42 can be moved to any selected position. A toggle switch 48 is provided on traveling block 38. When the switch contacts one of the stops, it moved to a second position. This second position causes the motor 34 to reverse, thus driving the screw 36 in the other direction. This, in turn, moves the traveling block 38, carriage 26 and transducer means 24 in the opposite direction. It continues moving in this opposite direction until it again encounters the second limiting stop means 42, at which time the toggle switch 48 is again switched to another position which reverses the motor 34. Leads 66, shown in FIG. 4, go from the traveling block 38 to the motor control panel 50. The motor control panel 50 then directs the motor 34 to reverse itself. Means are provided to mount the radiators above the movable transducer means. This includes a removable rack 55 which includes end support members 58 and two longitudinal support bars 56 which run the entire length of the tank and cross-members 54 upon which the radiator sits. As shown in FIG. 2 and indicated by the broken lines there is a first radiator 60 and a second radiator 62 sitting on the cross-members 54.
In operation I start with the rack 55 mounted above the transducer means 24 as shown in FIG. 2. I then fill the tank 10 with a cleaning fluid to the desired level and put in radiators 60 and 62 or whatever number is possible. I then apply heat using means not shown in well known manner to heat the cleaning fluids to a selected temperature. I then activate transducer means 24 so that it agitates the cleaning liquid surrounding the radiator portion emerged therein. At the same time, I activate motor 34 and it causes the carriage 26 to move to the right to the position shown at 22A which is under second radiator 62. All the time the cleaning liquid is being agitated that portion of the radiator emerged in the cleaning fluid is quickly and efficiently cleaned of all residue or the like which is deposited on the radiator. The accumulated deposits are removed even from hidden crevices and the like resulting in a substantially new looking radiator header upon removal of the radiator from the cleaning liquid 51. During this time, the carriage moves to the right until it gets to the position indicated by upright members 52A and dashed line where the limit switch 48 encounters limiting stop 42. This sends a signal to control panel 50 which reverses the direction of motor 34 and causes the transducer means 24 to be carried back to the original starting position as indicated in FIG. 2. There the toggle switch 48 again encounters another limiting stop 40 which again reverses the motor 24 to drive it back in the opposite direction. This travel in alternate directions continues during the cleaning operations. The sludge and deposits from the radiator drops downwardly and will eventually accumulate in the sludge pit. Some of the sludge falls on top of the transducer means 24. However, as it is moving and is vibrating rather highly, the sludge will fall off the trailing end of the transducer means and fall into the sludge pit. The sludge pit is typically about 4" deep and 7" wide which holds a large quantity of sludge. It has been found that it will need to be cleaned only about once every eight months or so. I have what may be called a self-cleaning transducer means. (Cleaning fluid can be removed through outlet port means not shown.) I have built one of these cleaning devices as illustrated in FIGS. 1, 2, 3, 4 and 5. The transducer is about 20" square and the tank was sufficiently large so that I can place two large truck radiators in there easily and up to 8 or 9 automobile radiator headers in there at one time. By moving the transducer means as I have indicated, I can clean all of these radiators at one time in about 10 minutes with only one transducer means. Inasmuch as I keep the sludge off the top, I have no arcing over problem.
Attention is next directed to FIG. 6 which shows another embodiment of my invention. Shown thereon is a first fixed transducer 70 and a second movable transducer 72. A carriage 74 supports upright transducer means 72 and moves along a track means 76 by a support rod not shown similar to drive rod 32 shown in FIG. 3. The travel of carriage 74 is determined by the positions of first stop 78 and second stop 80 which is mounted on a rod 82. A radiator 84 is mounted on a radiator rack 86 which may be similar to rack 55 of FIG. 2. If one wishes, one may put in the radiator 84 and then position the movable transducer means 72 to be in a position adjacent the radiator header of radiator 84. Then one can deactivate the motor 36 and perform the cleaning operations with the two transducers 70 and 72 in the positions shown in FIG. 6. One can also cause transducer means 72 to alternately travel between stops 78 and 80.
While this invention has been described with a certain degree of particularity, it is manifest than many changes may be made in the details of construction in the arrangement of components without departing from the spirit and scope of the disclosure. It is understood that the invention is not limited to the embodiment set forth herein for purposes of exemplification, but is limited only by the scope of the attached claim or claims, including the full range of equivalency to which each element thereof is entitled.
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A radiator having a header is cleaned by at least partially immersing the radiator in a cleaning liquid and then applying ultrasonic energy to the liquid. The cleaning liquid is held in a container which has a sludge pit along the bottom thereof. An ultrasonic transducer is mounted on a carriage and is movable above the sludge pit. A rack is provided above the movable transducer for holding or supporting radiators. The movement of the ultrasonic transducer is controlled in accordance with the width of the radiator being cleaned.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This is a divisional patent application of U.S. patent application Ser. No. 12/754,712 filed Apr. 6, 2010, which is hereby incorporated by reference in its entirety.
BACKGROUND OF THE INVENTION
Solar cells are typically manufactured using the same processes used for other semiconductor devices, often using silicon as the substrate material. A semiconductor solar cell is a device having an in-built electric field that separates the charge carriers generated through the absorption of photons in the semiconductor material. This electric-field is typically created through the formation of a p-n junction (diode) which is created by differential doping of the semiconductor material. Doping a part of the semiconductor substrate (e.g. surface region) with impurities of opposite polarity forms a p-n junction that may be used as a photovoltaic device converting light into electricity.
FIG. 1 shows a cross section of a representative substrate 100 , comprising a solar cell. Photons 101 enter the solar cell 100 through the top surface 105 , as signified by the arrows. These photons pass through an anti-reflective coating 110 , designed to maximize the number of photons that penetrate the substrate 100 and minimize those that are reflected away from the substrate.
Internally, the substrate 100 is formed so as to have a p-n junction 120 . This junction is shown as being substantially parallel to the top surface 105 of the substrate 100 although there are other implementations where the junction may not be parallel to the surface. The solar cell is fabricated such that the photons enter the substrate through the n-doped region, also known as the emitter 130 . While this disclosure describes p-type bases and n-type emitters, n-type bases and p-type emitters can also be used to produce solar cells and are within the scope of the disclosure. The photons with sufficient energy (above the bandgap of the semiconductor) are able to promote an electron within the semiconductor material's valence band to the conduction band. Associated with this free electron is a corresponding positively charged hole in the valence band. In order to generate a photocurrent that can drive an external load, these electron-hole (e-h) pairs need to be separated. This is done through the built-in electric field at the p-n junction. Thus any e-h pairs that are generated in the depletion region of the p-n junction get separated, as are any other minority carriers that diffuse to the depletion region of the device. Since a majority of the incident photons are absorbed in near surface regions of the device, the minority carriers generated in the emitter need to diffuse across the depth of the emitter to reach the depletion region and get swept across to the other side. Thus to maximize the collection of photo-generated current and minimize the chances of carrier recombination in the emitter, it is preferable to have the emitter region 130 be very shallow.
Some photons pass through the emitter region 130 and enter the base 140 . These photons can then excite electrons within the base 140 , which are free to move into the emitter region 130 , while the associated holes remain in the base 140 . As a result of the charge separation caused by the presence of this p-n junction, the extra carriers (electrons and holes) generated by the photons can then be used to drive an external load to complete the circuit.
By externally connecting the emitter region 130 to the base 140 through an external load, it is possible to conduct current and therefore provide power. To achieve this, contacts 150 , typically metallic, are placed on the outer surface of the emitter region 130 and the base 140 . Since the base 140 does not receive the photons directly, typically its contact 150 b is placed along the entire outer surface. In contrast, the outer surface of the emitter region 130 receives photons and therefore cannot be completely covered with contacts. However, if the electrons have to travel great distances to the contact, the series resistance of the cell increases, which lowers the power output. In an attempt to balance these two considerations; the distance that the free electrons must travel to the contact, and the amount of exposed emitter surface 160 ; most applications use contacts 150 a that are in the form of fingers. FIG. 2 shows a top view of the solar cell of FIG. 1 . The contacts are typically formed so as to be relatively thin, while extending the width of the solar cell. In this way, free electrons need not travel great distances, but much of the outer surface of the emitter is exposed to the photons. Typical contact fingers 150 a on the front side of the wafer are between 40 μm and 200 μm. These fingers 150 a are typically spaced between 2-3 mm apart from one another. While these dimensions are typical, other dimensions are possible and contemplated herein.
A further enhancement to solar cells is the addition of heavily doped substrate contact regions. FIG. 3 shows a cross section of this enhanced solar cell. The cell is as described above in connection with FIG. 1 , but includes heavily n-doped contact regions 170 . These heavily doped contact regions 170 correspond to the areas where the metallic fingers 150 a will be affixed to the substrate 100 . The introduction of these heavily doped contact regions 170 allows much better contact between the substrate 100 and the metallic fingers 150 a and significantly lowers the series resistance of the cell. This pattern of including heavily doped regions on the surface of the substrate is commonly referred to as selective emitter design. These heavily doped regions may be created by implanting ions in these regions. Thus, the terms “implanted region” and “doped region” may be used interchangeably throughout this disclosure.
A selective emitter design for a solar cell also has the advantage of higher efficiency cells due to reduced minority carrier losses through recombination due to lower dopant/impurity dose in the exposed regions of the emitter layer. The higher doping under the contact regions provides a field that collects the majority carriers generated in the emitter and repels the excess minority carriers back toward the p-n junction.
In addition to selective emitter designs, other solar cell designs require patterned doping. Another example is the interdigitated back contact (IBC) cell, which requires offset patterns of n-type and p-type dopants on the back side of the cell.
Such structures are typically made using traditional lithography (or hard masks) and thermal diffusion. An alternative is to use implantation in conjunction with a traditional lithographic mask, which can then be removed easily before dopant activation. Yet another alternative is to use a shadow mask or stencil mask in the implanter to define the highly doped areas for the contacts. All of these techniques utilize a fixed masking layer (either directly on the substrate or in the beamline).
All of these alternatives have significant drawbacks. For example, the processes enumerated above all contain multiple process steps. This causes the cost of the manufacturing process to be prohibitive and may increase wafer breakage rates. These options also suffer from the limitations associated with the special handling of solar wafers, such as aligning the mask with the substrate and the cross contamination with materials that are dispersed from the mask during ion implantation.
FIG. 4 shows the typical processing steps required to create patterned doping using a shadow or proximity mask. In step 400 , the solar cell is designed. This includes creating the dopant patterns and metallization layers. Based on the desired dopant patterns, a matching proximity mask is design (step 410 ). Pre-implant manufacturing processes are performed (step 420 ). For example, in some embodiments, the wafers arrive at the factory as raw sawn wafers. The first step on entering the factory is inspection. The wafers are checked for cracks, resistivity & size. After that, the wafer may go into a series of wet benches. The first wet step may be to remove the saw damage from the wafers. This is typically a 10 um etch from both sides of the wafer to remove the micro-cracks formed by sawing. The next step may be an anisotropic etch that forms the random pyramid texturing on the wafer surfaces. This may help light trapping. The pre-processed wafer is then physically aligned within the ion implanter (step 430 ). This step also includes precise positioning of the proximity mask. The ion implant of the wafer is then performed, with the proximity mask in place (step 440 ). After the wafer has been implanted, various post-processing steps, such as anneal and SiN x deposition, are performed on it (step 450 ). The wafer is aligned with respect to a reference edge or indicia prior to application of the metallization pattern (step 460 ). Finally, the metal layer is applied to the wafer (step 470 ). In the case of a solar cell, the metal layer is typically applied atop the heavily doped regions of the wafer (i.e. those regions implanted during implantation step 440 ). The final step of fabricating a solar cell is the firing step, where the printed metal is driven in to the cell to make the actual contacts.
However, there are many known problems with the use of a proximity mask, especially in solar cell applications. FIG. 5 shows a wafer 501 being implanted by an ion beam 502 , through a proximity mask 503 . The mask 503 has a plurality of slots, where each is separated from the adjacent slots by a slot-location spacing 500 . The first of these slots is offset from an indicia 504 by a distance 510 . The mask 503 has a certain thickness (t) and is offset vertically above the wafer 501 by a gap. As shown in FIG. 5 , the ion beam 502 may not be completely orthogonal to the wafer 501 . The beam angle (θ), the mask thickness (t) and the gap from the mask 503 to the wafer 501 all have an effect on the location of the implanted regions 505 . For example, the greater the gap between the mask 503 and the wafer 501 , the more lateral displacement between the desired implant region and the actual implant region 505 . Similarly, a thicker mask will tend to reduce the overall width of the implanted region 505 , to a width less than the slot width 520 . In addition, the use of a proximity mask 503 requires multiple alignment steps. First, the mask 503 must be aligned with the wafer 501 . Subsequently, the metal layer has to be aligned as well. FIG. 5 shows the metal 506 applied in the desired location. However, the variability of the steps creates a situation where the metal 506 is not applied over the center of the implanted region 505 . The offset from the implanted region 505 to the metal 506 is referred to as feature error, and is shown as being positive on the left side of the implanted region 505 and negative on the right side of the implanted region 505 .
In summary, proximity masks can cause the following problems:
Variability of desired feature placement due to machining tolerances; Variability of feature placement due to incident ion beam angle accuracy (resulting from mask gap or ion beam repeatability); Variability of feature placement due to wafer positioning; Variability of feature placement due to wafer size tolerances; and Tight alignment requirement for the application of metallization.
To accommodate these system tolerances, often the implanted region 505 is larger in size than optimally desired. In the case of selective emitter cells, the oversized implanted regions 505 expand into the emitter region, thereby reducing the surface area of the emitter region. This results in a lower cell efficiency.
FIGS. 6A-C show the impact of these wider implanted regions on a solar cell 600 . FIG. 6A shows a typically geometry of a solar cell with busbars 605 and metal fingers 610 . FIG. 6B is an expanded view of a portion of FIG. 6A , showing the metal fingers 610 , busbar 605 and implanted regions 615 in more detail. To insure that the metal fingers 610 and busbars 605 do not cover the emitter region 620 , the implanted regions 615 are created with a greater width than desired. Note that any area which is implanted and not covered by metal is less efficient in capturing solar energy.
FIG. 6C shows a section view of an existing process. The metal finger 610 is located at the leftmost position, based on known tolerances. To insure that the metal finger 610 does not contact the emitter region 620 , the implanted region 615 is made wide enough such that in all scenarios, with maximum tolerances and minimum widths, the metal finger is covering only implanted region 615 . However, the exposed portions of implanted region 615 are less efficient in capturing solar energy.
In addition, high precision alignment systems and the above described production method is inherently costly. Consequently, efforts have been made to reduce the cost and effort required to dope a pattern onto a solar cell.
Therefore, there exists a need to produce solar cells where the number and complexity of the process steps is reduced, while maintaining adequate accuracy so that subsequent process steps are correctly positioned. While applicable to solar cells, the techniques described herein are applicable to other doping applications.
SUMMARY OF THE INVENTION
An improved, lower cost method of processing substrates, such as to create solar cells, is disclosed. The doped regions are created on the substrate, such as using a mask. In other embodiments, the doped regions are created without the use of lithography or masks. After the implantation is complete, visual recognition is used to determine the exact region that was implanted. This information can then be used by subsequent process steps to crate a suitable metallization layer and provide alignment information. These techniques can also be used in other ion implanter applications.
In another aspect, a dot pattern selective emitter is created and imaging is used to determine the appropriate metallization layer.
BRIEF DESCRIPTION OF THE FIGURES
FIG. 1 shows a cross section of a solar cell of the prior art;
FIG. 2 shows a top view of the solar cell of FIG. 1 ;
FIG. 3 shows a cross section of a solar cell using selective emitter design;
FIG. 4 shows a production flowchart of the prior art;
FIG. 5 shows the sources of inaccuracy with a proximity mask;
FIGS. 6A-C show the relative widths and positions of implanted regions and metal layers according to the prior art;
FIG. 7A is a flowchart of the manufacturing process in accordance with one embodiment;
FIG. 7B is a flowchart of the manufacturing process in accordance with a second embodiment;
FIG. 8 is an expanded view of an implanted wafer;
FIG. 9 is the wafer of FIG. 8 with a metal layer applied;
FIG. 10 is a dot collector grid for a solar cell; and
FIG. 11 is the solar cell of FIG. 10 with metal linkages applied.
DETAILED DESCRIPTION OF THE INVENTION
As described above, current manufacturing processes require precise alignment of implanted regions on the solar cell with the metallization layer. By eliminating this requirement for precision, the manufacturing process can be simplified and made more cost effective.
To reduce this complexity, an image, such as a high resolution image, of the wafer is obtained after the wafer has been implanted. This image may be taken at various points in the process. For example, the image may be taken immediately after ion implantation, after activation (wither with or without oxidation), or after passivation with SiN x . The point in the process at which the image is taken may determine how clearly the implanted regions can be detected. The implanted regions can be differentiated from emitter regions on a high resolution image. This image is then processed to determine the position and sizes of the implanted features. Based on this processing, a metallization layer can be prepared. This metallization layer, which corresponds to the thickness and position of the implanted regions, is then applied to the wafer in a subsequent processing step. In this way, the efficiency of the solar cell is increased, as the emitter region can be maximized.
FIG. 7A shows a flowchart of one embodiment. Similar to the current processes, the parametric solar cell design is completed (step 700 ). In some embodiments, a metallization pattern is also generated at this time. The design of a matching proximity mask, based on the solar cell pattern is also created (step 705 ). These two components are used in pre-implant manufacturing processes (step 710 ). The wafer is then aligned in the ion implanter (step 715 ). This alignment need not be as precise as the alignment in the prior art (step 430 ). In the prior art, the subsequent processing steps were all based on alignment to known indicia or fiducials. Therefore, it was critical that all processes be tightly aligned to these indicia, to minimize variation. However, in the present embodiment, the subsequent steps are based on the indicia and the high-resolution image of the implanted regions. Thus, any variation in position of the implanted region with respect to the indicia or fiducials can be captured and compensated for later in the process.
In step 720 , the wafer is implanted by the ion implanter with the proximity mask located in front of the wafer. This implantation step creates the implanted regions onto which the metal is to be applied. It should be noted that other methods of selectively implanting the wafer may also be used. For example, other methods such as sheath engineering, modulation of the ion beam, and movement of the workpiece during ion implantation, can also be used to create a implant pattern in the wafer.
After implantation, an image, such as a high-resolution image, of the implanted wafer is obtained (step 725 ). This high resolution image can be obtained by any suitable means, including a CCD camera, electron beam (SEM), Auger Emission spectroscopy, an infrared camera, a photodiode, secondary ion mass spectroscopy (SIMS), surface contact resistance, photoluminence, a laser (such as Thermawave) or other systems. Thus, the term “image” is used to describe the pattern which indicates the relative placement of the implanted regions on the wafer, regardless of the means used to generate that pattern.
The high resolution image is then processed to determine the edges of the implanted regions, and to determine the overall pattern of the implanted region (step 730 ). The high-resolution image may be associated with the wafer, such as through an identifier and other characterizing mark. The image is processed by a computing device or controller. The controller has a processing unit, capable of executing instructions, and a memory device. The memory device typically contains computer readable and executable instructions, as well as other information. The executable instructions comprise the metallization algorithm. The memory may contain both volatile and non-volatile portions. The controller may include other functions, such as input/output ports, sensors, and other devices.
This information is then supplied to a metallization algorithm to define the specific shape of the metal pattern for this particular wafer. Such an algorithm is typically executed on a controller or computing device. The algorithm may be executed on the same controller as used for the image processing. In other embodiments, a different controller is utilized for the metallization algorithm.
The resulting data may be stored in a database, associated with the wafer identification. In this way, subsequent process steps can query the database to determine the appropriate measurements and setting to be used with a particular wafer.
After the high resolution image has been taken, the wafer is then subjected to post-implant processes (step 735 ).
The metallization algorithm determines the specific shape of the metal pattern. In some embodiments, the metal pattern is determined to altering the parameters of a pre-existing pattern (step 745 ). In this embodiment, the algorithm utilizes the predefined metallization parameters (step 740 ) as a initial draft of the metal pattern. Based on the image processing, the algorithm may increase or decrease certain predetermined parameters. For example, the width of the metal layer may be altered based on the actual measured thickness of the implanted regions. Similarly, metal-metal location 560 (see FIG. 5 ) may be altered based on actual placement of the implanted regions.
In other embodiments, the metallization algorithm creates a new metal pattern by offsetting the edges of the implant region (step 750 ). FIG. 8 shows an expanded view of a portion of the top surface of a solar cell, after the wafer has been implanted (step 720 ). At this point in the process, implanted regions 815 have been created amid emitter region 820 . The high resolution image determines the outline of the implanted regions 815 and creates a metallization layer, based on the actual size and shape of the implanted regions 815 . In some embodiments, the metal layer is made slightly thinner than the underlying implanted regions 815 to allow for tolerances and inaccuracies in the alignment process. A metal layer, such as that shown in FIG. 9 , is then created by the algorithm, and is subsequently applied.
In other embodiments, as shown in FIG. 7B , the metal layer is deposited through the use of inkjet printing technology. Ink jet printers eject modulated droplets of liquid through an array of nozzles onto a surface, such as a surface of a solar cell 100 . The nozzles may be controlled by, for example, a piezo electric motor or other methods known to those skilled in the art. The surface may be scanned across this array of nozzles, though the array of nozzles may be scanned as well. The pattern used by the inkjet printer can be created based on the high resolution image taken in step 725 . Based on the image, a metallization pattern for the inkjet printer can be created, as shown in step 770 . In this way, the inkjet nozzles can deposit metal exactly on top of the implanted regions, as shown in FIG. 9 .
Regardless of the method used, the metal layers are typically applied later in the production process. It may therefore be necessary to re-align the wafer to its initial position (from step 720 ). To do this, the wafer may be uniquely identified, such as by using position or characterizing marks on the wafer. Returning to FIG. 7A-B , a second image is taken of the wafer (step 755 ) to obtain its position. In some embodiments, its position is measured relative to a fixed indicia or fiducial. The wafer is then aligned to the indicia to return it to the exact location that it was in during the initial implant (step 760 ). These steps may be performed by a positioning system comprising an optical sensor and a motion control stage. Having determined and adjusted the position of the wafer, the wafer is then printed with a metal paste using a suitable method (step 765 ). The most commonly used method is screen printing. Ink jet printing, as shown in FIG. 7B , may also be used a non-contact printing method, which improves wafer yield due to less breakage, as shown in step 775 . Aerosol sprays may also be used. FIG. 9 shows the wafer after the metal layer 805 , 801 have been applied. Note that the ratio of the width of the metal layer to the width of the implanted region is much greater than was possible in the prior art (see FIG. 6B ). In the prior art, implanted regions having a width of 500 μm are used in conjunction with 110 μm metal lines. This is a ratio of about 20%. Using present printing methods, the placement of the metal line may be controlled to about 15 μm. Thus, for a 110 μm metal line, the implanted region only needs to be about 140 μm to guarantee that the metal line is applied atop the implanted region. Similarly for a 40 μm metal line, the implanted region only needs to be about 70 μm. The ratio of these widths varies with the desired metal line width and can be greater than 50%. In the case of 110 μm metal lines, this ratio can be greater than 75%.
The tolerance of the placement of the metal lines limits the ratio that can be achieved. As described above, currently, the placement of the metal lines can be controlled to about 15 μm. Thus, the width of the metal line, added to twice this tolerance establishes the minimum width for the implanted region. Thus, as the placement tolerances are reduced, the ratio of metal line width to implanted region width can be increased.
Although this process has been described in conjunction with selective emitter designs, the disclosure is not limited to this embodiment. As described above, interdigitated back contact (IBC) solar cells contain heavier patterned implanted regions on the back side of the wafer. The above technique could be used to determine the exact location, width and shape of the p+ and n+ doped regions. Based on the images, metal layers for each can be generated using the techniques described above (steps 745 and 750 ). These metal patterns can then be applied to the back side of the IBC solar cell.
In addition, this process has been described in conjunction with a proximity mask. However, this method can also be used with other methods of selective implantation, such as sheath engineering. In all cases, the implanted region is detected and the subsequent application of the metallization layer is modified based on the actual location of the implanted regions.
Although some embodiments of solar cells use a pattern that includes busbars and fingers, other configurations are also possible. FIG. 10 shows the top surface of a solar cell 1000 . In this embodiment, implanted regions 1010 are circular or nearly circular and arranged in a grid. For this selective emitter type application, the collector dots (i.e. implanted regions) are n++ implants (for a phosphorus implant). Typically there would also be a blanket emitter of n+ type. Although FIG. 10 shows the implanted regions 1010 forming a regularly shaped and spaced grid, any arrangement of implanted regions is possible. In this configuration, the metal layer comprises two components; the collector dots, which overlay the implanted regions 1010 , and the interconnects which connect the various collector dots together.
The size, shape and location of the metal collectors can be created using the process described above. In this way, the metal collectors can be formed so as to occupy as much of the implanted region as possible.
In addition to dot collectors on the top surface, this technique can also be used on the back side of the solar cell. For example, a dot collector may be used on the back side to create a back-surface field.
In addition to creating the metal collector pattern, the high resolution image can be used for other purposes. Unlike the configuration of FIG. 6 , the implanted regions can be connected in a variety of ways. For example, the metal collectors can be connected using a tree-like structure, where individual collectors are linked by very thin wires (due to the limited amount of current being passed). As individual collectors are linked, the metal collections become thicker, to accommodate the increased current load.
FIG. 11 shows an example of a dot collector solar cell, where the metal collectors 1010 are connected using metal wires. Note that wires which connect a single collector (i.e. 1020 ) are very thin, as the current is very low from a single collector. As the currents from a plurality of collectors are linked, the metal connections need to increase in size as well. Linkage 1020 connects a single collector, and therefore is very thin. Linkage 1025 connects two collectors and is therefore slightly thicker. Linkages 1027 , 1028 are progressively thicker due to the increase load through them. Ultimately, all of the collectors are connected to a busbar 1030 .
Smaller metal linkages (i.e. 1020 ) have a higher series resistance relative to their presented shadow. A dot pattern selective emitter can be designed to increase the current to increasingly larger linkages (i.e. 1027 , 1028 ) while simultaneously minimizing the number of linkages in the network. Based on the actual pattern of implanted regions, the algorithm can optimize the placement and thickness of the linkages connecting the metal collectors. The controller makes these adjustment based on predetermined control parameters, governed by the actual metal placement accuracy and other physical and electrical characteristics.
For example, a mask may create a first dot pattern. After the high resolution pattern has been created, a dynamic optimizing software program determined the location and size of each dot. Based on this, the software program can generate an optimal set of linkages.
Over time, various effects can cause this optimized linkage pattern to change.
For example, if the screen used for the implantation process is slightly offset relative to the wafer, all of the implanted dots will be correspondingly offset. Since this is a change that affects all of the dots in a uniform manner, the optimal linkage pattern may not need to be changed. However, each of the dots and linkages may also be correspondingly offset.
In another example, if the screen used for the implantation process is tilted, the placement and size of the dots may be affected. Assume the screen is tilted such that it is closer to the wafer on the left side. Since the screen is closer to the wafer on this side, the implanted dots will tend to be smaller as the beam expands less after passing through the screen. A tilt also affects the placement of the dots, bringing them closer together. Thus, a tilted screen may affect both the size and location of the dots. Since the effect may not be uniform across the entire wafer, the optimal linkage may change.
In another example, if the screen wears out or warps, the implanted pattern will be affected. Often, this type of wear out affects the implanted pattern in a non-uniform way. Therefore, the optimal linkages may change as a result of screen wearout.
By utilizing the high resolution image of the implanted regions to create an optimized linkage pattern, several benefits are achieved. First, there is greater tolerance as to the alignment of the mask to the wafer during implantation. Secondly, since imperfections due to mask wear out can be compensated for, the useful life of the mask can be increased.
The present disclosure is not to be limited in scope by the specific embodiments described herein. Indeed, other various embodiments of and modifications to the present disclosure, in addition to those described herein, will be apparent to those of ordinary skill in the art from the foregoing description and accompanying drawings. Thus, such other embodiments and modifications are intended to fall within the scope of the present disclosure. Further, although the present disclosure has been described herein in the context of a particular implementation in a particular environment for a particular purpose, those of ordinary skill in the art will recognize that its usefulness is not limited thereto and that the present disclosure may be beneficially implemented in any number of environments for any number of purposes. Accordingly, the claims set forth below should be construed in view of the full breadth and spirit of the present disclosure as described herein.
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An improved, lower cost method of processing substrates, such as to create solar cells, is disclosed. The doped regions are created on the substrate, using a mask or without the use of lithography or masks. After the implantation is complete, visual recognition is used to determine the exact region that was implanted. This information can then be used by subsequent process steps to crate a suitable metallization layer and provide alignment information. These techniques can also be used in other ion implanter applications. In another aspect, a dot pattern selective emitter is created and imaging is used to determine the appropriate metallization layer.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. Ser. No. 11/236,104, filed Sep. 26, 2005, and is incorporated by reference herein in its entirety.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] One aspect of the present invention relates generally to an excavator for breaking-up hard soils, rock, or concrete into manageable sized pieces for subsequent handling or processing. The excavator acts on an existing ground surface, acting on a layer of material to define a new ground surface that is below the original. The process is used for road construction and mining. This aspect of the present invention relates more particularly the apparatus, which allows control of the depth of cut and of the orientation of the resulting new ground surface.
[0005] 2. Description of the Related Art
[0006] Road Bed Preparation
[0007] In the preparation of a road bed one critical function is to establish the proper lateral grade. In most cases the desired lateral grade is level, with the exception of regions where the road curves and a banking effect is desirable. In both cases, when constructing new roads the grade of the native topography will typically need to be modified to achieve the desired grade. Certain ground conditions prohibit excavation in a manner wherein very fine adjustments can be made. These include conditions of rock and very hard soils. In these conditions the surface is typically excavated below the desired level, and finer more manageable materials backfilled to bring the grade to the desired level.
[0008] The process of replacing a damaged road surface often begins with the step of removing the existing road surface. The current methods of removing existing road surfaces of concrete are complicated by the existence of steel reinforcing rod that is integral to the concrete road surface. Current techniques of breaking up the road surfaces are slow and labor intensive often including the use of some form of impact wherein the existing road surface is struck from the above and broken into smaller pieces, and at the same time separating the reinforcing rod.
[0009] Mining
[0010] Many types of non-metallic rock are mined from shallow open-pit mines called quarries. The process is known as quarrying, open cast or surface mining. One quarrying technique involves drilling and blasting to break the rock. When usable rock is found, the surface is cleared to expose the desired rock. The area being mined is then drilled and blasted, a large number of low-powered explosives detonated at the same time to shatter the rock. The drillings are controlled to a depth to stay within the strata of desirable rock, as may have been determined by preliminary exploratory drillings. A single blast produces as much as 20,000 tons of broken stone. The broken stone is then loaded by handling equipment and transported to additional equipment to be crushed into smaller pieces and separated into uniform classes by screening methods. During that time the broken stone is exposed to the elements and some may be affected by weathering damage. This process is relatively labor intensive, produces work-in-process subject to damage. New techniques are recently being developed.
[0011] One such technique of quarrying is labeled as percussive mining in U.S. Pat. No. 5,338,102. In this reference a percussive mining machine is utilized to successively strike or impact the material with a cutting tool. In this case the cutting tools are mounted to a rotating drum that is propelled on a mining machine. The mining machine illustrated includes components representative of many machines which have recently been developed for this application. The machines typically include some form of ground drive, supporting frame for the drum, power unit to provide power to rotate the drum, a conveyance mechanism and some form of height control, to control the position of the drum. Examples of other machines, built specifically for this application, can be found in U.S. Pat. Nos. 5,092,659; 5,577,808; and 5,730,501. These machines are highly specialized, with limited additional use.
[0012] An example of a more versatile machine, built on a more generic platform, can be found in U.S. Pat. No. 4,755,001. This reference discloses an excavating machine that consists of a digging head mounted to an elongated digging member, both mounted to a main frame. The main frame resembles machines currently known as track trenchers.
[0013] Track trenchers, as is illustrated in FIG. 1 , were originally designed for forming trenches for the installation of drainage lines or other utilities in open trench installations. The basic components of a Track Trencher 10 include:
1) a main frame 30 , 2) a set of ground engaging track assemblies 20 which are fixedly supported by the main frame 30 in a manner that allows the drive sprocket 22 to be driven to propel the machine along the ground, 3) a power unit 40 typically a diesel engine, and 4) an excavation boom assembly 50 which is relatively narrow, as compared to its length, as most trenches are much deeper than they are wide.
[0018] The power unit 40 provides power to the driven/drive components of the machine. This is typically comprised of a diesel engine and a hydraulic system. The hydraulic power is transferred to various actuators mounted on the machine to perform the desired operations including:
1) a hydraulic motor 24 mounted onto the track drive frame that drives the track drive sprockets 22 , 2) a hydraulic motor 52 mounted on frame 30 that supports and drives a sprocket which drives the excavation chain 54 that is supported on an idler sprocket 56 which is supported by the boom frame 51 , and 3) a hydraulic system that includes cylinders 62 to raise and lower the excavation assembly.
[0022] In trenching the primary parameter that needs to be controlled is the depth of the trench. The machine provides this control by controlling the position of the boom relative to the ground engaging tracks, typically allowing the boom to pivot around an axis defined by the machine frame. This pivot is designed robustly to handle the severe loading, particularly experienced when excavating rock. Typically the only movement of the boom relative to the frame is provided by pivoting about this axis.
[0023] Controlling the height of each ground drive unit, track, independently allows the frame to be kept level and thus the orientation of the resulting trench can also be controlled. However, this technique of orientation is not ideal in that the entire machine is being controlled resulting in higher power requirements and reduced responsiveness.
BRIEF SUMMARY OF THE INVENTION
[0024] The present invention relates generally to an excavation machine having a frame and an excavation boom. The excavation boom is rotatably mounted to the frame at a boom mount pivot axis. The excavation boom includes an excavating chain that drives an excavating drum, both rotating about an excavation axis. The boom further includes an integral pivot that allows the position and/or orientation of the excavating drum to be independently adjusted, relative to the frame and the boom mount pivot axis. The excavating drum and the excavating chain both include cutters mounted in a predetermined pattern. The predetermined pattern involves the placement of the drum cutters in relation to the chain cutters. The predetermined pattern does not change as the chain and drums are operated.
[0025] Road Bed Preparation
[0026] The apparatus of the present invention is particularly useful for the preparation of a road bed with its ability to control the orientation of the final ground surface along with the excavation depth. In addition the excavating drum's width, relative to the width of the ground engage tracks and the arrangement of the cutting teeth on the excavating drum make it particularly useful in demolition of an existing road surface in preparation to install a new road surface.
[0027] Mining
[0028] The apparatus of the present invention is particularly useful for certain types of mining operations with its ability to control the excavating drum to optimize the orientation of the ground surface and the excavating parameters.
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] FIG. 1 is a side view of the prior art track trencher with a standard boom;
[0030] FIG. 2 is a side view of a track trencher with the boom of the current invention;
[0031] FIG. 3 is side view of the new boom;
[0032] FIG. 4 is a cross-section of the main pivot taken along line 4 - 4 of FIG. 2 ;
[0033] FIG. 5 is an isometric view of the main pivot;
[0034] FIG. 6 is a cross-section of the swivel of the present invention taken along line 6 - 6 of FIG. 3 ;
[0035] FIG. 7 is an enlarged side view of the head assembly of the new boom;
[0036] FIG. 8 is an end view of the head assembly of the new boom taken along line 8 - 8 of FIG. 7 ;
[0037] FIG. 9 illustrates the hydraulic drive motor and drive sprocket for the excavation chain;
[0038] FIG. 10 is a cross section through the head shaft and the excavation drums of the present invention taken along line 10 - 10 of FIG. 7 ;
[0039] FIG. 11 is a perspective view of a portion of the excavation chain assembly;
[0040] FIG. 12 is an exploded view of the base plates assembled onto the excavation chain;
[0041] FIG. 13 illustrates the pattern of the cutters mounted on the excavation chain and drums;
[0042] FIG. 14 is a top view of a track trencher with the boom of the current invention; and
[0043] FIG. 15 is an end view of a portion of the track trencher and excavation boom of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0044] Referring now to the drawings, like reference numerals designate identical or corresponding parts throughout the several views.
[0045] The current invention includes a track trencher with a new excavation boom. A preferred embodiment is illustrated in FIGS. 2 and 3 . In FIG. 2 the track trencher includes the basic components of the main frame 30 , track assemblies 20 , power unit 40 ; all with similar functions as described for the prior art track trencher. The excavation boom is replaced by a new excavation boom 100 of the present invention.
[0046] The new excavation boom 100 is illustrated in FIG. 3 and includes a mounting section 110 , swivel 120 and head unit 130 . The mounting section 110 includes a mount frame 112 that will mate with the main frame 30 as illustrated in FIG. 4 and FIG. 5 . The main frame 30 includes two coaxial holes with an array of tapped bolt holes, bolt patterns 32 , which define the main pivot axis 114 . Bolt pattern 32 is defined as including both the large diameter pilot hole 332 and the array of tapped holes 232 that fall on a bolt circle that is aligned with the pilot hole.
[0047] Outer pivot rings 113 attach to the main frame 30 with bolts 115 that are mated with bolt holes defining bolt pattern 32 . Inner pivot rings 116 mate with the outer pivot rings 113 , in a manner that they can freely rotate relative to the outer pivot rings 113 and frame 30 . The inner pivot rings 116 attach to the mount frame 112 at bolt pattern 117 defined by pilot hole 317 and an array of tapped holes 217 . There are two bolt patterns 117 , one on each side of mount frame 112 , that define an axis that passes through the centers of the two bolt patterns 117 . This joint is assembled by first inserting the mount frame 112 into the main frame 30 , then installing the inner pivot rings 116 into the pilot holes 317 though the sides of the frame 30 . The inner pivot rings 116 are then attached to the mount frame 112 by installing bolts 118 that mate with tapped holes 217 . The outer rings 113 , which are constructed in 3 sections, are then installed and attached to the main frame 30 by installing bolts 115 that engage tapped holes 232 . The excavation boom is thus able to pivot around the axis 114 to allow control of its position relative to the main frame.
[0048] FIG. 6 illustrates swivel 120 which includes a frame section 123 , swivel shaft 128 , inner pivot rings 126 , 127 , and outer pivot rings 125 . The pivot rings 125 , 126 , and 127 form two rotary supports 122 a and 122 b defining a swivel or pivot axis 124 . The rotary support 122 a comprises an outer pivot ring 125 and an inner pivot ring 126 . Rotary support 122 b comprises an outer ring 125 and an inner ring 127 . The outer rings of both rotary supports are constructed to be bolted to the frame section 123 . The inner rings 126 and 127 are constructed to be bolted to swivel shaft 128 . In this manner they provide both radial and longitudinal support of the swivel shaft 128 . Frame section 123 is constructed to fit within the mount frame 112 of mounting section 110 . It is secured to mount frame 112 with bolts 121 passing through the mount frame 112 at slots 119 such that the swivel or pivot axis 124 is perpendicular to and substantially aligned with main pivot axis 114 , defined by the main frame 30 and substantially parallel to the ground surface, or the plane defined by the two track assemblies 20 , as illustrated in FIG. 3 .
[0049] As illustrated in FIG. 3 positioning the swivel axis 124 perpendicular to main pivot axis 114 allows the orientation of the head unit 130 , which mounts on the swivel shaft, to be modified relative to main frame and ultimately the ground surface.
[0050] FIGS. 7 and 8 illustrate the head unit 130 . It includes a frame section 132 , an excavation assembly 140 , and positioning assembly 170 . The excavation assembly 140 comprises a center excavation chain 142 , drive sprockets 144 , driven sprockets 146 mounted on drums 148 which are rotatably mounted on head shaft 150 that is fixedly supported by extendable end section 152 of frame 132 . The centerline of head shaft 150 defines the excavation head shaft axis 151 . Power is transferred from the excavation hydraulic motors 52 , that have been mounted onto the frame section 132 of head unit 130 . Drive sprockets 144 are mounted onto motor shaft 145 which is supported in bearing assemblies 133 supported by frame 132 . Hydraulic motors 52 are mounted onto motor shaft 145 and held from rotating by torque arms 53 as illustrated in FIG. 9 . The drive sprockets 144 propel the excavation chain 142 which subsequently powers rotation of the sprockets 146 . Sprockets 146 are fixedly mounted onto drums 148 such that whenever the sprocket rotates, the drums are also rotated. The excavation drums 148 are rotatably mounted onto head shaft 150 by bearings 147 , as illustrated in FIG. 10 . The extendible end section 152 is attached to the frame section 132 at joint 153 . Joint 153 allows the extendible end section 152 to be moved perpendicular to the axis of rotation of the output shaft of drive motor 52 such that the distance between the drive sprockets 144 and the driven sprockets 146 can be adjusted to control chain tension.
[0051] Excavation chain 142 comprises external flanged side bars 141 and internal side bars 143 and rollers 143 a , as illustrated in FIG. 11 , and base plates 156 , as illustrated in FIG. 12 . Base plates 156 are typically bolted to the external flanged side bars 141 with bolts 158 and nuts 159 and include mounts 155 for supporting cutters 154 . Cutters 154 are known in a variety of configurations. It is well known to attach such cutters to chain. Similar cutters are also known to be attached to rotatable drums. The type of cutter or method of mounting are not a portion of this invention, and any such cutter or mount would be useful.
[0052] FIG. 13 illustrates the outer circumference of the two excavation drums 148 shown as 148 R and 148 L, corresponding to one drum on the left and one on the right, along with the base plates 156 of the excavation chain 142 . The pattern of the cutters 154 , their location and placement and the coordination of this placement for the three separate components, has been found to be critical in optimizing the excavation efficiency of the assembly. One aspect includes the arrangement of the cutters 154 into rows 160 and columns 162 . The columns 162 are parallel to the excavation axis, and spaced to coincide with the base plates 156 . As the chain is rotated the outer circumference illustrated in this FIG. 13 effectively moves from right to left. Thus, column 162 a contacts the ground surface first followed by 162 b , followed by 162 c etc.
[0053] Following one row 160 a , the first cutter 154 a is on column 162 h . As the chain and drums are rotated this first cutter 154 a will contact the ground surface, fracturing the surface and creating a groove. At column 162 i the second cutter 154 b is longitudinally spaced, away from the center of the base plate 156 , towards the outer edge, as compared to the first cutter 154 a . This longitudinal spacing defines the angle of the rows 160 . The material contacted by the second cutter 154 b will have been previously affected by the first cutter 154 a on one side while on the other side the material will be less affected by any previous cutters. Thus, if any material fractures, there is a higher probability that it will be material between the groove created by the first cutter 154 a and the groove now being created by the second cutter 154 b , material on the inside of the second cutter 154 b , than on the outside of the second cutter 154 b . Thus material fractured by the second cutter 154 b will tend to fracture towards the center of the base plates. As the chain and drum continue to rotate the cutters impacting the ground continue to move closer to the edge of the drum, in this case to the edge of drum 148 R. As that row 160 approaches the edge, the longitudinal spacing of the last few cutters is decreased to approximately zero. This is necessary due to the fact that the loading at the ends will be influenced by the sides of the excavated trench. When plunge cutting there will be walls on each side of the excavation assembly 140 . These walls will tend to force material against the outside teeth in such a manner that the loading is higher on these outside teeth.
[0054] The speed of the outer surface of excavation chain 142 must be coordinated with the speed of the outer surface of the drums 148 R and 148 L in order to maintain the relationship between the cutters mounted to the chain and the cutters mounted to the drums. To achieve this coordination the drums are sized to a specific outer diameter such that the one revolution of the excavation chain results in exactly an integer number of revolutions of the excavation drums. The pattern shown as 148 R includes 28 cutters 154 and represents one complete rotation of the excavation drum 148 . The pattern shown in FIG. 13 represents exactly ½, ⅓, or ¼ of the total length of the chain. Looking at an individual column there are always six cutters in each column, two on drum 148 L, two on excavation chain 142 and two on drum 148 R.
[0055] This cutter spacing and the coordination of the excavation chain length with outer diameter of the excavation drums results in consistent placement of the cutters 154 on the excavation drums relative to the cutters 154 on the excavation chain 142 . There is an identical number of cutters 154 in each vertical row, and slightly increased density of cutters 154 on the two outside edges of the excavating drums 148 L and 148 R. Many patterns can be developed, the disclosed pattern comprising a V wherein the legs of the V-pattern pass from the chain to each of the drums, is one example but many others are possible.
[0056] In operation the track trencher with the new excavation boom of the present invention is useful in surface mining or in surface preparation for road construction. The use of the track trencher for these applications is enhanced by the fact that the excavation assembly 140 always cuts wider than the tracks. One configuration is illustrated in FIG. 14 where the excavation assembly 140 is positioned with the excavation axis 151 parallel to the main pivot axis 114 .
[0057] Another configuration is illustrated in FIG. 15 where the excavation assembly is tilted to its extreme position and excavation axis 151 is at the maximum angle to the tracks 20 . In this configuration the swivel or tilt axis 124 is parallel to the longitudinal axis of the machine. Even in this extreme position the drum 148 will excavate wider than the tracks 20 .
[0058] Obviously many modifications and variations of the present invention are possible in light of the above teachings. It is therefore to be understood that, within the scope of the appended claims, the invention may be practiced otherwise than as specifically described.
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An excavating apparatus having a prime mover with a longitudinal centerline and a main frame with an engine, a ground drive system and an excavation boom operatively attached thereto wherein the excavation boom has a first end and a second end. The first end of the boom is operatively pivotally attached to the main frame along a main frame pivot axis. The main frame pivot axis is transverse to the longitudinal centerline of the prime mover. A head shaft operatively rotatably attached to the second end of said boom and is operatively pivotally attached to the second end of said boom Also, the excavation drum is mounted onto the head shaft in a manner that the excavation drum cooperates with the excavation chain and a fixed cutter pattern of the excavation chain to stay in consistent alignment with the fixed cutter pattern of the excavation drum.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to processes for the treatment of malodorous waste streams and more particularly to oxidative waste treatment processes for thioacetimidates.
2. Prior Art
Certain thioacetimidate derivatives such as methomyl are effective insecticides. These compounds and their preparation are described in U.S. Pat. No. 3,576,834, granted Apr. 27, 1971, to J. B. Buchanan. Preparation of certain intermediates for these compounds is described in U.S. Pat. No. 3,574,736, granted Apr. 13, 1971, to J. J. Fuchs. In the processes described, a number of waste streams are produced containing compounds which are very malodorous and in some cases also toxic. Traditionally, the waste streams are incinerated for disposal; however, because their major component is water, large amounts of fuel such as oil or natural gas are required. Because of the current energy situation, an alternative waste treatment process for these compounds is desirable.
The malodorous components in the above-described waste streams are mainly the sulfur-containing thioacetimidates. It is known in the art that sulfur-containing compounds can be oxidized by chlorine (Houben-Weyl, Methoden der organischem Chemie, Volume IX, p. 81, 1955). Unfortunately, chlorine oxidation of certain of these sulfur-containing compounds in the waste stream produces compounds that are explosive and/or toxic. Thus, any accumulation of these compounds in a separate oil phase represents a potential hazard.
SUMMARY OF THE INVENTION
According to the present invention there is provided a waste treatment process comprising (a) contacting an aqueous waste from the production of a compound of the formula: ##STR1## wherein R is CH 3 or C 2 H 5 ; and R 1 is H, ##STR2## wherein n is 0 or 1
with Cl 2 at a temperature of at least about 70° C. for a time sufficient to complete oxidation, and (b) contacting the resulting reaction mass with a basic compound selected from KOH, NaOH and Ca(OH) 2 at a pH greater than about 9.5 and at a temperature of at least about 70° C.
According to a preferred embodiment, the waste treatment is continuous and comprises (a) continuously feeding chlorine and an aqueous waste resulting from the production of one or several of the above-described compounds to an oxidation reaction zone maintained at a temperature in the range of about 70°-95° C., the aqueous waste being fed to the reaction zone through a scrubbing zone where off-gases from the reaction zone are contacted with the aqueous waste, and the chlorine being fed at a rate sufficient to maintain the oxidation-reduction potential of the reaction medium in the oxidation zone in the range of about 500-1200 millivolts, as measured between a platinum electrode and a silver electrode; (b) continuously withdrawing oxidized reaction mixture from the oxidation reaction zone and feeding it and a basic compound selected from the group consisting of NaOH, KOH and Ca(OH) 2 to a hydrolysis reaction zone maintained at a temperature in the range of about 70°-100° C., the basic compound being fed at a rate sufficient to maintain the pH of the reaction medium in the hydrolysis zone greater than about 9.5; and (c) continuously withdrawing hydrolyzed reaction mixture from the hydrolysis zone.
BRIEF DESCRIPTION OF THE DRAWING
The drawing is a schematic flow diagram showing a continuous process according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
The process of the invention can be shown by the following reaction sequence: ##STR3## It has been found that by conducting step 1 of the process at or above the autodecomposition point of the thermally most stable of the explosive intermediates (in the above reaction sequence compound C) accumulation of compound C as a separate oil phase, which could be hazardous, is avoided. This, coupled with conducting step 1 on the acidic side, enables the process to be controlled effectively on a continuous basis, since on the alkaline side the oxidation-reduction potential signal response is sluggish and unsuitable for process control. While a continuous process is preferred, the process of the invention can be carried out batch-wise.
With reference to the drawing, gaseous chlorine is fed into oxidation reaction vessel 10 equipped with stirrer 19 via line 11 from a pressurized storage tank 12. The chlorine feed rate is controlled by a by-pass valve 13 and a control valve 14 and monitored by flow meter 15. An aqueous waste stream containing one or more thioacetimidates and their by products, such as encountered in the manufacture of methomyl, and related insecticides as described in U.S. Pat. No. 3,576,834, is pumped by pump 16 into reaction vessel 10 via line 17 and counter-current scrubber column 18. Reaction vessel 10 is equipped with steam jacket 20 so that the reaction vessel can be heated and maintained at a temperature of at least about 70° C., a temperature above the autodecomposition point of compound C. The upper temperature limit is about the boiling point of the reaction mixture at ambient pressure, i.e., about 95° C. The preferred temperature range is about 80°-95° C.
During oxidation of thioacetimidates with chlorine in reaction vessel 10, off-gases (e.g. nitrogen, nitrous oxide, carbon dioxide) are formed which tend to carry with them some chlorine and some of the intermediates in gaseous form, particularly compound D. When this gas mixture enters scrubber 18, which is operated at an ambient temperature and pressure, the chlorine and intermediates in the off-gases (e.g. compound D) react to form compounds A, B or C, which are then returned to the oxidation reaction vessel. The counter-current flowing waste stream is an excellent scrubbing medium for the off-gases. The scrubbed off-gases are then vented through line 21 to a vapor incinerator or flare, preferably burned in order to remove any odor carried with the inert gases from the waste stream.
It is preferred that the oxidation reaction conducted in vessel 10 be on the acidic side for ease of control. Since hydrochloric acid and other acids are formed in this reaction, the acidic conditions are inherent in the reaction. The entering waste stream is preferred to be near a neutral pH; however, a basic waste stream can be tolerated as long as the net result is an acidic condition in the oxidation reaction. If the waste stream is rich in organic materials, cooling of vessel 10 may be required to maintain the required temperature.
The chlorine feed rate to vessel 10 is controlled so as to maintain an oxidation-reduction potential of between about 500-1200 millivolts, preferably about 600-900 millivolts, as measured between platinum and silver electrodes of an oxidation-reduction potential (ORP) probe 22 extending through vessel 10 into the reaction medium. The output of the ORP probe can be used for chlorine flow control via control valve 14 by conventional means. If the oxidation-reduction potential is maintained at a lower potential, the oxidation reaction may be incomplete. A higher potential is unnecessary and wasteful of chlorine.
Residence time in vessel 10 should be sufficient to allow essentially complete oxidation of the thioacetimidates. Generally, a time of 10 minutes to 2 hours is adequate depending upon well known reaction rate considerations such as temperature.
Oxidized reaction mixture in the acidic reaction medium from oxidation vessel 10 is fed via lines 23 and 24 by pump 25 to hydrolysis reaction vessel 26 where base, fed into vessel 26 through line 27 from storage tank 28 and through control valve 29, hydrolyzes intermediate compounds such as compounds A-D. The main hydrolysis products are acetate and sulfonate. While sodium hydroxide is the preferred base, potassium hydroxide and calcium hydroxide can also be used. Reaction vessel 26 is equipped with a stirrer 30, condenser 32 and a steam jacket 31 so that reaction vessel 26 can be heated and maintained at a temperature of at least about 70° C., preferably in the range of about 70°-100° C., and most preferably about 80°-95° C. A vent line 33 from condenser 32 allows small amounts of gaseous products such as methyl amine and ammonia to be vented or burned.
The base feed rate to hydrolyzer 26 is controlled so as to maintain the reaction medium at a pH of greater than about 9.5, preferably between about pH 10-11. A pH probe 34 extends through vessel 26 into the reaction medium so as to monitor and control pH. Temperature and pH controls are needed to obtain satisfactory hydrolysis rates. A higher temperature or pH will require more costly materials of construction in the reaction vessel and auxiliary equipment. For the reaction conditions employed, reaction times will range from about 10 minutes to about two hours.
Hydrolyzed reaction mixture from hydrolyzer 26 is withdrawn through line 35 and valve 36 and is then collected in collection vessel 37 for subsequent treatment such as neutralization, biooxidation and nitrification.
The invention can be further understood by the following example in which percentages are by weight.
Thirty-eight liters of a methomyl manufacturing process aqueous waste sample containing 0.76% S-methyl-N-[(methylcarbamoyl)oxy]-thioacetimidate, 0.65% S-methyl-N-hydroxy-thioacetimidate, 0.13% dimethyl disulfide, 0.04% methyl thiolacetate and minor amounts of a number of other compounds (some of them unidentified) was continuously treated using the apparatus and flows shown in the drawing. The sample was extremely malodorous. The reactors were steam heated 1-liter glass reactors and the scrubber was a five-plate Oldershaw column operated at room temperature and atmospheric pressure. The waste feed rate was 45 ml/min, the temperature of both reactors was maintained at 80° C., the oxidation-reduction potential in the oxidizer was maintained automatically at 700-800 mV using an oxidation-reduction potential probe having a platinum electrode and a silver electrode and the pH in the hydrolyzer was controlled similarly at pH 10.5 with sodium hydroxide. The run lasted 14 hours. 1.1 Kg of chlorine and 3.2 kg of 50% sodium hydroxide were consumed. 154 Ml concentrated hydrochloric acid was required to bring the treated hydrolyzed waste to pH 7. The treated waste so obtained contained no detectable thioacetimidates. Sodium acetate, sodium methane sulfonate and sodium chloride were the major components of the waste stream which also contained a few minor identified innocuous components. An odor evaluation detected only a faint acetamide-like smell. Evaluation of the neutralized waste in biotreatment simulators showed the treated waste to be highly biocompatible both in biooxidation and the subsequent nitrification step.
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Processes for the treatment of toxic and malodorous wastestreams produced in the manufacture of methomyl and related compounds are provided. In these processes, methomyl and related compounds are oxidized with chlorine at a temperature of at least about 70° C., preferably in the range of about 70°-95° C., preferably under acidic conditions, and then the resulting intermediate compounds are hydrolyzed with NaOH, KOH or Ca(OH) 2 at a temperature of at least about 70° C., preferably in the range of about 70°-100° C., and at a reaction medium pH of at least about 9.5. The process is preferably carried out continuously.
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FIELD OF THE INVENTION
[0001] The invention relates generally to monitoring network usage patterns, and more specifically to a method and system of detecting anomalies in network environments by monitoring user network behaviours.
BACKGROUND OF THE INVENTION
[0002] The topic on the anomaly based intrusion detection has been extensively studied in the past decade and witnessed so many security breaches made headlines. In order to improve weaknesses of signature based intrusion detection system (IDS), the anomaly detection systems come into play since in 1987 when Dorothy Denning presents a model of how an anomaly detection system could be implemented. The anomaly detection systems fall into six major categories, depending upon the methods they use to learn baseline behaviours and identify deviations from those established baselines. The six main detection types include neural networks, statistical analysis, signal processing, graph, payload and protocol-based systems. However, anomaly detection system is frequently plagued by time-consuming false positives. One design consideration for anomaly detection is that LAN environment is highly dynamic and any number of things can change the network traffic patterns; for example, adding new services, adding new employees or adding new resources. Another design consideration is that network user habits are deterministic and once engrained, these habits are difficult to change. A more accurate and effective network anomaly detection system should be based on user behavioural profiling and assume the network environment is always dynamic and not static. These two attributes (i.e. dynamic LAN environment and deterministic human habits) are used to design a system that applies behavioural analysis to measure anomaly and deviation in how the network resources are used by the user.
SUMMARY OF THE INVENTION
[0003] This invention applies behavioural analysis methods to establish individual user's set of network attributes baselines for measuring anomaly and deviation in the user's network usage on an internal local area network (LANs) that are behind firewalls at the network edge and DMZ. The said system in this invention deals with the complexity of LAN environment and network user's behaviour. The said system models these two attributes (i.e. dynamic LAN environment and complex network user's bebaviour) detect obvious, subtle, new, and unknown network anomalies often difficult to identify, distinguish, and differentiate in a highly dynamic LAN environment where constant changes of the network environment make it ineffective to use pre-defined network traffic patterns for detecting unknown, unforeseen, and new network attacks. The said system is deployed in an internal LANs environment and can be configured to sniff network packets either through SPAN port (ie port mirroring) or inline network tap. Both configurations duplicate a copy of a network packet to the said system. One or more network subnets/segments may be aggregated and have their network packets copy to the said system.
[0004] The said system uses the network packets to identify user and host on the LANs. A user is defined as one whose identity can be associated to a network resource used by that particular user. A host is defined as one which does not have an affiliation to a particular user. It is assumed that the network users and hosts on the LAN must have been authenticated before allowed access on the LAN or use any network services. Based on this assumption, the said system can trace the presence of network users and hosts on the LAN by interrogating the authentication server or installing a desktop software agent on the user's/host's machine to emit the presence information whenever the user/host is granted access to the network. The presence information is then correlated with the network IP address that is used by the network user/host. The said system can operate with both agent-based and agentless-based approaches to capture user's and host's identities automatically. Once user or host has been identified, the said system associates the network packets pertaining to a user or host and extract network usage attributes, from the network packets, to build a set of profiles of the user or host. By correlating presence and network information, a behavioural profiling can be established that uniquely reflect an individual user's/host's distinct network usage and network traffic patterns. A profile represents the behaviour of the user or host on the LAN, such as quantity and velocity of network connections, time of connectivity, direction of network packet flow, frequency and ratio of valid network packets, volume of network packets, length and size of network packets, etc. Each user and host has a set of profiles, which are various baselines that can be used to measure network behaviour deviation against learned/observed normal acceptable network behaviour. The baselines are a representation of accepted user's behaviour on the network that is learned by the said system over a period of time. The baselines can be learned and relearned continuously by the said system.
[0005] In addition to user and host profiles, a group profile can be defined by logically grouping network users who have similar or common network usage attributes (for example, a group of users who use certain types of network resources, or use a common point of entry into the networks via VPN wireless-LAN, a group of users belonging to a department, and etc.) Hence a group profile reflects the common behaviour of majority members in the group that are considered good network usage behaviour, based on the assumption that network security breaches are caused by a minority of network users on the LAN. The application of a group profile can effectively separate a particular “bad” behaviour from a collective “acceptable” behaviour.
[0006] The said system is composed of the following four components:
1. User presence detection—this is used to track where a user is connected to the network. 2. User, host and group profilings—this is used to build set of baselines for detecting network usage abnormality. 3. Behavioural deviation detection engine—this is used to identify deviations from the learned and observed historical network usage behavioural patterns. 4. Graphical User Interface (GUI)—this is used by an administrator to view, examine, and reporting on the events captured by the said system.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] For a better understanding of the embodiments described herein and to show more clearly how they may be carried into effect, reference will now be made, by way of example only, to the accompanying drawings which show at least one exemplary embodiment, and in which:
[0012] FIG. 1 is a diagram illustrating the components of a anomaly detection system;
[0013] FIG. 2 is a block diagram illustrating the components of the analysis server;
[0014] FIG. 3 is a flowchart illustrating the steps of an auto user presence detection method
[0015] FIG. 4 is an example illustrating how Identity Aggregate Module works
[0016] FIG. 5 is a flowchart illustrating the steps of user and group profiling method
[0017] FIG. 6 is an example illustrating visited HTTP service usage
[0018] FIG. 7 is a flowchart illustrating the steps of an anomaly detection method
DETAILED DESCRIPTION OF THE INVENTION
[0019] Reference is now made to FIG. 1 , where the components of the anomaly detection system 10 are shown in an exemplary embodiment. The detection system 10 is comprised of one or more computing stations 12 that communicate with an analysis server 14 through a corporate communication network 16 . The detection system 10 in an exemplary embodiment is used to profile user behaviour in relation to the use of one or more computing stations 12 that are part of the system 10 . By profiling user behaviour and group behaviour, as explained below, usage changes associated with a user can be detected and can then be used to determine whether any anomalies exist in a network (where the system 10 is part of a network).
[0020] The computing stations 12 may be any devices that can communicate with a communication network 16 , and may include, but are not limited to, desktop computers, slimline computers, server computers, handheld computers, and any other computing devices that can communicate with a corporate communication network 16 via wired or wireless communication medium. The network packets generated by the computing stations 12 are captured by network devices (not shown within the corporate communication network 16 ), using SPAN port configurable by software and hardware-based network tap, and duplicated and sent to the analysis server 14 .
[0021] The analysis server 14 , is further described with respect to FIG. 2 , and is used to detect the presence of users through one or more ways. Specifically, the analysis server may receive user presence information from an authentication server (not shown) which may be a server type computer which regulates access to the network and any associated devices that are part of the network. Alternatively, the server may receive information from software agents that are installed on the computing stations 12 . The software agent can be installed manually by the user and scheduled push installation. Once it is installed, the software agent is started at system boot and runs as a service. The software agent detects activities such as user-invoked log-on, user-invoked log-off, system-invoke time-out and screen-lock. These activities will trigger the software agent to transmit the present information to the analysis server 14 . The software agents would gather user information containing user identity and IP addresses of used computing stations 12 . The user identity may consist of a combination of identifiers that are gathered to uniquely associate with the user. Examples of user identifiers include, but are not limited to a user's network log-on identification and (host) name of the computing stations 12 . Also, the analysis server 14 may detect the presence of users through engaging in analysis or sniffing of the network traffic, which may be referred to as auto user presence detection. By analysis or sniffing of the network traffic data, the analysis server 14 may then decode the protocols that contain user information. The analysis server 14 also allows for user and group profiling, and anomaly detection as described below.
[0022] The corporate communication network 16 may be any network that allows for the exchange of data, and may be a combination of a wired or wireless network, and may include, but is not limited to, a local area network. For example, an Ethernet LAN. The corporate communication network 16 resides behind the firewall of the DMZ (Demilitarized Zone in Computer Networking, and network edge). The corporate communication network 16 may be partitioned into one or more network segments that are controlled by one or more network switches. One analysis server 14 may monitor one or more network segments. One analysis server 14 may be designated as the central analysis server to manage and control multiple node analysis servers 14 that are deployed across the entire corporate communication network 16 . The central analysis server is termed the “Controller” and the node analysis server is termed the “Sensor”. The “Sensor” performs the task of sniffing network packets, decoding the networks packets, and summarizing the network packets. Afterwards, the “Sensor” sends those summarized information to the “Controller” by syslog. The data transfer method via syslog between analysis servers 14 , specifically between one “Controller” and multiple “Sensors” is not only to reduce workload of the “Controller”, but also centralizes network information on the “Controller”. The “Controller” receives syslogs from the various “Sensors”, processes the syslogs, and stores the data into a database.
[0023] Reference is now made to FIG. 2 , where the components of the analysis server 14 are shown in an exemplary embodiment. The analysis server 14 has associated with it a user detection module 20 , a user and group profiling module 22 , an anomaly detection module 24 , and a reporting module 26 . The user presence detection module 20 is used to track where a user is connected to the corporate communication network 16 . User and group profiling module 22 is used to build a user and group profiling database (not shown) based on the information collected from a network access authentication system and network devices (not shown), such as network switch and network tap. The anomaly detection module 24 is used to identify network behavioural deviations from the established user and group profiling data (i.e. baseline or normal behaviour). The Reporting module 26 is used to monitor events and alerts and manage the detection engine by the administrators.
[0024] Reference is now made to FIG. 3 , where the steps of an auto user presence detection method 200 are shown. The auto user presence detection method 200 is used to automatically discover the user's and host's network identity information by only sniffing and analyzing network packets—i.e. without necessarily install a desktop agent software on the user's computer. Auto user presence detection, method 200 , in an exemplary embodiment begins at step 202 , where the analysis server 14 sniffs the network packets using a network packet capture library, such as pcap, libpcap, etc. At step 202 , by using a network packet capture library, the analysis server 14 captures packets from the network card directly. The analysis server 12 is installed with one or multiple network cards, operating at Mega or Giga bps, to capture and process the network packets. At step 204 , the network packets are decoded to identify the protocol that contains the clear-text user information. Specifically, protocols including DNS, DHCP, NetBIOS, Microsoft Windows domain authentication (Kerberos), POP3, SMTP, IMAP, and propertiary desktop agent software. First, the relevant network packet is decoded to obtain the ethernet header, IP header, and TCP header. From the various headers, the source IP address, destination IP address, source port, and destination port information are obtained. Then, based on the protocol's port number (for example, the port number typically used by protocol POP3 is 110), the specific protocol analyzer is used to extract the user information. In step 206 , the various user identities are extracted from the user information encoded in the protocol-specific network packet. The analysis server 14 implements various Extract User Information step 206 to extract user information from the various protocol-specific network packets that consist of clear-text user information. There is one Extract User Information step 206 for each protocol-specific authentication method. For example, if the analysis server 14 is decoding a SMTP network packet, then the user information as represented in the format of email address will be obtained. If only the IP address can be obtained, then the IP address is assigned as the user information of the computing station 12 . If only the host name and the IP address can be obtained, then the hostname is assigned as the user information of the computing station 12 . If username and the IP address can be obtained, then the username is assigned as the user information of the computing station 12 . In order to eliminate incorrect user identification, the step 208 correlates the user information with the authentication status reported in the protocol that requires authentication, such as POP3, SMTP, IMAP4 and Kerberos. Furthermore, because a person may have multiple identities (for example, one corporate email account, one VPN account, multiple personal email accounts, etc), the step 210 is used to associate multiple users' identities with the rightful person, and aggregate multiple users' identities into one single identity representing a network user. At step 212 , the user information is inserted into the analysis server's database.
[0025] Reference is now made to FIG. 4 , where the components of Identity Aggregate Module 210 are shown in an exemplary embodiment. Email address module 2102 parses email identity. However, it may obtain multiple email identities from a same IP address almost in the same time (for example, in one minute). Then, Check and select Module 2108 selects one of these email identities as the primary identity based on the following scenarios: 1). By analyzing the identity names, the one which is more similar to the host name of the used machine will be considered as the identity of this user; 2). The identity which has already been used by another IP or host name will be not considered as the identity of this user; 3). The one which has the name such as support, admin, administrator, root, etc., will not be considered as the identity of this user. Then we have one email identity of these email identities as the identity of this user, other email addresses will be discarded. VPN Login Module 2104 parses events from VPN log sent by VPN server. Windows Login Module 2106 parses user Windows account name. Combine Module 2110 combines the email identities to VPN or Windows login identity, when their status is login and all of them have the same IP address.
[0026] Reference is now made to FIG. 5 , where a flowchart illustrating the steps of a User and Group Profiling module are shown. Given the user's presence information, the said system could obtain the network packets through various methods to build the user and group profiling by Network Sniff Module 220 . Some of the methods are (1) proprietary and standard-based network packets collection protocols such as NetFlow, sFlow, jFlow, and cFlow, (2) network TAP, and (3) SPAN port. By aggregating information from user presence information and Network Sniff Module 220 , User Profiling Module 224 builds the profiling of a user's network activities including, but not limited to, such as network services used 2240 , Destination Visited 2242 , Bytes Consumed 2244 , Packets Consumed 2246 , Visited service usage 2248 , and network connection frequency 2249 . User Group Information Module 222 can either collect group information from an authentication server, such as LDAP, or be entered by an administrator manually. By aggregating information from user group information and User profiling, Group Profiling Module 226 builds the profiling of a group of users' network activities including, but not limited to, such as network services used 2260 , Destination Visited 2262 , Bytes Consumed 2264 , Packets Consumed 2266 , Visited service usage 2268 , and network connection frequency 2269 . A threshold level can be defined for each level of acceptable risk. When a deviation exceeds the pre-defined threshold, an alert is generated to record and notify the breach. Based on the alert generated, the Anomaly Detection Module 24 (shown in FIG. 7 ) performs further analysis to (A) correlate the deviation against known exploits (through known vulnerable network services), and (B) correlate the deviation with other anomaly behaviour to detect unknown and new threats.
[0027] Network Services used 2240 is calculated by measuring the average network service used and its standard deviation over a predefined period of time, for example, two weeks. The Network Services 2240 behaviour anomaly model can be used to detect spyware using unknown network services for communication with un-trusted system.
[0028] Destination Visited 2242 is calculated by measuring the average destination visited and its standard deviation over a predefined period of time, for example, two weeks. The Destination Visited 2242 behaviour anomaly model can be used to differentiate two types of attackes—“within” and “outbound”. For a “within” attack, a higher ratio of internal IP addresses of destination visited would be targeted. An example of such attack may be network probe. For an “outbound” attack, a higher ratio of external IP addresses of destination visited would be targeted. An example of such attack may be malware using the compromised host for sending spam, transmiting data, generating unauthorized network traffic, and etc.
[0029] Bytes Consumed 2244 is calculated by measuring the average bytes consumed and its standard deviation over a predefined period of time, for example, two weeks. The Bytes Consumed 2244 behaviour anomaly model can be used to detect burst of activity that exceeds or defies acceptable risk level.
[0030] Packets Consumed 2246 is calculated by measuring the average packets consumed and its standard deviation over a predefined period of time, for example, two weeks. Trend analysis, using simple moving average and exponential moving average, is also used to spot behavioural shift, even though the deviation is within acceptable risk threshold. Ratio of packet types are also calculated to measure abnormality in packet consumption. The Packet Consumed 2246 behaviour anomaly model can be used to detect subtle behavioural shift.
[0031] Suppose the network services usage of a particular user is represented in the form of a histogram. The X-axis represents the network services visited and the Y-axis represents the number of network packets generated using the network services. Using the histogram as a probability distribution, the analysis server 14 calculates the entropy (which is a measurement of the degree of dispersion of a distribution) to evaluate any shifts in user behaviour, which are shown as in FIGS. 6 . An entropy is calculated for each network service consumed by the user, and is recorded as one of his normal network activities. All entropies are normalized to provide a faster evaluation of anomalous score and to decide whether or not there are behavioural anomalies by comparing against the established baseline.
[0032] Visited service usage 2268 is calculated by measuring the average entropies and its standard deviation over a predefined period of time, for example, two weeks.
[0033] Network connection frequency 2269 is calculated by measuring the average network connection frequency and its standard deviation over a predefined period of time, for example, two weeks.
[0034] Group Profiling Module 2260 analyzes all the common network activities among a set of users to derive group profiles. All group profiling is calculated by measuring the average and its standard deviation over a predefined period of time among the group of users.
[0035] Reference is now made to FIG. 7 , which is an illustration of anomaly Detection Module 24 , are shown. The user and group profiling data could become input of any machine learning algorithms, such as ANN (Artificial Neural Network), SVM (Support Vector Machines), Decision tree, and create a detection engine and increase the accuracy of anomaly intrusion detection. For example, the heuristic decision tree algorithm can be used to detect behavioural anomaly. Specifically, a user's bytes consumed profile exceeded the deviation threshold and the service used was TCP 9100, then the behavioural anomaly might be printer abuse. However, suppose the deviation threshold was triggered by visited service usage profile, then the behavioural anomaly might be a scan for network vulnerability.
[0036] Reporting module 26 is used for analysis using a variety of graphical and text reports to notify an administrator what is going on in the corporate network and how the user uses the network.
[0037] The inventions have been described by reference to exemplary embodiments, but many additions, modifications, and/or deletions can be made thereto without departing from the spirit and scope of the inventions. In other words, the particular embodiments of the inventions described herein are merely illustrative and are not the only embodiments possible. Those skilled in the art can readily identify additional embodiments and features of the inventions that are within the spirit and scope of the inventions.
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A baseline can be defined using specific attributes of the network traffic. Using the established baseline, deviation can then be measured to detect anomaly on the network. The accuracy of the baseline is the most important criterion of any effective network anomaly detection technique. In a local area network (LAN) environment, the attributes change very frequently by many change agents; for example, new entities, such as users, application, and network-enabled devices, added to and removed from the LAN environment. The invention provides an improved method of establishing a baseline for network anomaly detection based on user's behaviour profiling. A user behaviour profiling is a distinct network usage pattern pertaining to a specific individual user operating on the LAN environment. No two users profiling would be the same. A group of users that have similar network usage attributes can be extrapolated using data mining technique to establish a group profiling baseline to detect network usage anomaly. By combining user and group profiling, a network anomaly detection system can measure subtle shift in network usage and as a result separate good user's network usage behaviour from the bad one. Using the said technique, a lower rate of false positives of network anomaly can be created that is suitable to operate in a highly dynamic LAN environment.
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CROSS-REFERENCE TO RELATED APPLICATION
The present application claims the benefit of co-pending Provisional U.S. Patent Application Ser. No. 60/390,337, filed Jun. 21, 2002, entitled: “Highly Integrated Dual-PHY Voice Co-Processor,” by P. McElroy, assigned to the assignee of the present application and the disclosure of which is incorporated herein.
FIELD OF THE INVENTION
The present invention relates in general to digital telecommunication systems, subsystems and components therefore, and is particularly directed to a new and improved integrated access device (IAD) platform, that employs a highly integrated time division multiplexed (TDM), a synchronous transfer mode (ATM) cell based architecture, to provide enhanced interfacing flexibility for multiple and diverse signaling protocols, and effectively reduces the cost and constraints as to choice of host processor used in conventional digital signal processor (DSP)-based IADs.
BACKGROUND OF THE INVENTION
In an effort to accommodate the diverse (e.g., voice and data signaling) requirements of a variety of telecommunication service providers and their customers, manufacturers of digital communication equipment currently offer what are known as integrated access devices (IADs), that allow a user to interface multiple types of digital voice and data signaling circuits with a (wide area) network. Unfortunately, current IAD designs are constrained by the lack or limited availability of reasonably priced and versatile communication control processors.
A fundamental shortcoming of these conventional controller chips is the fact that they are digital signal processor (DSP)-based, consume large amounts of power, and are procurable from essentially one semiconductor fabrication source. Being DSP-based means that the functionality of an TAD using such control chips is heavily dependent on embedded software. In addition, these chips have only a small number voice and data interface ports, which are typically permanently dedicated to specified signaling modes, thereby limiting their flexibility and efficiency in the face of dynamic signaling requirements.
SUMMARY OF THE INVENTION
In accordance with the invention, these and other shortcomings of conventional IADs are effectively obviated by a new and improved ‘DSP-less’ IAD architecture, that is configured as a dual PHY-based signal transport ASIC, and offers enhanced interfacing flexibility for multiple and diverse types of digital communication circuits. To this end, the dual PHY based IAD architecture of the invention comprises a multi-protocol communication interface (MCI) and an associated communication or host network processor (HNP). The MCI is configured to execute diverse types of digital communication signaling interface functions with a plurality of communication ports, under the control of supervisory control signals supplied via a generic, host processor interface. Advantageously, the host processor may be implemented using any one of a variety of reasonably priced, commercially available network processor chips.
A first, wide area communication network (WAN) port of the MCI terminates a WAN with a bidirectional digital cross-connect switch (XCS) and provides both ATM and high level data link control (HDLC) connectivity with the WAN. A second, voice TDM port terminates the digital cross-connect switch with a voice TDM circuit and provides digital transport connection to various TDM communication transceivers, such as analog codes and T1 (including fractional T1) transceivers. This TDM port may be configured as a conventional TDM mode port and supports standard TDM signaling control parameters, including Frame Sync, transmit and receive clock and data signals. The TDM port is additionally coupled to an adaptive clocking unit which is operative (during ATM mode operational mode) to adjust clock (Clk) and frame sync (Fs) to incoming cell delivery timing over an internal TDM bus from a bidirectional voice gateway.
The adaptive clocking unit may be configured as a digital phase locked loop (DPLL)-based adaptive clock recovery mechanism, of the type disclosed in co-pending U.S. patent application, Ser. No. 09/999,463, filed Oct. 31, 2001, by A. Ghobrial et al, entitled: “Method and Apparatus is for Providing Reliable Voice and Voice-Band Data Transmission Over A synchronous Transfer Mode (ATM) Network” (hereinafter referred to as the '463 application), assigned to the assignee of the present application and the disclosure of which is incorporated herein.
Coupled with the internal TDM bus are an echo canceler and ADPCM voice compression operator, preferably cascaded within TDM bus in the manner disclosed in co-pending U.S. patent application, Ser. No. 10/095,375, filed Mar. 12, 2002, by B Mitchell et al, al, entitled: “Echo Canceler and Compression Operators Cascaded in Time Division Multiplex Voice Communication Path of Integrated Access Device for Decreasing Latency and Processor Overhead” (hereinafter referred to as the '375 application), assigned to the assignee of the present application and the disclosure of which is incorporated herein. The internal TDM bus is also coupled to a dual tone multifrequency detector (DTMF) unit which contains a plurality of DTMF detectors, that may be selectively dedicated to tone sensing functions for signaling operations on the TDM bus. The DTMF unit also provides the MCI with the ability to detect dial tone.
A third, UTOPIA port terminates a dual UTOPIA L2 PHY interface with a byte-wide, ATM cell-based UTOPIA bus, that serves as the principal ‘data’ transport path with the host network processor. The dual UTOPIA L2 PHY interface and its associated UTOPIA bus operate at a very high frequency (on the order of 200 MHz, which equates to a data transport rate on the order of 25 MBps) relative to network and terminal rates, that typically have data rates on the order of only 1.5-2.0 Mbps (e.g., a WAN rate of 2304 kpbs). As such, signaling transport communications between the MCI and the host network processor may be considered to effectively quasi-instantaneous, so that participation by the host processor in the transport of both digitized voice and data communication signals over any of the routing paths among the signaling ports of the MCI will not burden (slow down) the operational speed of any of the external communication circuits to which the IAD is ported.
The dual UTOPIA L2 PHY interface has two separate PHY portions or layers (PHY 0 for data, and PHY 1 for voice), each PHY layer being byte-wide, containing separate transmit (TX) and receive (RX) buses. The PHY 1 portion has the higher priority of the two PHY portions and is exclusively used for voice ATM cell transfers between bidirectional voice playout buffers of a multi-channel voice playout buffer unit and the host network processor, and for ATM voice cell transfers between the host network processor and the WAN. The data PHY portion (PHY 0 ) is used for data ATM cell transfers between the host network processor and TX and RX data first-in, first-out registers (FIFOs) serving the WAN and an auxiliary V.35 circuit path.
A fourth, auxiliary NxPORT terminates an external port of a bidirectional multiplexer (mux/demux) with an auxiliary (Nx56/64) digital communication path, over which non cell-based (e.g., V.35) digital communications are conducted with an auxiliary digital communication device. A fifth communication port is a TDM legacy port, that terminates a voice gateway with a legacy voice TDM communication link, to provide TDM connectivity with the internal TDM bus containing the TDM transport path-cascaded echo canceler and ADPCM voice compression operator.
The internal TDM bus is further coupled to the bidirectional digital cross connect switch. This internal TDM voice interconnect path makes the MCI compatible with legacy IAD architectures, where TDM-IN and TDM-OUT interfacing are used. In such a legacy TDM mode, the TDM port by-passes ATM signal processing paths that use the dual UTOPIA L2 PHY interface and UTOPIA bus to the host network processor.
The TDM voice gateway is also coupled to plurality of bidirectional voice playout buffers of a multi-channel voice playout buffer unit containing thirty-two channels of bidirectional FIFOs, each being sized to store a full ATM cell, as well as accommodate transport delay to and from the host network processor. This serves to provide for an effectively continuous flow and conversion of TDM communication signals on the TDM bus with ATM cells interfaced with dual UTOPIA L2 PHY interface over a full duplex ATM cell bus therebetween.
The voice playout buffer unit contains a plurality of (e.g., 32 voice channel-associated) bidirectional, first-in, first-out registers (FIFOs), each of which is sized (e.g., has a 64 byte capacity) to store a standard 44-byte payload of a full ATM cell (53 bytes), and also provide sufficient capacity to accommodate expected worst case transport delay to and from the host network processor. As successively received voice sample data is written into a playout buffer from the internal TDM bus, a voice pointer (VP) is successfully incremented, when it points to the forty-third byte location, 44 bytes of TDM voice data are ready to be immediately encapsulated into a 53 byte ATM packet and burst-routed over the PHY 1 port of the dual PHY layer to the host processor for delivery to a downstream WAN circuit. For optimizing direct memory access (DMA) transfer efficiency of as many playout buffers (up to 32 channels) that currently have data for the host processor, the playout buffer unit employs a single write interrupt. At this single interrupt ATM cells for up to 32 channels of data are loaded in processor memory under DMA control.
The fact that each individual voice playout buffer has a sixty-four byte capacity means that for a 44 byte data field of a respective 53 byte ATM cell, there is a twenty-byte window within which the host processor must return a response ATM voice packet for the POTS channel of interest. ATM encapsulation of a respective 44 byte data field by the PVC router includes a four byte AAL2 header, a HEC byte and a four byte ATM header, as customarily employed in the art to realized a standard 53 byte ATM cell. Within the AAL2 header, the cell identification byte (CID) byte may be made programmable, so as to provide selective mapping to timeslots of a TDM frame, and thereby accommodate variations among different vendor equipment.
In the return direction from the host processor, the PVC router strips off the ATM overhead and begins writing the 44 bytes of voice payload data into the successive locations of the playout buffer, as pointed to by a cell pointer (CP), beginning with the location of the first byte of the 44 bytes that had just been burst out over the PHY bus to the processor. As long as the voice pointer (VP) which has been and continues to be incremented at the relatively slower TDM rate, has not reached the end (byte location 63) of the playout buffer and begun ‘wrapping around’ to the lowest byte location, and with the contents of the first 44 byte locations of the playout buffer having been read out to the processor and therefore stale, return voice cell data from the processor may be written into those same (stale data) byte locations (0-43) of the playout buffer from which the previous burst was received.
As result, since it operates at a considerably higher speed than the TDM bus, the host processor is expected to return a response ATM voice cell containing 44 bytes of TDM data to the playout buffer, well prior to voice pointer reaching the end of the twenty cell window of the playout buffer, even though there may be some byte differential (one to twenty bytes, in the present example of a 64 bytes capacity playout buffer) between the current location of the voice pointer (VP) and that of the playout pointer (PP). This flexibility offered by the practical size of the playout buffer greatly reduces the cost and complexity of the digitized voice transport path. Namely, as long as this ‘turn-around’ differential remains within the twenty byte window, continuity of voice packet flow (with no overflow and no underflow) will be effectively maintained throughout the call. If a return cell is not ready to send, the host processor resends the last transmitted cell, to maintain continuous voice cell flow.
The digital cross-connect switch is used to provide external communication signaling port terminations with the WAN and the voice TDM circuit, and includes a TDM voice port through which the TDM voice circuit is coupled to the internal TDM bus. It further includes an ATM port and an HDLC port which respectively provide connectivity between the WAN port and a WAN ATM transceiver and a WAN HDLC transceiver. The digital cross-connect switch also has a sixth, Nx port that is coupled to the mux/demux. The mux/demux is coupled to an NxPORT HDLC transceiver.
The digital cross-connect switch has two modes of operation: direct DS 0 -mapping mode, and ATM/HDLC transceiver interface mode. In DS 0 -mapping mode, the internal dual ATM PHY conversion and transport functionality of the MCI is effectively bypassed, with DS 0 time slots on the voice TDM link directly mapped through the cross-connect switch to the WAN, using a user-controlled mapping scheme. DS 0 time slots on the voice TDM link are directly mappable to the voice port, so that they may be coupled to the internal TDM bus. DS 0 time slots may also be directly mapped via to Nx mux/demux for Nx56/64 clear channel (V.35) operation.
In ATM/HDLC transceiver interface mode, the cross-connect switch couples the WAN port to the appropriate one of ATM and HDLC transceiver ports, which are respectively coupled to a WAN ATM transceiver and a WAN HDLC transceiver. For ATM mode communications incoming from the WAN toward the network processor, the WAN ATM transceiver couples to a WAN receive (RX) FIFO incoming ATM cells from the cross-connect switch. The WAN RX FIFO may have a relatively small depth, such as one that accommodates only two ATM cells, due to the considerably higher speed of the UTOPIA L2 PHY bus. ATM cells supplied to the WAN RX FIFO are forwarded via a permanent virtual circuit (PVC) router to the (PHY 0 ) portion of the dual UTOPIA L2 PHY interface for transport over the UTOPIA bus to the network processor.
The PVC router is preferably implemented using multibit table entries in internal memory to steer the flow of ATM data cells of various virtual circuits within the MCI for voice and data signaling transport. The PVC routing table supports entries for transmit and entries for receive, and specifies to/from which interface the ATM cell of interest is delivered. In a customary manner, the PVC router is configured to analyze the contents of a respective packet presented to it and then selectively route the packet to the appropriate output port based upon the results of that analysis.
For incoming ATM voice cells from the WAN, routing to the network processor is from the RX FIFO to the PHY 1 portion of the dual UTOPIA L2 PHY interface; transmitted WAN voice routing from the processor toward the WAN is from the PHY 1 portion of dual PHY layer to a voice WAN TX FIFO. For incoming voice calls from the TDM2 network, routing flows from the voice playout buffer unit to the PHY 1 portion of dual PHY interface. Conversely, for outgoing ATM voice calls to the TDM2 network, routing is from the PHY 1 portion of the dual PHY interface to the voice playout buffer unit.
For ATM data cells received from the WAN by way of the ATM transceiver, routing of data to the network processor is from the WAN RX FIFO to the PHY 0 port of the dual UTOPIA L2 PHY interface, whereas transmitted WAN data routing from the processor flows from the PHY 0 portion of dual PHY layer to a WAN data (D) TX FIFO and to the WAN ATM transceiver.
For HDLC traffic received from the WAN via an HDLC receiver, routing to the network processor is from the WAN RX FIFO to the PHY 0 port of the dual UTOPIA L2 PHY interface 130 , whereas transmitted WAN data from the processor is from the PHY 0 portion of the dual PHY layer to the WAN data transmit (DTX) FIFO and HDLC transceiver. For incoming auxiliary V.35 routing, the PVC router directs data entries in an V.35 RX FIFO to the PHY 0 portion of the dual UTOPIA L2 PHY interface, and for outgoing auxiliary V.35 routing, the PVC router directs the AAL5 encapsulated data from the PHY 0 portion of the dual UTOPIA L2 PHY interface into the V.35 TX FIFO.
In the transmit direction (outgoing to the WAN from the network processor), the WAN ATM transceiver selectively interfaces to the WAN, either ATM data cells from the DTX FIFO or ATM voice cells from a voice transmit (VTX) FIFO. The VTX FIFO may also have a relatively small depth of 128 bytes due to the considerably higher speed of the UTOPIA L2 PHY bus. On the other hand, the data TX FIFO may have a much larger depth (e.g., on the order of 2K bytes), for buffering a relatively large number of cells or frames of data (such as a full size Ethernet frame with ATM overhead); this serves to accommodate transmission priority given to the voice TX FIFO, and helps to alleviate UTOPIA PHY 0 backpressure at the host processor.
The host processor monitors conventional buffer ‘watermarks’ in the transmit FIFOs, to keep the transmit FIFOs full during transmission. To avoid backing up a packet into the host processor's UTOPIA PHY interface FIFO structure, or ‘starving’ one of the transmit FIFOs in the MCI, the host processor waits for watermark confirmation before sending a new frame of data to the data transmit FIFO.
The WAN ATM transceiver employs a priority-based, quality of service (QoS) steering mechanism to controllably interface either (PHY 1 -sourced) voice ATM cells buffered in the voice cell transmit FIFO, or (PHY 0 -sourced) data cells buffered in the data cell transmit FIFO. The QoS controller gives priority to (PHY 1 ) voice cells, and continuously examines the voice cell transmit FIFO to determine whether it has voice cells awaiting transmission. If so (and the data transmit FIFO is not currently being read out), the QoS controller immediately couples the voice cell transmit FIFO to the WAN ATM transceiver, so that voice cells may be read out of the VTX FIFO to completion. However, if the data transmit FIFO is currently being read out, then upon completion of this operation, the QoS controller outputs any ATM voice cells buffered in the voice transmit FIFO to the WAN ATM transceiver for transmission over the WAN. However, if the voice cell transmit FIFO does not contain voice cells, the QoS controller allows any data cells buffered in the data transmit FIFO to be coupled to the WAN ATM transceiver for application to the WAN.
For HDLC mode communications incoming from the WAN toward the network processor, the WAN HDLC transceiver interfaces ATM cells containing HDLC frames to the WAN RX FIFO. To provide ATM-compatibility with the dual UTOPIA L2 PHY interface, an ATM encapsulation mechanism performs HDLC-ATM conversion of the incoming frames, stripping off HDLC information and encapsulating the data using, for example, ATM Adaptation Layer 5 (AAL5) for storage in the RX FIFO. The AAL5 encapsulated frame buffered in the RX FIFO are read out and routed to the data (PHY 0 ) portion of the dual UTOPIA L2 PHY interface for transport to the network processor. In the transmit direction to the WAN, ATM cells containing AAL5-encapsulated HDLC data interface from the host processor are buffered into the DTX FIFO by the PVC router and then converted by the ATM encapsulation mechanism back into HDLC frames. The WAN HDLC transceiver then outputs the HDLC frames through the XCS for application to the WAN.
The NxPORT HDLC transceiver is configured similar to the WAN HDLC transceiver and provides the ability to interface ATM cell traffic on the PHY 0 portion of the dual UTOPIA L2 PHY interface with an auxiliary digital communication path. In the receive direction from the Nx communication path toward the network processor, the NxPORT HDLC transceiver interfaces ATM-encapsulated data cells to a V.35 RX FIFO. These ATM-encapsulated cells contain the contents of the auxiliary protocol (e.g., V.35) data frames (e.g., FRP or PPP) that are coupled to the Nx mux/demux. ATM-encapsulation is used by NxPORT HDLC transceiver to provide ATM-compatibility with the dual UTOPIA L2 PHY interface.
In the transmit direction to the Nx communication path from the host processor, ATM cells containing AAL5-encapsulated HDLC data, are buffered into a V.35 TX FIFO by the PVC router. The host processor monitors buffer watermarks in the V.35 TX FIFO, to keep the V.35 TX FIFO full during V.35 mode transmission, and waits for watermark confirmation before sending a new frame, to avoid back into the host processor's UTOPIA PHY interface FIFO structure, or ‘starving’ the V.35 TX FIFO. Outgoing ATM cells buffered in the V.35 TX FIFO from the PVC router are converted by the ATM encapsulation mechanism back into V.35 data. The NxPORT HDLC transceiver then outputs the V.35 data to the Nx mux/demux for application to the auxiliary (Nx56/64) digital communication path.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 diagrammatically illustrates the overall architecture of a non-limiting, but preferred, embodiment of the dual PHY-based integrated access device of the present invention;
FIG. 2 diagrammatically illustrates a bidirectional playout buffer of the voice playout buffer unit of the multi-protocol communication interface of the IAD architecture of FIG. 1 ;
FIG. 3 highlights a DS 0 cross-connect path 3000 between ports of the digital cross-connect switch of the dual PHY-based integrated access device shown in FIG. 1 ;
FIG. 4 highlights a DS 0 cross-connect path 4000 between a voice TDM port and an internal TDM bus port of the digital cross-connect switch of the dual PHY-based integrated access device shown in FIG. 1 ;
FIG. 5 highlights a further TDM transport path 5000 between a mux/demux and an NxPort of the digital cross-connect switch of the dual PHY-based integrated access device shown in FIG. 1 ;
FIG. 6 highlights an ATM voice cell transport path 6000 from the WAN port to a TDM port in the dual PHY-based integrated access device shown in FIG. 1 ;
FIG. 7 highlights an ATM voice cell transport path 7000 from the TDM port to the WAN port in the dual PHY-based integrated access device shown in FIG. 1 ;
FIG. 8 highlights an ATM data cell transport path 8000 from the WAN port to the network processor transport direction, in the dual PHY-based integrated access device shown in FIG. 1 ;
FIG. 9 highlights an ATM data cell transport path 9000 from the network processor to the WAN port transport direction, in the dual PHY-based integrated access device shown in FIG. 1 ;
FIG. 10 highlights an HDLC transport path 10000 from the WAN port to the network processor transport direction, in the dual PHY-based integrated access device shown in FIG. 1 ;
FIG. 11 highlights an HDLC transport path 11000 from the network processor to the WAN port transport direction, in the dual PHY-based integrated access device shown in FIG. 1 ;
FIG. 12 highlights a V.35 NxPORT HDLC transport path 12000 from an NxPORT interface port to the network processor, in the dual PHY-based integrated access device shown in FIG. 1 ; and
FIG. 13 highlights a V.35 NxPORT HDLC transport path 13000 from the network processor to the NxPORT interface port, in the dual PHY-based integrated access device shown in FIG. 1 ;
DETAILED DESCRIPTION
Before detailing the dual PHY-based integrated access device according to the present invention, it should be observed that the invention resides primarily in a prescribed arrangement of conventional digital communication circuits and components, and an attendant host communications microprocessor, and application software therefore, that controls the operations of such circuits and components. In a practical implementation, the invention may be readily constructed of field programmable gate array (FPGA)-configured, digital application specific integrated circuit (ASIC) chip sets. Consequently, in the drawings, the configuration of such circuits and components, and the manner in which they may be interfaced with various telecommunication circuits have, for the most part, been illustrated by readily understandable block diagrams, which show only those specific details that are pertinent to the present invention, so as not to obscure the disclosure with details which will be readily apparent to those skilled in the art having the benefit of the description herein. Thus, the block diagrams of the Figures are primarily intended to show the various components of the invention in convenient functional groupings, so that the present invention may be more readily understood.
Attention is now directed to FIG. 1 , which diagrammatically illustrates the overall architecture of a non-limiting, but preferred, embodiment of the dual PHY-based integrated access device of the present invention. As shown therein this new architecture comprises two essential components: 1- a multi-protocol communication interface (MCI) 100 ; and 2- an associated communication processor 200 , hereinafter referred to as a host network processor (HNP). The MCI 100 has no intelligence of its own, but performs digital communication signaling interface functions in accordance with supervisory control inputs supplied by way of a generic, host processor interface (HPI) 160 from HNP 200 . Advantageously, the host processor may be implemented using any one of a variety of commercially available network processor chips, such as, but not limited to, RISC/CISC based processors with integrated memory controllers, chip select logic, I/O debug interfaces, ATM and Ethernet interfaces of the type available from vendors including is Motorola, Infineon, Texas Instruments, IDT, and Virata/Globespan.
In order to provide signal transport and network processor control interconnectivity, MCI 100 contains a plurality of signaling interface ports P 1 -P 6 , of which ports P 1 -P 5 interface digital communication signals with the HNP 200 and various external communication paths, and port P 6 of which interfaces control signals with the HNP 200 . In particular, a first, wide area communication network (WAN) port P 1 terminates a WAN 10 with a first port 111 of a conventional bidirectional digital cross connect switch (XCS) 110 , and provides both ATM and high level data link control (HDLC) connectivity with the WAN 10 .
A second, voice TDM or TDM2 port P 2 terminates a second port 112 of the digital cross connect switch with a voice TDM circuit 20 , and provides digital transport connection to various TDM communication transceivers, such as analog codes and T1 (including fractional T1) transceivers. Port P 2 may be configured as a conventional TDM mode port and supports standard TDM control parameters, including Frame Sync, transmit and receive clock and data signals. In addition, port P 2 is coupled to an adaptive clocking unit 260 , which is operative (during ATM mode operational mode) to adjust clock (Clk) and frame sync (Fs) to incoming cell delivery timing over an internal TDM bus 210 from a bidirectional voice gateway 150 .
For this purpose, adaptive clocking unit 260 may be configured as a digital phase locked loop (DPLL)-based adaptive clock recovery mechanism, of the type disclosed in the above-referenced '463 application. As described therein, this DPLL-based adaptive clock recovery mechanism produces a recovered clock based upon a DPLL's phase detector's count of the number of high frequency service clock cycles that occur between transitions in an input signal representative of instances of receipt of ATM cells written into a cell jitter buffer and subject to cell delay variations through the cell transport path, and a reference clock signal whose frequency is a prescribed fraction of that of the output clock.
Installed within the internal TDM bus 210 is a cascaded arrangement of a TDM transport path-cascaded echo canceler 270 and ADPCM voice compression operator 280 , which are preferably of the types disclosed in the above-referenced '375 application. As described therein, this cascaded compression and echo cancellation arrangement implements G.726 ADPCM voice compression and G.168 echo cancellation by operating directly on the TDM encoded voice stream. Producing a processed digitized voice signal stream in this manner relieves the host processor of having to use data bus cycles to download processed digitized voice samples.
The TDM bus 210 is also coupled to a dual tone multifrequency detector (DTMF) unit 250 which contains a plurality of DTMF detectors, that may be selectively dedicated to tone sensing functions for signaling operations on the TDM bus. For example, for a 32 TDM voice channel example of the present embodiment, the DTMF unit 250 may include a practical number of DTMF detectors (e.g., sixteen) for any DS 0 via the bidirectional digital cross connect switch (XCS) 110 , to provide DTMF detection where required for digital collection and analysis. In addition, the DTMF unit 225 provides the MCI with the ability to detect dial tone.
A third, UTOPIA port P 3 terminates a dual UTOPIA L2 PHY interface 130 with a byte-wide, ATM cell-based UTOPIA bus 30 . This bus serves as the main ‘data’ or communication signal transport path with the host network processor. The dual UTOPIA L2 PHY interface 130 and its associated UTOPIA bus 30 operate at a very high clocking frequency (on the order of 200 MHz, which equates to a data transport rate on the order of 25 MBps) relative to network and terminal rates, which have data rates on the order of only 1.5-2.0 Mbps (e.g., a WAN rate of 2304 kpbs). As such, signaling transport communications between the MCI 100 and the host network processor 200 may be considered to effectively quasi-instantaneous, so that participation by the host processor in the transport of both digitized voice and data communication signals over any of the routing paths among the signaling ports of the MCI will not burden (slow down) the operational speed of any of the external communication circuits to which the IAD is ported.
For this purpose, the dual UTOPIA L2 PHY interface 130 contains two separate PHY portions (PHY 0 for data, and PHY 1 for voice), each PHY layer being byte-wide and containing separate transmit (TX) and receive (RX) buses. The PHY 1 portion is dedicated to voice signaling and has the higher priority of the two PHY portions. Conversely, the PHY 0 portion (associated with data transport) is the lower priority of the two portions. The voice PHY portion (PHY 1 ) of the dual UTOPIA L2 PHY interface 130 is used for voice ATM cell transfers between bidirectional voice playout buffers of a multi-channel voice playout buffer unit 290 and the host network processor 200 , and for ATM voice cell transfers between the host network processor 100 and the WAN via a voice WAN FIFO 330 , as will be described. The data PHY portion (PHY 0 ) of the dual UTOPIA L2 PHY interface 130 is used for data ATM cell transfers between the host network processor and sets of TX and RX data FIFOS, serving the WAN and an auxiliary V.35 circuit path, as will be described.
A fourth, NxPORT P 4 of the MCI 100 terminates an external port 143 of a bidirectional multiplexer (mux/demux) 140 with an auxiliary (Nx56/64) digital communication path 40 , over which non cell-based (e.g., V.35) digital communications are conducted with an auxiliary digital communication device. The fifth communication port P 5 is a TDM legacy port, that terminates a first port 151 of the gateway 150 with a legacy voice TDM communication link 50 . As pointed out above, gateway 150 provides TDM connectivity with a TDM bus 210 containing the TDM transport path-cascaded echo canceler 270 and ADPCM voice compression operator 280 .
The TDM bus 210 is further coupled to TDM voice port 113 of bidirectional digital cross connect switch (XCS) 110 . This internal TDM voice interconnect path makes the MCI compatible with legacy IAD architectures, such as those which employ a Motorola 860 processor. The TDM legacy port P 5 readily supports these architectures where TDM-IN and TDM-OUT interfacing are used. In such a legacy TDM mode, port P 5 is TDM-coupled to port P 2 , by-passing ATM signal processing paths that use the dual UTOPIA L2 PHY interface 130 and UTOPIA bus 30 to the host network processor.
A second port 152 of the TDM voice gateway 150 is coupled via a link 212 to port 291 of bidirectional voice playout buffers of a multi-channel voice playout buffer unit 290 . As will be described, for the 32 voice channel example here, the voice playout buffer unit 290 comprises 32 channels of bidirectional first-in, first-out registers (FIFOs). Each FIFO is sized (e.g., has a 64 byte capacity) which is sufficient to store a full ATM cell (53 bytes), as well as accommodate transport delay to and from the host network processor, to allow for an effectively continuous interfacing/flow and conversion of TDM communication signals on the TDM bus 210 with ATM cells interfaced with dual UTOPIA L2 PHY interface 130 over a full duplex ATM cell bus 214 therebetween. The remaining port P 6 of the MCI terminates a control signal bus 60 with a generic, host processor interface (HPI) 160 , through which control signals are interfaced with the HNP 200 for configuring and managing the functionality of the MCI.
As pointed out briefly above, the digital cross-connect switch (XCS) 110 , which may of conventional construction, provides first and second external communication signaling port terminations 111 /P 1 and 112 /P 2 with the WAN 10 and voice TDM circuit 20 , respectively. In addition to its two external ports 111 and 112 , XCS 110 includes a third, TDM voice port 113 , through which TDM voice circuit 20 is coupled to the internal TDM bus 210 . XCS 110 has a fourth, ATM port 114 , and a fifth, HDLC port 115 , which respectively provide connectivity between the WAN port 111 and a WAN ATM transceiver 220 , and a WAN HDLC transceiver 230 . The digital cross connect switch 110 further includes a sixth, Nx port 116 , that is coupled to a first internal port 141 of mux/demux 140 . A second internal port 142 of mux/demux 140 is coupled to an NxPORT HDLC transceiver 240 .
The digital XCS 110 has two modes of operation: 1-direct DS 0 -mapping mode, and 2-ATM/HDLC transceiver interface mode. In DS 0 -mapping mode, the internal dual ATM PHY conversion and transport functionality of the MCI is effectively bypassed; instead, DS 0 time slots on the voice TDM link 20 at port 112 are directly mappable to port 111 and WAN 10 , based upon a user-controlled mapping scheme. In addition, DS 0 time slots on the voice TDM link 20 at port 112 are directly mappable to the voice port 113 , so that they may be coupled to the internal TDM bus 210 . DS 0 time slots at port 112 may also be directly mapped via port 116 to port 141 of Nx mux/demux 140 for Nx56/64 clear channel (V.35) operation. As noted above, DTMF detector unit 250 coupled to internal TDM bus 210 may be used to analyze DTMF and dial tone signals.
In ATM/HDLC transceiver interface mode, XCS 110 couples the WAN port 111 to the appropriate one of ATM and HDLC transceiver ports 114 and 115 , which are respectively coupled to WAN ATM transceiver 220 and WAN HDLC transceiver 230 . Considering first, ATM mode communications, in the is receive direction (incoming from the WAN toward the network processor), the WAN ATM transceiver 220 is configured to interface, over an eight bit wide receive bus 222 to a receive (RX) FIFO 310 , incoming ATM cells that have been coupled thereto via port 114 of XCS 110 . As a non-limiting example, RX FIFO 310 may have a relatively small depth (e.g., 128 bytes, which accommodates two ATM cells or 106 bytes) due to the considerably higher speed of the UTOPIA L2 PHY bus. ATM cells supplied to RX FIFO 310 are output via a permanent virtual circuit (PVC) router 120 to the data (PHY 0 ) portion of the dual UTOPIA L2 PHY interface 130 , for transport over UTOPIA bus 30 to the network processor.
The PVC router 120 is preferably implemented using multibit table entries in internal memory to control or ‘steer’ the flow of ATM data cells of various virtual circuits within the MCI for voice and data signaling transport. For the 32 channel example of the present embodiment, the PVC routing table supports 32 entries for transmit and 32 entries for receive, and specifies to/from which interface the ATM cell of interest is delivered. In a customary manner, PVC router 120 is configured to analyze the contents of a respective packet presented to it and then selectively route the packet to the appropriate output port based upon the results of that analysis.
For incoming ATM voice cells from the WAN 10 , routing to the network processor is from the RX FIFO 310 to the PHY 1 port of the dual UTOPIA L2 PHY interface 130 , whereas transmitted WAN voice routing from the processor is from the PHY 1 portion of dual PHY layer to the voice WAN FIFO 330 . For incoming voice calls from the TDM2 network 20 , routing is from the cell bus 214 serving the voice playout buffer unit 290 to the PHY 1 portion of interface 130 , whereas outgoing voice calls to the TDM2 network 20 , routing is from the PHY 1 portion of interface 130 over the cell bus 214 to the voice playout buffer unit 290 .
For ATM data cells received via ATM transceiver 220 from the WAN 10 , routing to the network processor is from the RX FIFO 310 to the PHY 0 port of the dual UTOPIA L2 PHY interface 130 , whereas transmitted WAN data routing from the processor is from the PHY 0 portion of dual PHY layer to the WAN DTX FIFO 320 and to WAN ATM transceiver 220 . For HDLC traffic received via HDLC receiver 230 from the WAN 10 , routing to the network processor is from the RX FIFO 310 to the PHY 0 port of the dual UTOPIA L2 PHY interface 130 , whereas transmitted WAN data routing from the processor is from the PHY 0 portion of the dual PHY layer to the WAN DTX FIFO 320 and to HDLC transceiver 230 .
For incoming auxiliary V.35 routing, the PVC router 120 directs data entries in the V.35 RX FIFO 340 to the PHY 0 portion of the dual UTOPIA L2 PHY interface 130 ; for outgoing auxiliary V.35 routing, PVC router 120 directs the AAL5 encapsulated data from the PHY 0 portion of the dual UTOPIA L2 PHY interface 130 into the V.35 TX FIFO 350 .
In the transmit direction (outgoing to the WAN from the network processor), WAN ATM transceiver 220 selectively interfaces to the WAN data, either ATM data cells via a data byte bus 221 from a data transmit (DTX) FIFO 320 (which is coupled via PVC router 120 to the data portion (PHY 0 ) of the dual UTOPIA L2 PHY interface 130 ), or ATM voice cells via a voice byte bus 331 from a voice transmit (VTX) FIFO 330 (which is coupled via PVC router 120 to the voice portion (PHY 1 ) of the dual UTOPIA L2 PHY interface 130 ). As a non-limiting example, like RX FIFO 310 , VTX FIFO 330 may have a relatively small depth of 128 bytes due to the considerably higher speed of the UTOPIA L2 PHY bus.
On the other hand, DTX FIFO 320 may have a much larger depth (e.g., on the order of 2K bytes), for buffering a relatively large number of cells or frames of data (such as a full size Ethernet frame with ATM overhead); this serves to accommodate transmission priority given to the VTX FIFO 330 , and helps to alleviate UTOPIA PHY 0 backpressure at the host processor. Via processor interface 160 , the host processor monitors conventional buffer levels or ‘watermarks’ in the transmit FIFOs, in order to keep the transmit FIFOs full during transmission. To avoid undesirably backing up a packet into the host processor's UTOPIA PHY interface FIFO structure, or ‘starving’ one of the transmit FIFOs in the MCI 100 , the processor waits for watermark confirmation before sending a new frame of data to the DTX FIFO 320 .
The WAN ATM transceiver 220 employs a priority-based, quality of service (QoS) steering mechanism 225 , which selectively interfaces either (PHY 1 -sourced) voice ATM cells buffered in voice cell transmit FIFO 330 , or (PHY 0 -sourced) data cells buffered in data cell transmit FIFO 320 . QoS controller 225 is configured to give priority to (PHY 1 ) voice cells. For this purpose, QoS controller 225 continuously examines the voice cell transmit FIFO 330 to determine whether it has voice cells awaiting transmission. If so (and the data transmit FIFO 320 is not currently being read out), the QoS controller 225 immediately couples the voice cell transmit FIFO 330 to WAN ATM transceiver 220 , so that voice cells may be read out of the VTX FIFO 330 to completion. However, if data transmit FIFO 320 is currently being read out, then upon completion of this operation, QoS controller 225 outputs any ATM voice cells buffered in FIFO 330 to the WAN ATM transceiver 220 for transmission over the WAN 10 . So long as the voice cell transmit FIFO 330 does not contain voice cells, however, QoS controller 225 allows any data cells buffered in the data FIFO 320 to be coupled to WAN ATM transceiver 220 for application to WAN 10 .
For HDLC mode communications, in the receive direction (incoming from the WAN toward the network processor), WAN HDLC transceiver 230 is configured to interface over an eight bit wide receive bus 221 to RX FIFO 310 , ATM cells containing the contents of incoming HDLC frames that have been coupled thereto via port 115 of XCS 110 . In order to provide ATM-compatibility with the dual UTOPIA L2 PHY interface 130 , WAN HDLC transceiver 230 employs an ATM encapsulation mechanism 235 , which performs HDLC-ATM conversion of the incoming frames (which may employ frame relay (FR) protocol, or point-to-point protocol (PPP), as non-limiting examples). The ATM encapsulation mechanism 235 is operative to strip off HDLC information and then encapsulate the remaining contents of the data using, for example, ATM Adaptation Layer 5 (AAL5) for storage in RX FIFO 310 . The contents of the AAL5 encapsulated frame buffered into the RX FIFO 310 are read out and routed via PVC router 120 to the data (PHY 0 ) portion of the dual UTOPIA L2 PHY interface 130 , for transport over UTOPIA bus 30 to the network processor.
In the transmit direction (to the WAN from the network processor), ATM cells containing AAL5-encapsulated HDLC data, as transported over the data portion (PHY 0 ) of the dual UTOPIA L2 PHY interface 130 from the host processor, are buffered into the DTX FIFO 320 by the PVC router 120 . They are then coupled over byte-wide bus 322 from the DTX FIFO 320 and converted by the ATM encapsulation mechanism 235 back into HDLC frames. WAN HDLC transceiver 230 then outputs the HDLC frames to port 115 of XCS 110 for application to WAN 10 .
As pointed out above, MCI 100 contains an additional (NxPORT) HDLC transceiver 240 , which is configured similar to WAN HDLC transceiver 230 and provides the ability to interface ATM cell traffic on the PHY 0 portion of the dual UTOPIA L2 PHY interface 130 with an auxiliary (e.g., Nx56/64) digital communication path 40 . For this purpose, in the receive direction (incoming from the Nx communication path 40 toward the network processor), NxPORT HDLC transceiver 240 is configured to interface ATM-encapsulated data cells over an eight bit wide receive bus 341 to a (V.35) RX FIFO 340 . These ATM-encapsulated cells contain the contents of auxiliary protocol (e.g., V.35) data frames (e.g., FRP or PPP) that are coupled thereto via port 142 of Nx mux/demux 140 . Like FIFOs 310 and 330 , described above, V.35 RX FIFO 340 may have a relatively small depth of 128 bytes.
As in the case of WAN HDLC transceiver 230 , ATM-encapsulation is used by NxPORT HDLC transceiver 240 to provide ATM-compatibility with the dual UTOPIA L2 PHY interface 130 . For this purpose, NxPORT HDLC transceiver 240 contains an ATM encapsulation mechanism 245 which performs HDLC-ATM (AAL5) conversion of the incoming frames (which may employ frame relay (FR) protocol, or point-to-point protocol (PPP), as non-limiting examples). The AAL5-encapsulated V.35 data is buffered in V.35 RX FIFO 340 , and then read out and routed via PVC router 120 to the data (PHY 0 ) portion of the dual UTOPIA L2 PHY interface 130 , for transport over UTOPIA bus 30 to the network processor.
In the transmit direction (to the Nx communication path 40 from the host processor 200 ), ATM cells containing AAL5-encapsulated HDLC data, as transported over the data portion (PHY 0 ) of the dual UTOPIA L2 PHY interface 130 , are buffered into a V.35 TX FIFO 350 by the PVC router 120 . Like DTX FIFO 320 , V.35 TX FIFO 350 may have a depth on the order of 2K bytes, to accommodate buffering a full size Ethernet frame with ATM overhead), and alleviate UTOPIA PHY 0 backpressure at the host processor. As with the DTX FIFO 320 , via interface 160 , the host processor monitors buffer watermarks in the V.35 TX FIFO, to keep the V.35 TX FIFO full during V.35 mode transmission, and waits for watermark confirmation before sending a new frame, to avoid back into the host processor's UTOPIA PHY interface FIFO structure, or ‘starving’ the V.35 TX FIFO. Outgoing ATM cells buffered into the V.35 TX FIFO 350 from the PVC router 120 are coupled over byte-wide bus 351 from the V.35 TX FIFO 350 and converted by the ATM encapsulation mechanism 245 back into V.35 data. The NxPORT HDLC transceiver 240 then outputs the V.35 data to port 142 of Nx mux/demux 140 for application to auxiliary (Nx56/64) digital communication path 40 .
As described briefly above, the voice playout buffer unit 290 contains a plurality of (e.g., 32 voice channel-associated) bidirectional, first-in, first-out registers (FIFOs), each of which is sized (e.g., has a 64 byte capacity) to store a standard 44-byte payload of a full ATM cell (53 bytes), and also provide sufficient capacity to accommodate expected worst case transport delay to and from the host network processor; this serves to ensure effectively continuous interfacing/flow and conversion of TDM communication voice data on the TDM bus 210 with ATM cells that are interfaced with dual UTOPIA L2 PHY interface 130 over the full duplex ATM cell bus 214 therebetween.
This may be readily understood by reference to FIG. 2 , which diagrammatically illustrates an individual one of 32 (64 kbyte) bidirectional playout buffers 400 - 1 , . . . , 400 - 32 that reside within the voice playout buffer unit 290 . For transmitting and receiving ATM cells via the full duplex ATM cell bus 214 , the voice playout buffer 400 is coupled to an ATM cell port 292 . For transmitting and receiving TDM data with respect to the TDM bus 210 , the is voice playout buffer is coupled to a TDM port 291 .
Consider the flow of TDM voice traffic received from the TDM bus 210 (as sourced from the TDM2 port P 2 that terminates port 112 of the digital cross connect switch with voice TDM circuit 20 ). For purposes of simplification, let it be initially assumed that all of the playout buffers are cleared or reset, so that received TDM voice traffic from TDM bus 210 are written into successive byte locations of the playout buffer 400 , beginning with the lowermost or ‘0’th byte location (as pointed to by a (bit-oriented) voice pointer (VP)), which is incremented through successive storage locations of the playout buffer, at the rate of the received data clock. As successively received voice sample data is written into the playout buffer from the TDM bus 210 , the voice pointer (VP) will eventually point to the forth-third byte location. At this time, 44 bytes of TDM voice data are ready to be immediately encapsulated into a 53 byte ATM packet and burst-routed via PVC 120 and the dual PHY layer 130 to the host processor for delivery to a downstream WAN circuit. For optimizing DMA transfer efficiency of as many playout buffers (up to 32) that currently have data for the host processor, the playout buffer unit employs a single write interrupt. At this single interrupt ATM cells for up to 32 channels of data are loaded in processor memory under DMA control.
The fact that each individual voice playout buffer 400 has a sixty-four byte capacity means that for a 44 byte data field of a respective 53 byte ATM cell, there is a twenty-byte window within which the host processor must return a response ATM voice packet for the POTS channel of interest. ATM encapsulation of a respective 44 byte data field by the PVC router 120 includes a four byte AAL2 header, a HEC byte and a four byte ATM header, as customarily employed in the art to realized a standard 53 byte ATM cell. Within the AAL2 header, the cell identification byte (CID) byte may be made programmable, so as to provide selective mapping to timeslots of a TDM frame, and thereby accommodate variations among different vendor equipment.
In the return direction from the host processor, the PVC router 120 strips off the ATM overhead and begins writing the 44 bytes of voice payload data into the successive locations of the playout buffer, as pointed to by a cell pointer (CP), beginning with the location of the first byte of the 44 bytes that had just been burst out over the PHY bus to the processor. As long as the voice pointer (VP), which has been and continues to be incremented at the relatively slower TDM rate, has not reached the end (byte location 63 ) of the playout buffer and begun ‘wrapping around’ to the lowest byte location, and with the contents of the first 44 byte locations of the playout buffer having been read out to the processor and therefore stale, return voice cell data from the processor may be written into those same (stale data) byte locations ( 0 - 43 ) of the playout buffer from which the previous burst was received.
Thus, if the host processor has (and due to its considerably higher speed is expected to have) returned a response ATM voice cell containing 44 bytes of TDM data to the playout buffer, before the end of the twenty cell window of the playout buffer has been reached, there can expected to be some byte differential (one to twenty bytes, in the present example of a 64 bytes capacity playout buffer) between the current location of the voice pointer (VP) and that of the playout pointer (PP). This flexibility offered by the practical size of the playout buffer greatly reduces the cost and complexity of the digitized voice transport path. Namely, as long as this ‘turn-around’ differential remains within the twenty byte window, continuity of voice packet flow (with no overflow and no underflow) will be effectively maintained throughout the call. If a return cell is not ready to send, the host processor will resend the last transmitted cell, to maintain continuous voice cell flow.
Having described the overall architecture of the dual PHY-based signal integrated access device of the is present invention, the following discussion will review the various communication signal (voice and data) flow paths through the IAD for its various modes of operation. Although these communication signal flow paths have been discussed in the context of the components through which they pass, using respective Figures to show each communication path in a bold overlay format on the architecture diagram of FIG. 2 is believed to facilitate an appreciation of the versatility and flexibility of the invention relative to the limited capabilities of conventional DSP-based IAD platforms, described above.
TDM Voice Time Slot Cross-Connect Mapping Mode ( FIGS. 3-5 )
In this mode of operation, the IAD essentially provides DS 0 cut-through or ‘patching’ together of voice time slots of external TDM circuits, so that the ATM cell transport functionality of the dual PHY MCI is effectively bypassed. FIG. 3 shows a DS 0 cross-connect path 3000 between ports P 1 and P 2 of the digital cross-connect switch 110 . As described above, path 3000 is used in DS 0 -mapping mode to map DS 0 s on the voice TDM link 20 directly through the cross-connect switch to the WAN 10 , using a user-controlled mapping scheme. FIG. 4 shows a DS 0 cross-connect path 4000 between port P 1 and the internal TDM bus port 113 of the XCS 110 to the internal TDM bus 210 and voice gateway 150 , so that DS 0 time slots on the legacy TDM link 50 may be coupled to WAN 10 . FIG. 5 shows a further TDM path 5000 between mux/demux 140 and the NxPort 114 of the cross connect switch 110 , for directly mapping DS 0 time slots for Nx56/64 clear channel (V.35) operation.
2—TDM Voice—ATM WAN Communication Mode ( FIGS. 6 and 7 )
In this mode, for the WAN to TDM link transport direction, shown by a path 6000 in FIG. 6 , the XCS 110 couples the WAN port 111 to the ATM transceiver port 114 for connection to the WAN ATM transceiver 220 . ATM voice cells from the WAN are buffered from WAN ATM transceiver 220 into the WAN RX FIFO 310 . ATM voice cells in the RX FIFO 310 are then output via the PVC router 120 to the PHY 1 portion of the dual UTOPIA L2 PHY interface 130 and UTOPIA bus 30 to the network processor. The voice ATM cells are then returned over the PHY 1 portion of the PHY interface to the designated playout buffer associated with the destination channel, which the forty-data bytes per cell are loaded for that channel. From the playout buffer the store TDM data is readout via gateway 150 and transport over internal TDM bus 210 for delivery via XCS 100 to the TDM voice link 20 at port P 5 .
FIG. 7 shows a path 7000 for voice signal transport from the TDM link to the WAN as ATM cells. For incoming voice calls from the TDM2 network 20 , routing is from port P 5 of the cross connect switch XCS 110 over the internal TDM bus 210 and the voice gateway to the playout buffer unit. As described above, as groups of forty-four TDM bytes are read out of the voice playout buffer, they are assembled into ATM cells for transport over the ATM cell bus 214 to the PHY 1 portion of interface 130 , and transport to the host processor. In the WAN direction, the ATM voice cells are returned from the processor over the PHY 1 portion of the dual UTOPIA L2 PHY interface 130 and routed to VTX FIFO 330 .
As pointed out above, the WAN ATM transceiver 220 employs a priority-based, quality of service (QoS) steering mechanism 225 , which gives priority to PHY 1 -sourced voice ATM cells buffered in the voice cell transmit FIFO 330 over PHY 0 -sourced data cells buffered in data cell transmit FIFO 320 . So long as the DTX FIFO 320 is not currently being read out, the QoS controller 225 immediately couples the voice cell transmit FIFO 330 to WAN ATM transceiver 220 , so that voice cells may be read out of the VTX FIFO 330 to completion.
3—DATA ATM Communication Mode ( FIGS. 8 and 9 )
In this mode, for the WAN to the network processor transport direction, shown by a path 8000 in FIG. 8 , the XCS 110 couples the WAN port 111 to the ATM transceiver port 114 for connection to the WAN ATM transceiver 220 . ATM data cells from the WAN are buffered from WAN ATM transceiver 220 into the WAN RX FIFO 310 . ATM data cells in the RX FIFO 310 are then extracted via the PVC router 120 to the PHY 0 portion of the dual UTOPIA L2 PHY interface 130 and UTOPIA bus 30 to the network processor.
The outgoing ATM WAN data path is shown at 9000 in FIG. 9 , wherein outgoing ATM data cells from the processor are steered by the PVC router 120 off the PHY 0 portion of the PHY interface and into the WAN DTX FIFO 320 . As pointed out above, read out of the WAN DTX FIFO 320 is controlled by the QoS controller 225 , which gives priority to voice cells awaiting transmission in the VOICE WAN VTX FIFO 330 until completion. However, if the voice cell transmit FIFO 330 is empty, the QoS controller 225 allows any data cells buffered in the data FIFO 320 to be coupled to WAN ATM transceiver 220 for application to the WAN.
4—HDLC Communication Mode ( FIGS. 10 and 11 )
For HDLC traffic received via the WAN HDLC transreceiver 230 from the WAN 10 , via the frame port 115 of XCS 110 , routing to the network processor is over a path 10000 shown in FIG. 10 from the RX FIFO 310 to the PHY 0 portion of the dual UTOPIA L2 PHY interface 130 . Transmitted WAN HDLC data routing from the processor traverses a path 11000 , shown in FIG. 11 , from the PHY 0 portion of the dual PHY layer to the WAN DTX FIFO 320 and HDLC transceiver 230 , for application to frame port 115 of the XCS 110 and delivery to the WAN.
5—V.35 Communication Mode ( FIGS. 12 and 13 )
The NxPORT HDLC transceiver 240 is configured similar to the WAN HDLC transceiver 230 and provides the ability to interface ATM cell traffic on the PHY 0 portion of the dual UTOPIA L2 PHY interface 130 with an auxiliary (e.g., Nx56/64) digital communication path 40 . FIG. 12 shows a path 12000 for the receive direction from the Nx communication path 40 toward the network processor. Here, the NxPORT HDLC transceiver 240 interfaces ATM data cells as encapsulated by ATM encapsulation mechanism 245 to V.35 RX FIFO 340 . These ATM-encapsulated cells contain the contents of auxiliary protocol (e.g., V.35) data frames (e.g., FRP or PPP) that are coupled to Nx mux/demux 140 . The AAL5-encapsulated V.35 data buffered in V.35 RX FIFO 340 is read out and routed via PVC router 120 to the data (PHY 0 ) portion of the dual UTOPIA L2 PHY interface 130 , for transport over UTOPIA bus 30 to the network processor.
FIG. 13 shows a path 13000 in the transmit direction to the Nx communication path 40 from the host processor 200 . Here, ATM cells containing AAL5-encapsulated HDLC data, as transported over the data portion (PHY 0 ) of the dual UTOPIA L2 PHY interface 130 , are buffered into a V.35 TX FIFO 350 by the PVC router 120 . ATM cells buffered in the V.35 TX FIFO 350 from the PVC router 120 are coupled from the V.35 TX FIFO 350 and converted by the ATM encapsulation mechanism 245 back into V.35 data. The NxPORT HDLC transceiver 240 then outputs the V.35 data to port 142 of Nx mux/demux 140 for application to the auxiliary (Nx56/64) digital communication path 40 .
As will be appreciated from the foregoing description, shortcomings of conventional DSP-based IADs are effectively obviated in accordance with the present invention, by using a relatively high speed, dual PHY based transport path to interface a multi-protocol communication interface with a reasonably priced host network processor available from a variety of processor chips vendors. As the signaling transport speed of the dual PHY based path is an order of magnitude greater than that of any of the plurality of communication paths with which the IAD is interfaced, the TAD of the invention provides effectively real time support for different communication requirements, including TDM, ATM, HDLC, and the like.
While we have shown and described an embodiment in accordance with the present invention, it is to be understood that the same is not limited thereto but is susceptible to numerous changes and modifications as known to a person skilled in the art. We therefore do not wish to be limited to the details shown and described herein, but intend to cover all such changes and modifications as are obvious to one of ordinary skill in the art.
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A dual PHY-based integrated access device (IAD) platform employs a highly integrated time division multiplexed (TDM), a synchronous transfer mode (ATM) cell based architecture, to provide enhanced interfacing flexibility for multiple and diverse signaling protocols, effectively reducing the cost and constraints as to choice of host processor used in conventional digital signal processor (DSP)-based IADs. With the signaling transport speed of the dual PHY based path being an order of magnitude greater than that of any of the plurality of communication paths with which the IAD is interfaced, the IAD of the invention provides effectively real time support for different communication requirements, including TDM, ATM, HDLC, and the like.
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PRIORITY CLAIM AND REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to related, commonly owned U.S. provisional patent application No. 61/453,832, filed Mar. 17, 2011, the entire disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to media Consumer or audience sampling, survey or measurement systems and methods.
[0004] 2. Discussion of the Prior Art
[0005] The Nielsen Company, Arbitron and others have long sought for improved methods for measuring audiences for broadcast television other media platforms and services. Audience measurements of media, such as television or radio programs, are typically carried out by monitoring or measuring media consumption (e.g., the viewing of or listening to audio/video content) within households that are statistically selected to represent particular demographic groups, geographic regions, etc, as shown in FIG. 1 .
[0006] Using various statistical methods, the collected media consumption data may be processed to determine audience size and demographics for media presentations or programs of interest. Such audience size and demographic information may be valuable to advertisers, broadcasters and any other media delivery entity or service provider that wants to know an audience size and demographic associated with a particular program. For example, audience size and demographic information is a significant factor in the development of improved program lineups, the placement of advertisements targeted at a particular demographic, as well as in valuing commercial time slots during particular programs.
[0007] Audiences are increasingly using more than one type of media device or platform configured to display or play back more than one type of media format. Thus, audiences can interact with multiple media formats—TV (e.g., conventional, cable, satellite, Internet Protocol TV (IPTV)), online content (e.g., web browsing, searching, etc., except video), content adapted for playback or display on PDAs and cell phones, print media and outdoor ads, and conventional radio. These multiple media formats can be classified into three primary groups—video (including IPTV), online (excluding video) and outdoor media. These multiple media formats—TV (conventional, cable, satellite, Internet Protocol TV (IPTV)), online (web browsing, searching, etc., except video), cell phone, print, and outdoor ads, except conventional radio—will be collectively referred to as “Media”.
[0008] The prior art audience measurement methods and systems do not meet everyone's need, though. Media producers, broadcasters, advertisers, marketers and other stake holders are still seeking a method or system which can provide timely verification or confirmation that a selected audience has been reached and retained.
[0009] There is a need, therefore, for a cost-effective system and method for gathering audience measurement data in a comprehensive manner, across multiple media formats that can be used to estimate audience measurement metrics with a higher degree of confidence than is possible using the prior art systems.
SUMMARY OF THE INVENTION
[0010] Accordingly, it is an object of the present invention to overcome the above mentioned difficulties by providing an effective, flexible, cost-effective and unobtrusive system and method for interactively gathering audience measurement data in a comprehensive manner, across multiple media formats or platforms. For purposes of nomenclature, media formats include but not limited to television, conventional television, satellite television, cable television, Internet Protocol TV, online (web browsing, searching, etc. except video), cellphone, print, and outdoor ads, except conventional radio). The data are used to estimate audience measurement metrics with a higher degree of confidence.
[0011] Another object of the method and system of the present invention is providing media producers, broadcasters, advertisers, marketers and other stake holders with a method and system for timely verification or confirmation that a selected audience has been reached and retained, on any of several media formats.
[0012] The present invention comprises a system and method for gathering Audience Measurement (“AM”) data and Audience Participation (“AP”) data in a timely, verifiable and comprehensive manner. Each participating Consumer or audience member uses or carries a smart phone (e.g., an iPhone® or Blackberry®) or similar transportable personal Device and is given access to a downloadable computer program or Device Application for use in a self-selection Audience Participation (AP) process such as a Consumer survey.
[0013] The Consumer is given access to media content such as a broadcast television program developed by the Program's producer or an advertiser (Client or customer). That program or media content is broadcast or displayed with at least one unique, pre-defined Visual Cue Management symbol or Visual Cue (“VQ” or “Midy”) which incorporates an encoded graphic element with encrypted identification information. The Visual Cue has a pre-defined two dimensional configuration or shape (e.g., a circle) and the interior of the Visual Cue contains a plurality of subdivided areas or graphical data fields which are encoded or encrypted with regions having a selected color, pattern or other visible indicia adapted for optical sensor detection. The Visual Cue is packaged with select customer parameters, which have been obtained from the Client, including but not limited to display parameters (format, location, start time and duration). In the preferred embodiment, the Visual Cue is sized and configured for convenient use with optical sensors or digital cameras such as are customarily incorporated in smart phones, Personal Digital Assistants (PDAs) and other transportable personal Devices which are programmed with the system's downloadable Device Application.
[0014] In accordance with the present invention, a method and system for verifiable two-way communication and interaction with audiences who may be using one or more of a selected plurality of media formats or platforms includes four major elements, namely:
(a) Visual Cue Management (VCM) Software, for managing a plurality of unique visible indicia (i.e., “Visual Cues” or “VQs”) which function much like digital fingerprints and so uniquely identify a particular segment of media programming and a particular media producer, broadcaster, advertiser, marketer or other stake holders (“Clients”) for the time and duration or Selected Visual Cue Display Interval specified by customer parameters, (b) a Device Application (referred to as an “App”) residing on an individual Consumer's transportable smart Device (e.g., a smart phone equipped with GPS and a digital camera), (c) a Supervisory Program (SP): to manage flow of data to and from external sources—Clients and Consumers—and functions such as a decoding, data parsing, VCM, Database Management System (DBMS), Visual Cue Image Validation, etc., and (d) an Image Validation Program (IVP): to validate that Consumer images have at least one valid Visual Cue.
[0019] In the method of the present invention, from the Consumer's perspective, media content or programming such as an advertisement is shown on TV, and at a selected start time during the ad or a show a Visual Cue (VQ) appears for a Selected Visual Cue Display Interval in a selected position within the display area. For example, if the Client is a restaurant placing an ad in a newspaper, the Selected Visual Cue Display Interval may be one week or if the ad is shown on TV it may be for 30 seconds. Another example is if the Client is a realtor selling a home, the Selected Visual Cue may be one month. Another example is when the Client has an advertisement being shown regularly throughout the day via a publisher or broadcaster and the customer parameters accompanying the Visual Cue may indicate a Selected Visual Cue Display Interval that is a subset of the overall ad duration, specifically, the start time may be 5:30 pm and the Selected Visual Cue Display Interval is 30 minutes.
[0020] When the VQ appears, the Consumer makes a decision about whether to participate and, if so, the Consumer activates the previously downloaded Device App on the Consumer's Smartphone and points the Smartphone's camera or image sensor at the display including the VQ. The nomenclature “Smartphone” as used herein, should be construed to include the iPhone™, the Blackberry™, the Droid™ and any other of the popular, transportable data communication and display instruments now in common use, and their equivalents.
[0021] In response to the Consumer's decision to participate and Device App activation, the Consumer's Device App enables and initiates a set of programs or routines that activate the Smartphone's camera which detects, senses and then records or captures an image or snap-shot of the display or TV screen or display (while VQ is still visible). The Device App stores the captured image of the VQ along with a time and date stamp, preferably with information on the sensed GPS location of Consumer at the time the image was captured. The Device App collects the stored image data with the VQ data, the time and date stamp, and other Consumer-specific data entered by the Consumer or taken from memory on the Smartphone and assembles Audience Measurement (“AM”) and Audience Participation (“AP”) data into an AM-AP Consumer Input File adapted for digital transmission over a data communication network. For purposes of nomenclature, data communications network should be construed to include wired or wireless telecommunications networks, dedicated (e.g., Ethernet) data communications networks, the Worldwide Web or the Internet.
[0022] The Consumer's Smartphone or other portable Device may optionally be connected to a personal computer programmed to transmit the AM-AP Consumer Input File over the Internet via a wired or wireless connection to a remotely located Supervisory Program computer system programmed to receive and store many AM-AP Consumer Input Files from many users simultaneously. The Supervisory Program computer system continuously receives and processes AM-AP Consumer Input Files from a plurality of assigned Consumers, verifies the data in each AM-AP Consumer Input File and collates the data from all assigned Consumer as the AM-AP Consumer Input Files are received. In response to receiving the Consumer's AM-AP Consumer Input File, the Supervisory Program computer system generates a plurality of reports for use by Consumer and Clients including a Record of Consumer's incentives for each Consumer assigned to a given Supervisory Program computer system and an aggregate report for all of the Consumers assigned to that Supervisory Program computer system. Each Supervisory Program computer system also generates a Record of Consumer's behaviors or selections, and this data is collated for each Consumer assigned to the Supervisory Program computer system along with and an aggregate report for all of the Consumers assigned to that Supervisory Program computer system, for use by authorized Clients and, optionally, by selected authorized Consumers. If the Consumer's AM-AP Consumer Input File indicates that a customer response is required based on the Record of Consumer's Incentives, then the Supervisory Program responds accordingly.
[0023] In an alternative embodiment, there is only a single Supervisory Program and all Consumers are thus “assigned” to or aggregated within that single Supervisory Program's received Input files and reports.
[0024] The above and still further objects, features and advantages of the present invention will become apparent upon consideration of the following detailed description of a specific embodiment thereof, particularly when taken in conjunction with the accompanying drawings, wherein like reference numerals in the various figures are utilized to designate like components.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 illustrates the prior art methods for gathering Audience Measurement (“AM”) metrics for broadcast and other media.
[0026] FIG. 2 illustrates a system and method for gathering AM data in a comprehensive manner, and providing audience member self-selection Audience Participation (“AP”) data across multiple media formats or platforms for use in estimating AM and AP metrics with a higher degree of confidence, in accordance with the present invention.
[0027] FIG. 3 also illustrates a system and method for gathering AM data in a comprehensive and interactive manner, and providing audience member self-selection AP data across multiple media formats or platforms for use in estimating AM and AP metrics with a higher degree of confidence, in accordance with the present invention.
[0028] FIG. 4 illustrates a system and method for gathering AM metrics and providing AP data by inserting a Visual Cue in a media format for a dynamic media environment.
[0029] FIG. 5 illustrates a system and method for gathering AM metrics and providing AP data by inserting a Visual Cue in a non-video online media format.
[0030] FIG. 6 illustrates a system and method for gathering AM metrics and providing AP data by inserting a Visual Cue in an outdoor media format.
[0031] FIG. 7 illustrates a system and method for gathering AM metrics and providing AP data using a smart device and standalone version of Device App.
[0032] FIG. 8 illustrates a system and method for gathering AM metrics and providing AP data using a smart device with an Allied Device.
[0033] FIG. 9 illustrates a system and method for the processing and handling of data by the Visual Cue Management System, Image Validation System and the Supervisory System.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0034] Referring now to FIGS. 1 , 2 and 3 , the present invention comprises a system 100 and method for gathering Audience Measurement (“AM”) and Audience Participation (“AP”) data in a timely, verifiable and comprehensive manner. Each participating Consumer 50 or audience member carries a smart phone (e.g., an iPhone® or Blackberry®) or similar transportable personal Device 110 and is given access to a computer program or Device Application for use in a self-selection AP process such as a Consumer survey. As noted above, the nomenclature “Smartphone” as used herein, should be construed to include the iPhone™, the Blackberry™, the Droid™ and any other of the popular, transportable data communication and display instruments now in common use, and their equivalents.
[0035] The Consumer 50 is given access to media content such as a broadcast television program developed and broadcast or displayed by the Program's producer or an advertiser (the “Client”). That media content 120 is broadcast or displayed with at least one unique, pre-defined Visual Cue, VQ or “Midy” 130 which incorporates an encoded graphic element with encrypted identification information. The Visual Cue 130 has a pre-defined two dimensional shape (e.g., a circle, as shown in FIG. 2 ) and the interior of the Visual Cue 130 contains a plurality of subdivided areas or graphical data fields which are encoded or encrypted with regions having a selected color, pattern or other visible indicia adapted for optical sensor detection. In the preferred embodiment, the Visual Cue 130 is sized and configured for convenient use with optical sensors or digital cameras such as are customarily incorporated in smart phones, Personal Digital Assistants and other transportable personal Devices 110 which can be programmed with the system's downloadable Device Application as a commercial “App”.
[0036] The method and system 100 for verifiable two-way communication and interaction with audiences who may be using one or more of a selected plurality of media formats or platforms includes four major elements, namely:
(a) Visual Cue Management (VCM) Software, for managing a plurality of unique visible indicia (“Visual Cues” 130 ) which function much like digital fingerprints and so uniquely identify a particular segment of media programming 120 and a particular media producer, broadcaster, advertiser, marketer or other stake holder (or “Client”) for the time and duration or selected interval specified by customer parameters, (b) a Device Application (referred to as an “App”) residing on an individual Consumer's transportable smart device 110 (e.g., a smart phone equipped with GPS and a digital camera), (c) a Supervisory Program (SP) stored on a Supervisory Program computer system 200 : to manage flow of data to and from external sources—Clients and Consumers—and functions such as a decoding, data parsing, VCM, Database Management System (DBMS), Visual Cue Image Validation, etc., and (d) an Image Validation Program (IVP): to validate that Consumer images have at least one valid Visual Cue 130 .
[0041] In the method of the present invention, media content such as displayed static images or video or motion picture programming 120 (e.g., an advertisement) is shown or displayed (e.g., on a TV, video display, sign or billboard), and (for TV or Video programming) at a selected start time during the ad or a show, a Visual Cue (VQ) 130 appears for a selected interval in a selected position within the display area. When VQ 130 appears, the Consumer “self selects” or makes a decision about whether to ignore or participate in the method of the present invention.
[0042] If Consumer 50 decides to participate, the Consumer activates a previously downloaded Device App on the Consumer's Device or Smartphone 110 and points the Smartphone's camera or image sensor at the display including VQ 130 . In response, the Consumer's Device App initiates a set of programs or routines that activate the Smartphone's camera which detects, senses and then records or captures an image or snap-shot of the display or TV screen (while VQ 130 remains visible). The Device app stores the image along with a time and date stamp, preferably with information on the sensed GPS location of the Consumer at the time the image was captured. The Device app collects the stored image data with the VQ data, the time and date stamp, and other Consumer-specific data entered by the Consumer or taken from the Smartphone memory and then organizes or compiles that Consumer-specific data into selected Audience Measurement (“AM”) and Audience Participation (“AP”) data. The AM and AP data are formatted into an “AM-AP Consumer Input File” adapted for digital transmission over a data communication network such as an Ethernet data communications network, the Worldwide Web or the Internet. As noted above, for purposes of nomenclature, the term “data communications network” should be construed to include (without limitation) wired or wireless telecommunications networks, dedicated (e.g., Ethernet) data communications networks, the Worldwide Web or the Internet.
[0043] The Consumer's Smartphone 110 or other portable Device may optionally be connected to a personal computer 150 programmed to transmit the AM-AP Consumer Input File 160 over the Internet via a wired or wireless connection to a remotely located Supervisory Program computer system 200 programmed to receive and store many AM-AP Consumer Input Files from many users simultaneously. The Supervisory Program computer system 200 continuously receives and processes AM-AP Consumer Input Files from a plurality of assigned Consumers, verifies the data in each AM-AP Consumer Input File 160 and collates the data from all assigned Consumers as the AM-AP Consumer Input Files are received. In response to receiving the Consumer's AM-AP Consumer Input Files, the Supervisory Program computer system 200 generates a plurality of reports for use by authorized Consumers and authorized Clients including a Record of Consumer's incentives for each Consumer assigned to a given Supervisory Program computer system and an aggregate report for all of the Consumers assigned to each Supervisory Program computer system. Alternatively, as illustrated in FIG. 3 , Supervisory Program computer system 200 is used to interact with the Consumer by sending selected information back to a selected Consumer in response to receipt of the Consumer's AM-AP Consumer Input File(s) 160 .
[0044] Each Supervisory Program computer system 200 also generates a Record of Consumer's behaviors or selections, and this data is collated for each Consumer assigned to the Supervisory Program computer system along with and an aggregate report for all of the Consumers assigned to that Supervisory Program computer system, for use by authorized Clients and, optionally, by selected authorized Consumers.
[0045] The method and system of the present invention is configured for use by a Consumer observing media content in any of several media formats (e.g., whether reading a magazine, seeing a billboard, watching a movie in a cinema, watching TV at home or watching a video streamed wirelessly to a Smartphone). Thus, the media may be displayed using any portable or fixed media format and so the method and system of the present invention tracks each Consumer no matter where, when or how that Consumer receives their media content and provides data for use in estimating AM and AP metrics with a higher degree of confidence.
[0046] In an alternative embodiment, there is only a single Supervisory Program computer system 200 and all Consumers are thus “assigned” to or aggregated within that single Supervisory Program's received Input files and reports.
[0047] Referring now to FIG. 4 , Supervisory Program computer system 200 receives a request for one or more Visual Cues from a broadcast facility's Media Asset Management (MAM) system 210 . The Supervisory Program computer system 200 transfers the request to the Visual Cue Management (VCM) system 300 . The VCM retrieves the correct Visual Cue(s) from storage and releases it to a broadcast facility's MAM for storage in their ad server 230 . A Visual Cue 130 is packaged with necessary instructions for how it should be inserted into the broadcast stream. Visual Cue 130 will be released along with the Client's ad, from the broadcast facility's ad server 230 , in a predetermined manner—either along with the ad or after a delay—per Client's instructions. The ad and accompanying Visual Cue 130 are inserted into the broadcast stream by equipment generically known in the TV industry as multiplexers 232 . The video signal, which now includes the Visual Cue 130 , is broadcast via one or more media formats—conventional TV, cable, satellite, online or cellphone. A report detailing the placement of Visual Cue 130 with information such as time, location, information on the ad, etc. is forwarded to the Image Validation Program (IVP) 400 for use as a reference. A clip of the broadcast with the ad and Visual Cue 130 can also be fed back to Supervisory Program computer system 200 to be used as a master by the Image Validation Program (IVP) 400 . The Consumer equipment or device 140 —TV, video recording device or computer—receives the video signal, processes it and displays the resulting image with Visual Cue 130 .
[0048] In FIG. 5 , Supervisory Program computer system 200 instructs Visual Cue Management (VCM) system 300 on a regular basis to transfer Visual Cue(s) 130 to ad servers 230 where corresponding primary ad is stored. Consumer 50 visits a website while browsing the internet. As the Consumer's device 140 loads a webpage ad serving code on the webpage, which is included in the webpage by website publisher or website owner 240 , it requests the nearest ad server for an ad. Based on targeting criteria embedded in the request, the ad server selects the most suitable ad from its inventory and sends it to Consumer 50 . Consumer's device 140 receives the information, decodes it and displays the ad on the webpage. If the selected ad is one with Visual Cue 130 of the present invention then Consumer's device 140 would display the requested webpage, the Client's ad and Visual Cue 130 . A report detailing the placement of Visual Cue 130 with information such as time, location, information on the ad, etc. is forwarded to the Image Validation Program (IVP) 400 for use as a reference.
[0049] FIG. 6 illustrates a system and method for inserting a Visual Cue Management symbol 130 in an outdoor media format. When an ad on static billboard 250 is changed or a Client requests an update, display parameters are downloaded onto a Cue Display Unit (“CDU”). A CDU is hardware that is mounted onto conventional billboard 250 comprising a display, electronics to power and control the display unit and a standalone version of Visual Cue Management (VCM) software. Based on the display parameters, VCM on the CDU 256 of the billboard sends control signals to the CDU display unit 258 to turn on a specified Visual Cue. The display unit receives the signal and displays the appropriate Visual Cue 130 .
[0050] For electronic billboards 252 , on a regular basis Supervisory Program computer system instructs VCM 300 to transfer Visual Cue 130 to electronic billboard's ad servers 230 where corresponding primary ad is stored. Visual Cue 130 will be released along with the Client's ad, from the billboard's ad server, in a predetermined manner—either along with the ad or after a delay—per Client's instructions. The ad and accompanying Visual Cue 130 are displayed on the electronic billboard 252 . A report detailing the placement of the Visual Cue 130 with information such as time, location, information on the ad, etc. is forwarded to the Image Validation Program (IVP) 400 for use as a reference.
[0051] For print media 254 , on a regular basis Supervisory Program computer system 200 instructs VCM 300 to transfer Visual Cue 130 to ad printer 260 where Client's corresponding ad is sent for printing. Ad printer 260 overlays Visual Cue 130 on Client's corresponding ad and schedules it for printing. The ad with the Visual Cue is printed and circulated in targeted media market.
[0052] FIG. 7 illustrates a system and method for gathering AM metrics and providing AP data using a smart device 110 and standalone version of Device App. A Consumer notices Visual Cue 130 appear on media content 120 on the display device—TV screen, computer monitor, cellphone or billboard. Consumer 50 orients smart device 110 , with the camera facing media content 120 in an orientation that captures most of the scene, and triggers Device App 350 . In addition to capturing the image the App also records other data including: GPS location, date & time, serial number of device and camera settings. Device App 350 encodes and packages the AM & AP data into AM-AP Consumer Input File(s) 270 and transmits it to central computer 200 . The transmission could be immediate to facilitate real-time data gathering and/or interactions. In the case where immediate transmission is not possible, Device App 350 would store-and-forward data whenever a connection becomes available.
[0053] FIG. 8 illustrates a system and method for gathering AM metrics and providing AP data using a smart device and an Allied Device. An Allied Device is a separate standalone device that runs the App. Consumer 50 notices Visual Cue 130 appear on media content 120 on the display device—TV screen, computer monitor, cellphone or billboard. Consumer 50 orients the smart device, with the camera facing media content 120 in an orientation that captures most of the scene, and triggers the camera's shutter release button. In addition to capturing the image smart device 110 also records other data including: GPS location, date & time, serial number of device and camera settings. The smart device is then connected to an Allied Device on which a version of Device App 350 is installed. Device App 350 is started and it recognizes smart device 110 that is connected to the Allied device. Consumer 50 logs in to his/her account, selects the image on smart device 110 . Device App 350 formats the data into AM-AP Consumer Input File 270 adapted for digital transmission and uploads it to central computer 200 .
[0054] FIG. 9 illustrates a system and method for the processing and handling of data by the Visual Cue Management system 300 , Image Validation Program 400 and Supervisory Program computer system 200 . Client's display parameters are entered into Supervisory Program computer system 200 . Supervisory Program computer system 200 forwards the display parameters including Visual Cue 130 information to Visual Cue Management system 300 and Image Validation Program 400 . Supervisory Program computer system 200 receives feedback information from publishers—broadcast facilities, ad servers and billboard operators—indicating id of Visual Cue 130 inserted, channel number, date and time, channel and IP address of visitor. Supervisory Program computer system 200 forwards the data to a parsing sub-routine to deconstruct the data into its components—image data, location, date and time. Image data along with other information—location, date and time—are forwarded to the Image Validation Program 400 . The data bundle or package from the Consumer's smart device is received by Supervisory Program computer system 200 and forwarded to the decoder routine. When decoding is completed Supervisory Program computer system 200 forwards data to parsing sub-routine to deconstruct data into its components—image data, location, date and time, device serial number and camera settings. Image data along with other information—location, date and time, and device serial number are forwarded to Image Validation Program 400 and remaining information is sent to data warehouse to be catalogued by Database Management System (DBMS) 280 . Image Validation Program 400 receives the image data and other information such as location, date and time and device serial number from the Supervisory Program computer system 200 . Depending on the nature of the image data—reference image or image from Consumer 50 —the data is sent to reference image storage 290 or for validation. Image Validation Program 400 sends the validation report back to Supervisory Program computer system 200 .
[0055] In the preferred embodiment, the present invention is a method for verifiable two-way communication and interaction with audiences using multiple media formats comprising:
(a) obtaining a selected set of customer parameters, said parameters being taken from a list including media of interest, media market of interest, channel of interest, start date, end date, start time, end time, specific time, Selected Visual Cue Display Interval and delay time; (b) packaging a unique Visual Cue management symbol for said client with customer parameters, said customer parameters provides publishers with instructions and include the format, location, start time and Selected Visual Cue Display Interval; (c) storing of said symbol by software for management of storage, retrieval and release of said symbol; (d) releasing and transmitting said symbol and said customer parameter instructions to at least one publisher; (e) maintaining communication with said publisher to enable and monitor symbol placement in selected media formats in accordance with said customer parameter instructions packaged with said symbol; (f) displaying said Visual Cue management symbol by said publisher in said selected media formats. (g) viewing said Visual Cue management symbol by at least one consumer; (h) capturing at least one image of said symbol with a smart device by said consumer; (i) packaging of said image with consumer information as a package by software for management, collection and transmission of market audience data, said information being taken from a list including phone number or device number, date, time, location, camera settings and customer survey answers. (j) transmitting of said package to software for management, collection and transmission of market audience data; (k) unpacking of said package by software for management, collection and transmission of market audience data; (l) receiving publisher information from said publishers, said publisher information being taken from a list including symbol identifier, channel of symbol displayed, start time of symbol and stop time of symbol. (m) validating said image by software for management, collection and transmission of market audience data (n) compiling and reporting the received data when said image is validated by software for management, collection and transmission of market audience data. (o) sending customer response to said consumer by software for management, collection and transmission of market audience data based on customer parameters.
[0071] Having described preferred embodiments of a new and improved method, it is believed that other modifications, variations and changes will be suggested to those skilled in the art in view of the teachings set forth herein. It is therefore to be understood that all such variations, modifications and changes are believed to fall within the scope of the present invention as set forth in the claims.
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A system and method for verifiable two-way communication and interaction with audiences using Visual Cues and images to enable an audience, irrespective of size, to interact with multiple media formats, using smart devices such as smartphones and smart cameras. Allows interactions with viewers in real-time that will provide richer data that can be used to measure an audience more reliably.
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BACKGROUND OF THE INVENTION
This invention relates to trailer hitches and particularly to improved controlling systems connected to the hitches, or fifth-wheel mountings, for operating automatically the brakes of trailers.
In U.S. Pat. No. 3,397,899 issued to Theodore F. Thompson on Aug. 20, 1968, a fifth-wheeled hitch with an improved controlling system with stabilizing means is described. Two brackets are mounted on opposite sides of a frame at the rear of a tractor to secure a fifth wheel for supporting the front end of a trailer. The fifth wheel is mounted to the pair of brackets through a pair of upright supporting links that permit the fifth wheel to move about 1/2 inch (1.27 cm) to 1 inch (2.54 cm) fore and aft with respect to the frame of the tractor. A control for the brakes of the trailer that is being pulled is coupled to the upright links and is operated as force applied from the fifth wheel causes the links to move through the short distance.
While a tractor is pulling a trailer, the fifth wheel is in a rearward position to actuate the braking control for maintaining the brakes of the trailer released. Should the momentum of the trailer tend to cause the trailer to overrun the tractor, the fifth wheel is pushed forwardly with respect to the frame of the tractor to apply brakes in sufficient amount to slow the traler and to return the fifth wheel to a rearward position.
To provide stability, an indexing or toggle action for the upright supports is required. When the fifth wheel has moved to either a forward or a rearward position, a substantial change of force in the opposite direction must be required to return the fifth wheel to its former position. In the embodiment described in the patent to which reference has been made above, each of the upright links has a pivot at the bottom and has a stop arrangement that permits the upper portion of the link to move a short distance fore and aft to travel through the position at which the load or downward force is supported directly over the pivot. Through this construction, the front end of the trailer is at its highest point with respect to the frame of the tractor when the fifth wheel is at an intermediate point with respect to the fore-and-aft movement of the fifth wheel and gradually assumes a slightly lower position with respect to the frame as the fifth wheel moves past the intermediate point. The amount of indexing is therefore directly proportional to the load on the trailer.
When a trailer is heavily loaded, this type of hitch has not functioned satisfactorily. When a heavily loaded trailer with its tractor is stopped, the fifth wheel is in a forward position and the brakes of the trailer are applied. Before the trailer can be started forward again, either the brakes must be released by a special manual control or the tractor must provide sufficient traction to raise the load a small amount required to move the fifth wheel in a rearward position. Although the vertical distance through which the trailer is to be moved is very small, the amount of starting traction to be provided by the tractor is undesirably great.
SUMMARY OF THE INVENTION
An adjustable stop is connected to each of a pair of brackets of a fifth-wheel hitch for contacting a respective one of the upstanding links to which the fifth wheel is connected. The setting of the stops determines the distance that the fifth wheel can move forward past the peak where the resistance to the movement starts to decrease and where movement in the reverse direction starts to increase. Each stop may include either a pair of screws or a bar with a single screw to be contacted by each of the pivoted links as it moves forward a predetermined distance past the peak. When a tractor is to support a trailer that is heavier than a trailer to which it was previously connected, the screws are adjusted inwardly to decrease the distance that the fifth wheel can travel forward past the peak. By decreasing this distance of forward travel, the amount of traction that is required for moving the fifth wheel rearwardly sufficiently to release the brakes of the trailer is decreased.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a top view of a fifth-wheel hitch assembly shown on a rear portion of a tractor frame;
FIG. 2 is a longitudinal, cross-sectional view of one of the brackets of FIG. 1 to show a stop limiting the forward movement of a pivoted support for a fifth wheel;
FIG. 3 is a perspective view of a bracket to show a different embodiment of a stop using a single screw and a block;
FIG. 4 is a top view of a modified adjuster using a single screw; and
FIG. 5 is a central, longitudinal cross-sectional view of a portion of a bracket and supporting link and a cutaway view of the adjuster of FIG. 4.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The rear portion of a frame 11 of a tractor supports laterally spaced brackets 12 and 13 for supporting a conventional fifth wheel 14. As shown for bracket 12, each bracket has an upright link 15 connected to the bracket 12 and an upright supporting member 16 connected to a frame for supporting the fifth wheel 14. The link 15 is connected to the bracket 12 as described below to permit the upper end of the link to move a short distance fore or aft according to a change in the direction of force applied to the link by the fifth wheel 14. At each of the brackets 12 and 13, the link 15 is connected to an arm 17 for actuating a braking control device 18. The arm 17 is connected through an arrangement of linkages and a crank as described in the patent mentioned above to the device 18 that may be a hydraulic cylinder, reservoir, and valve. To prevent movements of short duration from operating the braking control device 18, a pair of cushioning or shock-absorbing devices 19 are connected between the frame 11 and the linkages that connect the lever 17 to the braking control device 18.
Summarizing the operation of the braking control as described in the patent mentioned above, when a tractor is starting to pull a trailer such that a rearwardly directed force is applied to the fifth wheel 14 with respect to the frame 11, the upper portions of a pair of links 15 are moved rearwardly a short distance with respect to the brackets 12 and 13. The movement of the links 15 actuates the braking control device 18 to release the brakes of the trailer that is being pulled. When the tractive force is decreased and the momentum of the trailer causes the trailer to push forwardly on the tractor, the upper portions of the links 15 are moved a short distance forwardly to rotate the pair of arms 17 for operating the braking control device 18. The braking control device 18 is now operated in the required direction for operating the brakes of the trailer that have been connected to the device.
The arrangement for supporting the link 15 for slight rotation within the bracket 12 is shown in the cross-sectional view of FIG. 2. The link 15 has a lower shaft 20 and an upper shaft 21 separated vertically for connecting the link 15 within the sides of the bracket 12. The lower shaft 20 is secured within the link 15 and rotates within bearings through the sides of the bracket 12. The upper shaft 21 is also secured within the link 15 and extends through the walls of the bracket 12, but is movable fore and aft a short distance within an elongated opening 22 within each wall of the bracket 12. Assuming that the base of the bracket 12 is level, the center of the opening 22 is on a vertical line through the center of the shaft 20, and when the upper shaft 21 is centered within the opening 22, the fifth wheel 14 and therefore the load supported by the fifth wheel is at a highest position with respect to the frame 11 to which the bracket 12 is attached. As shown more clearly in FIG. 3, a central space is provided in the upper portion of the link 15 to receive the upright supporting member 16 to which is attached a frame for supporting the fifth wheel 14.
The shape of the opening 22 is such that the link 15 can be moved easily through a small arc as long as a load is not applied to the link. The bottom portion 23 of the opening 22 has a radial center at the center of the lower shaft 20 and likewise, the upper portion of the opening has the same center. The right side of FIG. 2 is toward the rear of a tractor, and when the fifth wheel 14 is pulled to the right, the upper shaft 21 moves rearwardly until it is stopped by the rear arcuate portion of the opening 22. When the base of the bracket 12 is level, the rearward position of the fifth wheel 14 tends to be stable because the fifth wheel 14 and the load supported by it must be raised slightly above the bracket 12 to follow the arc about the center of the lower shaft 20 as the upper shaft 21 moves forwardly within the bracket 12. Likewise, when the upper shaft 21 is moved forwardly until it is in contact with the front portion of the opening 22, the position of the fifth wheel 14 with respect to the bracket 12 tends to be stable because sufficient force from a tractor will need to be applied forwardly on the bracket 12 with respect to the fifth wheel 14 to raise the wheel slightly before the upper shaft 21 can be returned to the rearward position.
As described above, when a trailer is to be started and the fifth wheel 14 is forward, an excessive amount of power is required if a trailer is heavily loaded to start the tractor forward before the brackets 12 and 13 are moved forwardly with respect to the fifth wheel 14. The rearward movement of the fifth wheel 14 is necessary to operate the braking control 18 of FIG. 1 for releasing the brakes of the trailer. Two adjustment screws 24 and 25 as shown for the bracket 12 has been added to the brackets 12 and 13 for adjusting the forward travel of the upper part of the link 15 and its shaft 21 within the opening 22. As shown in FIG. 2, a heavy crossbar 26 is welded between the sides of the bracket 12 parallel with the upper portion of the link 15. The screws 24 and 25 (FIG. 1) are turned through the block 26 to bear on respective separated upper portions of the link 15. When a load on the fifth wheel 14 is light, the screws 24 and 25 are unnecessary and can be turned outwardly so that the rotation of the link 15 is determined by the ends of the elongated opening 22. For increasingly heavy loads, the screws 24 and 25 for each of the brackets 12 and 13 are turned inwardly with the ends of the screws being kept even on a transverse line so that the ends function as stops to limit the distance through which the upper portion of the links 15 can rotate about their lower shafts 20.
With reference to FIG. 3, a different embodiment uses a single adjusting screw at each of the brackets 12 and 13 for readily adjusting the amount of forward movement of the link 15. A crossbar 27 having an internally threaded hole for receiving an adjusting screw is like crossbar 26 described above in that it is welded between the sides of one of the brackets 12 and 13 at a distance in front of the upper portion of the link 15. However, the distance between the crossbar 27 and the link 15 will probably need to be greater to accommodate an intermediate stop bar 28, and the crossbar 27 would likely be somewhat thicker to withstand the pressure that would be concentrated at the center of the block when the upper portion of the link 15 moves forwardly. The length of the block 28 is somewhat less than the distance between the sides of the bracket 13, has sufficient thickness to withstand the stopping force, and has a slight recess in the side facing the link 15 to straddle the upright supporting member 16 (FIG. 1). Retaining means having only moderate strength is required to hold the stop bar 28 at the required height within the sides of the bracket 13. The end of an adjustment screw that is to bear against the stop bar 28 might be turned down, and a hole drilled in the center of the block for receiving the turned-down portion. A conventional retaining clip can be used at the end of the screw to retain the bar. Alternately, to prevent drilling and weakening the center of the bar 28 where the greatest strength is required, a pair of straps 29 fabricated from spring material may be connected to the side of the bar 28 opposite the link 15 and extend downwardly to be fastened to the base of the bracket 13. A large adjusting screw 30 is turned inwardly through the center of the crossbar 27 such that its inner end bears against the center of the forward side of the stop bar 28. To provide easy adjustment, a knob 31 is secured to the outer end of the screw 30.
A locking or an indexing device will be required for the screw 30 to prevent its turning after it is adjusted. A locking nut can be provided to lock the screw 30 against the forward side of the crossbar 27, but preferably an indexing means that also indicates the amount of rotating of the screw 30 during adjustment is preferred. An indexing wheel 32 having circumferential notches is shown rigidly fastened to the screw 30 and is spaced far enough from the knobs 31 to permit space for grasping the knob. A flat indexing spring 33 having one end connected to one of the sides of the bracket 13 extends transversely such that one of its faces at the other end is urged against the notched circumference of the indexing wheel 32. The free end of the indexing spring 33 is formed, or a small cross member added to the face, to provide a ridge transversely thereacross for entering the notches of the wheel to provide conventional indexing operation. The indexing spring 33 has sufficient width to contact the wheel over the usual range of adjustment of the screw 30.
During adjustment, the rearward shoulders of the two stop bars 28 should be even on a tranverse line for contacting evenly the upper spaced portions of the links 15 within the brackets 12 and 13. The stop bars 28 function as the levers with arms of equal lengths to divide the stopping force substantially evenly between the two upper portions of an individual one of the links 15. To equalize the spacings between the stop bars 28 and the links 15 for the opposite brackets an indicator may be provided on each of the adjustment screws 30. For example, spaced marks of different colors such as the marks 34 on the outer face of the indexing wheel 32 may be applied either to the indexing wheel 32 or to the knob 31 for determining the turns or fractions of turns of the adjusting screw 30. For additional accuracy after the indicating marks are similarly positioned, the number of notches of the indexing wheel encountered during rotation of the screw 30 can be counted. While the fifth wheel 14 and the pair of links 15 are in their farthest rearward position with respect to the brackets 12 and 13, the knobs 31 at each of the brackets 12 and 13 can be rotated until the stop bars 28 are positioned against their respective links 15. Then by counting the turns of rotation of the knobs 31 and counting the number of times that the indexing spring 33 enters notches of the indexing wheel 32, the adjusting screws 30 can be turned outwardly to provide equal distances that the links 15 will travel forwardly before being stopped by their respective stop bars 28 and adjusting screws 30.
Another embodiment showing a single screw adjuster but with indicating means to provide easy direct reading of the setting of the screw is shown in FIGS. 4 and 5. Narrow bands of color 36 on a sleeve 37 about an adjusting screw 35, that corresponds to the adjusting screw 30 of FIG. 3, provides the direct indication. As described previously, the screw 35 is turned through the crossbar 26 to position a stop bar 38 against the upper separated portions of the link 15. To maintain the stop bar 38 at the correct height, the inner end of the adjusting screw 35 is rotatively connected to the forward face of the stop bar 38. A small portion of the inner end of the adjusting screw 35 is turned down so that its diameter is slightly less than the inside diameter of the internal threads of the crossbar 26, and a shallow circular cavity in the center of the forward side of the stop bar 38 receives the turned-down end of the screw 35. A circumferential groove 39 that is about 3/16 inch (0.48 cm) deep and 3/16 inch from the end of the screw is formed to receive inner circular edges of a pair of retaining plates 40 that are fastened to the forward side of the crossbar 26. The indicator to show the distance that the adjusting screw 35 and the stop bar 38 is moved rearwardly is provided by two coaxial cylinders about the screw 35. The inner cylinder is a sleeve 37 on which are placed narrow bands of different colors 36 about that end adjacent the crossbar 26. The sleeve 37 has a flange fastened to the crossbar 26 in a usual manner by screws.
The outer cylinder of the indicator is a thimble 41 that has an inside diameter that is slightly greater than the outside diameter of the sleeve 37. To facilitate fastening the outer end of the thimble 41 to the screw 35, one end of the thimble 41 may be closed except for a central hole of the proper size for receiving a screw 42. The outer end of the adjusting screw 35 has a threaded hole for the screw 42, and the screw 42 is positioned through a knob 44, a lock washer 43, the hole in the end of the thimble 41, and then turned into the end of the adjusting screw 35. The bands of color 36 cover about a 1/2-inch (1.27-cm) length of the screw 35, and the length of the thimble 41 is proportioned with respect to the length of the screw such that the inner edge of the thimble 41 is moved along the bands of color 36 over the normal range of adjustment of the stop bar 38. By lengthening the sleeve 37 and the thimble 41 substantially as shown in FIGS. 4 and 5, an indexing means for preventing turning of the screw 35 after it is adjusted is provided within the thimble 41. The outer end of the sleeve 37 extends sufficiently beyond the bands of color 36 to accommodate a knurl 45 to be engaged by an end of a spring 46 attached to the inner wall of the thimble 41. The length of the knurl 45 should be long enough to be contacted by the full width of the spring 46 throughout the useable range of adjustment of the screw 35. The spring 46 has one end fastened to the inner surface of the thimble 41, and the outer end extending circumferentially formed in a cross-sectional V-shape so that a vertex extending across the spring 46 is urged against the knurl 45 of the screw 35. The adjusting screws 35 at the opposite brackets 12 and 13 can now be adjusted easily to position the respective stop bars 38 evenly on a transverse line by merely turning the adjusting screws 35 until bands 36 of the same color are even with the inner edges of the respective thimbles 41.
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A prior fifth-wheel braking control has a pair of links that support a trailer and rotate a small amount to operate brakes of the trailer to prevent overriding. A toggle or indexing action for stability is obtained by raising the fifth wheel and its load slightly to change positions of the links between a pulling condition and an overriding condition. The present improvement comprises adjustable stops positioned with respect to the links to determine the distance of their forward travel and therefore determine the amount of forward traction to be supplied by a tractor for changing position of the links as required for releasing the brakes of the trailer. The stops have different settings for substantially different weights of trailers to limit the amount of traction required to start the trailers.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is based upon and claims the benefit of priority from prior Japanese Patent Application No. 2004-008290, filed Jan. 15, 2004, the entire contents of which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a pattern forming method for use in processing a substrate such as a semiconductor substrate, a glass substrate, and a resin substrate.
[0004] 2. Description of the Related Art
[0005] In recent years, there has been a growing demand for highly integrated LSIs. Concurrently, there has been a demand for a processing technique with very high precision for forming a fine device pattern of 100 nm or less in a semiconductor lithography technique. Therefore, in a pattern exposure apparatus, high resolution is accelerated by producing short wavelengths with an excimer laser for use in KrF→ArF→F 2 . On the other hand, with more fining, pattern breakage of a resist film cannot be ignored. Therefore, a multilayer resist process for preventing pattern breakage by reducing the film thickness of a chemically amplified resist is used.
[0006] For example, as described in Jpn. Pat. Appln. KOKAI Publication No. 6-84787, there has been a problem that an upper-layered resist pattern falls (is released) in a multilayer resist process. In Jpn. Pat. Appln. KOKAI Publication No. 6-84787, it has been reported that an SOG film surface is temporarily subjected to hydrophobic processing, and then, a chemically amplified resist is formed, thereby restricting release of the resist pattern. However, this method has proved insufficient, although a certain advantageous effect is attained in restricting the release of the resist pattern.
[0007] As described above, in the multilayer resist process, there has been a problem that an upper-layered resist pattern is released/falls.
BRIEF SUMMARY OF THE INVENTION
[0008] According to an aspect of the present invention, there is provided a pattern forming method comprising: forming a spin on dielectric film on a substrate; washing the spin on dielectric film by using a washing liquid; drying a surface of the spin on dielectric film after the washing; forming a photosensitive film on the dried spin on dielectric film; emitting energy rays to a predetermined position of the photosensitive film in order to form a latent image on the photosensitive film; developing the photosensitive film in order to form a photosensitive film pattern which corresponds to the latent image; and processing the coating type insulation film with the photosensitive film pattern serving as a mask.
[0009] According to another aspect of the present invention, there is provided a pattern forming method comprising: preparing a first substrate; forming a photosensitive film on the first substrate; washing the photosensitive film by using a first washing liquid; emitting energy rays to a predetermined position of the photosensitive film by using an immersion type exposure in order to form a latent image on the photosensitive film after washing the photosensitive film; developing the photosensitive film in order to form a photosensitive film pattern which corresponds to the latent image; and processing the first substrate with the photosensitive film pattern serving as a mask.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
[0010] FIGS. 1A to 1 G are sectional views each showing procedures in a pattern forming method according to a first embodiment;
[0011] FIG. 2 is a sectional view schematically showing a pattern release when a pattern has been formed in a conventional three-layer resist process;
[0012] FIGS. 3A to 3 E are sectional views each showing procedures in a pattern forming method in a second embodiment;
[0013] FIG. 4 is a view schematically showing a resist pattern breakage phenomenon which occurs due to shortage of resist strength; and
[0014] FIGS. 5A to 5 G are sectional views each showing procedures in a pattern forming method according to a third embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Hereinafter, embodiments of the present invention will be described with reference to the accompanying drawings.
FIRST EMBODIMENT
[0016] The first embodiment describes a pattern forming method in a three-layer resist process. In this three-layered film, an anti-reflection film made of carbon is defined as a lower-layered film; an SOG film (spin on dielectric film) is defined as an intermediate film; or a chemically amplified resist film (photosensitive film) is defined as an upper-layered film. Hereinafter, a pattern forming method for a chemically amplified resist film which is an upper-layered film in the three-layer resist process will be specifically described.
[0017] FIGS. 1A to 1 G are sectional views each showing procedures in a pattern forming method according to a first embodiment of the present invention.
[0018] First, a solution including an anti-reflection material is coated on a substrate 11 with a spin coating technique. As shown in FIG. 1A , heating is carried out under a condition of 300° C. for 120 seconds, whereby an anti-reflection film 12 of 300 nm in film thickness is formed on the substrate 11 . In addition, spun-on C made of carbon, for example, is used for the anti-reflection film 12 .
[0019] Next, in order to form an intermediate film, a spin on dielectric material is coated on the anti-reflection film 12 with the spin coating technique. As shown in FIG. 1B , heating is carried out under a condition of 350° C. for 120 seconds, whereby an SOG film 13 of 50 nm in film thickness is formed on the anti-reflection film 12 .
[0020] Next, as shown in FIG. 1C , in order to wash a surface of the SOG film 13 , pure water (ultra-pure water) 15 is supplied from a nozzle 14 onto the SOG film 13 while the substrate 11 is rotated. A washing process is carried out for 60 seconds. The surface of the SOG film 13 is dried with a spin drying technique.
[0021] Next, as shown in FIG. 1D , the substrate 11 is placed on a hot plate 16 . The substrate 11 is heated under a condition of 200° C. for 60 seconds, whereby a water molecule adsorbed onto the surface of the SOG film 13 is removed. This heating process may be omitted if there is no necessity.
[0022] Next, a coating material for ArF light (193 nm in wavelength) chemically amplified positive resist film is coated onto the SOG film 13 with the spin coating technique. As shown in FIG. 1E , by heating at 120° C. for 60 seconds, a resist film 17 of 200 nm in film thickness is formed on the SOG film 13 .
[0023] Next, a pattern formed on an exposure reticle by using an ArF excimer laser is reduced, projected, and exposed to the resist film 17 , whereby a latent image is formed on the resist film 17 . The substrate 11 is heat-treated under a condition of 130° C. for 60 seconds. The substrate 11 is transported to a developing device. Due to a developing liquid being supplied onto the resist film 17 , a developing process is started. After 30 seconds, in order to stop the developing process and washing, pure water is supplied onto the substrate 11 . After stopping supply of the pure water, the surface of the resist film 17 is dried with a spin drying technique. By carrying out these processes, as shown in FIG. 1F , a 1:1 line and space pattern 18 is formed on the substrate 11 .
[0024] A cross section of the resist pattern formed with the above processes was observed by using a scanning electronic microscope (SEM). In a pattern of 70 nm in dimensions of the 1:1 line and space pattern 18 as well, a resist pattern fall/release was not observed on a boundary surface between the resist film 17 and the SOG film 13 , and it was verified that a vertical pattern was formed.
[0025] Next, as shown in FIG. 1G , the SOG film 13 is patterned with the line and space pattern 18 being a mask. In general, the line and space pattern 18 is eliminated while the SOG film 13 is etched. Then, with the SOG film as a mask, the anti-reflection film 12 and the substrate 11 are sequentially etched and patterned.
[0026] On the other hand, as carried out in a conventional three-layer resist process, a chemically amplified resist film was formed on the SOG film 13 without carrying out a process of washing the SOG film with pure water, and then, a pattern was reduced, projected, exposed by using the ArF excimer laser, and developed, whereby a 1:1 line and space pattern 21 was formed. A cross section of the formed resist pattern was observed by using the scanning electronic microscope (SEM). In a pattern of 100 nm or less in dimensions of the 1:1 line and space pattern 21 , thinning was observed at a lower end of the pattern 21 , and much of the line and space pattern 21 was released on a boundary surface between the pattern 21 and the SOG film 13 ( FIG. 2 ).
[0027] As has been described above, a semiconductor device fabricated by processing for a mask the pattern 18 produced by using the method described in the first embodiment successfully processed a pattern which is finer than a semiconductor device fabricated without carrying out this process, and yield was successfully improved.
[0028] In a spin on dielectric material, in addition to a resin serving as a film framework, a subsidiary component other than a resin is contained for the purpose of enhancing preservation stability of the spin on dielectric material. When the spin on dielectric material is coated and sintered to form a film on the substrate, segregation in which this subsidiary component has been segregated is formed in the vicinity of the surface of the SOG film. Next, after a chemically amplified resist film has been formed on this segregated layer, when a desired pattern is reduced, projected, exposed, and developed, the subsidiary component contained in the segregated layer diffuses into the chemically amplified resist film, and a resist pattern bottom part is decomposed. In this manner, there occurs a resist pattern release on a boundary surface between the chemically amplified resist and the SOG as shown in FIG. 2 .
[0029] Therefore, as in the present embodiment, after forming the SOG film, the surface is washed by pure water, whereby the subsidiary component which is excessively segregated in the SOG film top layer can be eliminated. In this manner, the degree of diffusion of the subsidiary component into the chemically amplified resist can be restricted, and a resist pattern release on the boundary surface between the chemically amplified resist and the SOG film can be restricted.
[0030] Further, in the present embodiment, although pure water was used as a wash chemical for the SOG film, the wash chemical is not limited to the pure water. In particular, it is more effective to use ozone water or hydrogen peroxide water. Since these chemicals have oxidization properties, the subsidiary component is oxidized and decomposed, whereby advantageous effect of eliminating the subsidiary component segregated on the SOG top layer is enhanced more significantly. In the case where the ozone water was used for wash water, a resist pattern release produced on the boundary surface between the resist and the SOG film was not observed even in a fine 1:1 line and space pattern of 60 nm in dimension.
[0031] Furthermore, in the present embodiment, after terminating the process of washing the SOG film, a heating process is carried out under a condition of 200° C. for 60 seconds in order to eliminate a water molecule adsorbed to the SOG film top layer. However, the heating process condition is not limited thereto. A heating temperature and a heating time will suffice if they can eliminate the water molecule adsorbed to the SOG film top layer. However, the subsidiary component can be removed by the washing process only in the vicinity of the SOG top layer. Therefore, there is a danger that, if the heating temperature is excessively high, the subsidiary component remaining in the SOG film is segregated again on the SOG film top layer during the heating process. Accordingly, it is desirable that the heating process temperature for eliminating the adsorbed water be equal to lower than at least the film forming temperature of the SOF film. In addition, the heating process condition may be properly selected according to type of the SOG film to be used. Further, this heating process may be omitted if there is no necessity.
[0032] Although the present embodiment has described a case of the SOG film, a material which is effective to the present embodiment is not limited thereto. Specifically, the embodiment is effective to a material classified into the publicly known spin-on dielectric (SOD) film.
[0033] Moreover, although a chemically amplified resist which has reactivity with ArF was used as a resist for use in the present embodiment, similar advantageous effect was attained for another alicyclic resin (acrylic based, cyclo olefin methyl adamantine (coma) based, and hybrid based resins) as well without being limited thereto. In addition, the embodiment is also effective to a resin having an aromatic compound. Further, advantageous effect was verified with respect to an i-beam or g-beam resist having a novolac resin; a KrF resist composed of a resin having a polyvinylphenol framework; an electron beam exposure resist; or a soft X-ray (EUV) exposure resist as well.
SECOND EMBODIMENT
[0034] In the second embodiment, as in the first embodiment, a description will be given with respect to a pattern forming method for forming a resist pattern even in a state in which a segregated layer has formed on an SOG film top layer. A multi-layered film having a three-layer structure is formed on a substrate. In this multi-layered film, an anti-reflection film made of carbon is defined as a lower-layered film; an SOG film is defined as an intermediate film; and a chemically amplified resist film is defined as an upper-layered film. Hereinafter, a specific description will be given with respect to a method for forming a pattern of a chemically amplified resist layer which is an upper-layered film in the three-layer structure.
[0035] FIGS. 3A to 3 E are sectional views each showing procedures in a pattern forming method according to a second embodiment of the present invention.
[0036] First, as shown in FIG. 3A , as in the first embodiment, an anti-reflection film 12 and an SOG film 13 are formed on a substrate 11 .
[0037] Next, as shown in FIG. 3B , in order to carry out a washing process of a surface of the SOG film 13 , pure water 15 is supplied onto the SOG film 13 while the substrate 11 is rotated. The washing process is carried out for 60 seconds. After the washing process, the SOG film 13 is dried with a spin drying technique.
[0038] Next, as shown in FIG. 3C , in order to carry out hydrophobic processing of the surface of the SOG film 13 , the substrate 11 is processed to be heated under a condition of 100° C. for 60 seconds in a processing unit filled with hexamethyl disilazane steam.
[0039] Next, as shown in FIG. 3D , a water molecule adsorbed to the surface of the SOG film 13 is removed by heating the substrate under a condition of 200° C. for 60 seconds. Through a process similar to that of the first embodiment, as shown in FIG. 3E , a line and space pattern 18 is formed. Further, with the pattern 18 as a mask, the SOG film 13 and the substrate 11 are etched.
[0040] When a cross section of the pattern 18 formed with the above processes was observed by using a scanning electronic microscope (SEM), even if dimensions of the 1:1 line and space pattern 18 was 60 nm, a resist pattern release was not observed on a boundary surface between the resist film and the SOG film, and a vertical pattern 18 was formed.
[0041] As has been described above, a semiconductor device fabricated by processing for a mask the resist pattern produced by using the method described in the second embodiment successfully processed a pattern which is finer than a semiconductor device fabricated without carrying out this process, and yield was successfully improved.
[0042] In the present embodiment, after terminating the process of washing the SOG film, a hydrophobic processing for the SOG top layer is carried out by exposure to hexamethylene disilazane steam. An organic film including an ArF chemically amplified positive resist film is highly hydrophobic. By performing the hydrophobic processing for the SOG film after the subsidiary component has been removed in accordance with the washing process, when a next chemically amplified resist film is formed on the SOG film, coherence between the chemically amplified resist film and the SOG film is improved. Thus, the advantageous effect that a resist pattern release can be restricted more significantly. Moreover, with the present embodiment, hydrophobic process is performed after the washing and heating process is carried out after that. However, a processing order is not limited to this. For example, it is also possible to use as the order of washing processing, heating processing, and hydrophobic processing.
[0043] In addition, in the present embodiment, although pure water was used as a wash chemical for the SOG film, the wash chemical is not limited to the pure water. In particular, it is more effective to use ozone water or hydrogen peroxide water. Since these chemicals oxidize and decompose the subsidiary component, and the SOG resin itself is oxidized, a hydroxide group or a carboxylic group is produced on the surface of the SOG film 13 . In this manner, the surface of the SOG film 13 becomes hydrophilic, and there is a danger that some resist resins to be used lowers coherence with the SOG film. Therefore, the hydroxide group or carboxylic group formed on the SOG resin top layer can be eliminated by carrying out the hydrophilic process after terminating the washing process, and the coherence with the SOG film can be maintained. For example, in the case where the ozone water was used for wash water, even in a fine 1:1 line and space pattern of 55 nm in dimension, a resist pattern release produced on a boundary surface between the resist and the SOG film was not observed. However, as shown in FIG. 4 , in a pattern 31 of less than 60 nm, a pattern breakage phenomenon occurred due to breakage of the resist produced by insufficient strength of the resist ( FIG. 4 ).
[0044] In the present embodiment, the hydrophobic processing for the SOG film top layer is carried out after washing the SOG film surface. Thus, a heating process is carried out under a condition of 100° C. for 60 seconds in a processing unit filled with hexamethylene disilazane steam. However, the heating process condition is not limited thereto. An optimal processing condition may be properly selected such that a resist pattern does not break according to a material for a resist film or an intermediate film to be used. In addition, other silazanes, chlorosilanes, or alkoxysilanes be selected for the hydrophobic processing without being limited to hexamethylene disilazane as long as it is properly optimal.
[0045] In the present embodiment, after the hydrophobic processing for the SOG film, a heating process is carried out under a condition of 200° C. for 60 seconds in order to remove a water component adsorbed to the SOG film top surface. However, the heating process condition is not limited thereto. As in the first embodiment, an optimal heating process condition such as a temperature and time under which the water molecule adsorbed to the SOG film top layer and which is properly optimal according to the type of SOG film may be selected. Further, this heating process may be omitted if there is no necessity.
[0046] Although the embodiment has described a case of the SOG film, a material for which the processing described in the embodiment is efficient is not limited thereto. Specifically, the present embodiment is effective to a material classified into a publicly known SOD film.
[0047] In addition, although a chemically amplified resist which has reactivity with ArF was used as a resist for use in the present embodiment, similar advantageous effect was attained for another alicyclic resin (acryl based, coma based, or hybrid based resin). Further, advantageous effect was verified with respect to an i-beam or g-beam resist having a novolac resin; a KrF resist composed of a resin having a polyvinylphenol framework; an electron beam exposure resist; or a soft X-ray (EUV) exposure resist as well.
THIRD EMBODIMENT
[0048] The present embodiment describes a pattern forming method when a resist pattern is formed by a liquid impregnation type projecting and exposure apparatus. Here, as is the above-described embodiments, a pattern forming method in a three-layer resist process will be described. An anti-reflection film made of carbon is defined as a lower-layered film, an SOG film is defined as an intermediate film, and a chemically amplified resist is defined as an upper-layered film.
[0049] In the first and second embodiments, after washing the SOG film surface, a resist film was formed. As in washing the SOG film, when a resist film surface before developing the resist film was washed, an advantageous effect was attained for improvement of dimensional uniformity of a pattern after developed or for restriction of line edge roughness. An embodiment of washing the surface of the resist film will be described below.
[0050] FIGS. 5A to 5 G are sectional views each showing procedures in a pattern forming method according to a third embodiment of the present embodiment.
[0051] As shown in FIG. 5A , as in the first embodiment or the second embodiment, an anti-reflection film 12 and a SOG film 13 are sequentially formed on a target substrate 11 .
[0052] Then, as shown in FIG. 5B , ArF light (193 nm in wavelength) chemically amplified positive resist material is coated on the SOG film 13 in accordance with a spin coating technique, and then, heating is carried out at 120° C. for 60 seconds, thereby forming a chemically amplified positive resist film 17 of 200 nm in film thickness.
[0053] Next, as shown in FIG. 5C , in order to wash the surface of the chemically amplified positive resist film 17 , pure water 15 is supplied onto the chemically amplified positive resist film 17 while the target substrate 11 is rotated. The washing process is carried out for 60 seconds. After the washing process, the surface of the chemically amplified positive resist film 17 is dried in accordance with a spin drying technique.
[0054] Subsequently, as shown in FIG. 5D , the target substrate 11 is placed on a hot plate 16 . In order to remove a water molecule adsorbed to the surface of the chemically amplified positive resist film 17 , the substrate 11 is heated under a condition of 130° C. for 60 seconds.
[0055] Next, in a liquid impregnation type projecting and exposure apparatus described in Jpn. Pat. Appln. KOKAI Publication No. 6-124873, a desired pattern provided on a reticle is transferred to the positive resist film 17 by using an ArF excimer laser, and a latent image is formed on the positive resist film 17 . For example, as shown in FIG. 5E , the substrate 11 is placed in a liquid tank 31 , and a pattern is projected, and exposed on the positive resist film 17 via a water layer 33 formed in an optical path between the chemically amplified positive resist film 17 and an optical system 32 of the projecting and exposure apparatus.
[0056] The substrate 11 is heat-treated under a condition of 130° C. for 60 seconds. The substrate 11 is transported to a developing device. The developing liquid is supplied onto the resist film 17 , whereby a developing process is started. After 30 seconds, in order to stop the developing process and washing, pure water is supplied onto the rotating target substrate 11 . After stopping supply of the pure water, the surface of the resist film 17 is dried in accordance with the spin drying technique. By carrying out this processing, as shown in FIG. 5F , a 1:1 line and space pattern 18 of 90 nm in thickness is formed on the substrate 11 .
[0057] Subsequently, as shown in FIG. 5G , with the pattern 18 of the resist film being a mask, the SOG film 13 is patterned. In general, while the SOG film 13 is etched, the pattern 18 is eliminated. Then, with the SOG film 13 being a mask, the anti-reflection film 12 and the target substrate 11 are sequentially etched and patterned.
[0058] In accordance with the above process, the uniformity of the dimensions in the substrate surface of the formed pattern 18 was 3 nm in 3σ. In addition, when dispersion in line edge roughness of the pattern 18 was measured, 3σ was 1.5 nm in a conventional method. On the other hand, as is carried out in a three-layer resist process using a conventional immersion exposure apparatus, when a 1:1 line and space pattern of 90 nm was formed by reducing, projecting, exposing, and developing a pattern without carrying out the washing process for the chemically amplified positive resist film with pure water, the uniformity of the dimensions in the target substrate surface of the resist pattern was 7 nm in 3σ. Further, the dispersion in line edge roughness of the resist pattern was 4 nm in 3σ.
[0059] As has been described above, a semiconductor device fabricated by processing for a mask a resist pattern produced by using the method described in the present embodiment was more successfully improved in yield than a semiconductor device fabricated without carrying out this processing, and device reliability was successfully enhanced.
[0060] Some chemically amplified positive resist material contains an optical acid generating material or the like which is decomposed when light is emitted and which generates a strong acid, in addition to a resin which becomes a film framework. If a heating process is carried out after exposure, a resist resin is decomposed by an action of the acid produced from an optical acid generating material, whereby a light emitting portion becomes soluble to a developing liquid. As a result, a resist pattern is formed. The optical acid generating material is segregated on the surface of the chemically amplified resist film when the chemically amplified resist film is coated to form an film on the substrate. However, during immersion exposure, the optical acid generating material is dissolved in the liquid contained in the liquid tank provided between the substrate and a projecting optical system. As in a general exposure apparatus, when exposure was carried out by a step and repeat operation, liquidation occurs with the liquid. Thus, the optical acid generating material dissolved according to the liquid liquidation also liquidates, and the optical acid generating material is localized on the chemically amplified resist film surface. Next, when the heating process and developing process are carried out while the optical acid generating material is localized on the surface of the substrate, the resist resin of the light emitting portion is dissolved according to the amount of the optical acid generating material localized on the surface of the substrate, and a resist pattern is formed. Thus, the dimensional uniformity in the substrate surface of the chemically amplified resist pattern deteriorates.
[0061] Therefore, as in the embodiment, the washing process is carried out with pure water after forming the chemically amplified resist film, the optical acid generating material excessively segregated in the top layer of the chemically amplified resist film can be removed. In this manner, the dimensional uniformity or line edge roughness in the surface of the substrate of the chemically amplified resist pattern can be improved as compared with the conventional method.
[0062] The present embodiment has described a case in which the chemically amplified resist surface was washed before immersion exposure by using the immersion type projecting and exposure apparatus. However, the effectiveness of the present invention is not limited to washing the surface of the chemically amplified resist. The liquid impregnation exposure process includes a process for forming a protective film in a resist film in order to prevent water penetration into the chemically amplified resist or pattern deterioration due to dissolution of the substance included in the resist film into water. However, even such a protective film cannot eliminate effect of water perfectly. Therefore, as in the present invention, the surface of the protection film formed on the chemically amplified resist is washed before immersion or exposure, whereby the dimensional uniformity or line edge roughness in the surface of the substrate can be improved as compared with a case in which no washing process has been carried out.
[0063] The embodiment has described a pattern forming method when a resist pattern is formed by using a immersion type projecting and exposure apparatus. However, the effectiveness of the present invention is not limited to a case of using the immersion type exposure apparatus. Even in the case where a resist pattern is formed by using a general exposure apparatus and in the case where a desired pattern is reduced, projected, and exposed after carrying out the washing process after forming the chemically amplified resist film, the dimensional uniformity or line edge roughness in the surface of the substrate can be improved as compared with a case in which no washing process has been carried out.
[0064] Further, in the embodiment, pure water was used as a washing chemical for the chemically amplified resist film, the washing chemical is not limited thereto. In particular, the present invention is more effective in the case where ozone water or hydrogen peroxide water was used. Since these chemicals have oxidization properties, the subsidiary component is oxidized and decomposed, whereby advantageous effect of eliminating the subsidiary component segregated on the top layer of the chemically amplified resist is enhanced more significantly. The dimensional uniformity or line edge roughness in the surface of the target substrate is improved more significantly.
[0065] Furthermore, in the embodiment, after terminating the process of washing the chemically amplified resist film, in order to remove the water molecule adsorbed to the top layer of the chemically amplified resist film, a heating process is carried out under a condition of 130° C. for 60 seconds. However, the heating process condition is not limited thereto. Any heating temperature or heating time may be used as long as it can remove the water molecule adsorbed to the top layer of the chemically amplified resist film.
[0066] Although the present embodiment has described a case of the SOG film, a material for which the present invention is effective is not limited thereto. Specifically, the invention is effective to a material classified into a publicly known SOD film.
[0067] Moreover, although the chemically amplified resist having reactivity with ArF light was used as a resist for use in the present embodiment, a similar advantageous effect was attained for another alicyclic resin (acryl based, coma based, or hybrid based resin) without being limited thereto. In addition, the present invention is also effective to a resin having an aromatic compound. Further, the advantageous effect was verified with respect to an i-beam or g-beam resist having a novolac resin; a KrF resist composed of a resin having a polyvinylphenol framework; an electron beam exposure resist; or a soft X-ray (EUV) exposure resist as well.
[0068] Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
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A pattern forming method comprises forming a spin on dielectric film on a substrate, washing the spin on dielectric film by using a washing liquid, drying a surface of the spin on dielectric film after the washing, forming a photosensitive film on the dried coating type insulation film, emitting energy rays to a predetermined position of the photosensitive film in order to form a latent image on the photosensitive film, developing the photosensitive film in order to form a photosensitive film pattern which corresponds to the latent image, and processing the spin on dielectric film with the photosensitive film pattern serving as a mask.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a method of manufacturing 3,3′,4,4′-tetraaminobiphenyl in an effective manner.
[0003] 2. Background Art 3,3′,4,4′-Tetraaminobiphenyl is an industrially important compound as a raw material for heat resistant polymers, dyes, electronic materials and the like.
[0004] Various methods are known as a general manufacturing method for this 3,3′,4,4′-tetraaminobiphenyl. Examples of such methods include a benzidine method (Non-patent Document 1), a biphenyl method (Patent Document 1), a dichlorobenzidine method (Patent Document 2) and a coupling method (Patent Document 3).
(Benzidine Method)
[0005] The benzidine method is a classical method of manufacturing 3,3′,4,4′-tetraaminobiphenyl using benzidine as a raw material. A series of several steps are used to synthesize 3,3′,4,4′-tetraaminobiphenyl starting with benzidine (4,4′-diaminobiphenyl).
[0006] That is, amino groups in benzidine are first protected by N-acetylation with acetic anhydride, and the resulting acetylated compound is then converted into 3,3′-dinitro-N,N′-diacetylbenzidine by nitration. For example, this nitration is performed with concentrated nitric acid in a mixture of acetic anhydride and acetic acid. 3,3′-Dinitro-N,N′-diacetylbenzidine is treated with a base to remove the acetyl groups and then treated with tin (II) chloride in hydrochloric acid to reduce the nitro groups to yield 3,3′,4,4′-tetraaminobiphenyl (Scheme 1).
[0000]
(Biphenyl Method)
[0007] A method according to Patent Document 1 is known as an improved method of manufacturing 3,3′,4,4′-tetraaminobiphenyl starting with biphenyl as a raw material.
[0008] Biphenyl is first diacylated with acetyl chloride under a Friedel-Crafts condition. 4,4′-Diacetylbiphenyl obtained is then treated with hydroxylamine to give a corresponding oxime, which is further converted into N,N′-diacetylbenzidine in the presence of an acid via Beckmann rearrangement. After that, this compound is successively subjected to nitration, deprotection by a base and then reduction of the nitro groups to yield 3,3′,4,4′-tetraaminobiphenyl in the same manner as in the above benzidine method (Scheme 2).
[0000]
(Dichlorobenzidine Method)
[0009] A method according to Patent Document 2 is known as a method directly utilizing a benzidine skeleton. 3,3′-Dichlorobenzidine is treated with ammonia in the presence of a copper catalyst at high temperature (150 to 250° C.) and high pressure (1 to 10 MPa) to yield 3,3′,4,4′-tetraaminobiphenyl (Patent Document 2, Scheme 3).
[Chem. 3]
Scheme 3
[0010]
(Coupling Method)
[0011] A method according to Patent Document 3 can be listed as a manufacturing method for 3,3′,4,4′-tetraaminobiphenyl not using the benzidine skeleton as a starting material. This method uses Suzuki's coupling between 4-acetylamino-3-nitrobromobenzene and 4-acetylamino-3-nitrophenyl borate to form the benzidine skeleton, followed by deprotection with a base and reduction of the nitro groups in turn to yield 3,3′,4,4′-tetraaminobiphenyl.
[0000]
Patent Document 1: U.S. Pat. No. 5,041,666
Patent Document 2: Japanese Patent Laid-Open Publication No. 2004-161643
Patent Document 3: US Patent Application No. 2005/0215823
Non-patent Document 1: H. Vogel, C. S. Marvel, J., Polym. Sci., 50, 511 (1961)
Non-patent Document 2: I. A. Belenkaya, T. A. Shulla, J. Heterocyclic Chem. 11, 1555-1558 (1989)
[0017] However, the above benzidine method has a problem that it involves likelihood of deterioration of working conditions and pollution of the environment, because benzidine, which is the starting material, is a carcinogen.
[0018] The above biphenyl method is inefficient, since it requires many steps and heavy use of a stoichiometric quantity of reagents in order to obtain 3,3′,4,4′-tetraaminobiphenyl.
[0019] The above dichlorobenzidine method has problems that it requires special attention to deterioration of working conditions and environmental pollution because dichlorobenzidine used is a mutagen, and that it requires special manufacturing facilities because the reaction in the presence of ammonia requires a high temperature and a high pressure.
[0020] Moreover, the above-mentioned coupling method additionally requires Grignard reaction and the like to synthesize a borate compound as the starting material for the coupling reaction as well as an expensive palladium catalyst for the coupling reaction. There is thus a problem that it requires steps for catalyst recovery, recycling and the like to complicate the process as a whole and increase a manufacturing cost.
[0021] An object of the present invention is thus to provide a manufacturing method capable of efficiently producing 3,3′,4,4′-tetraaminobiphenyl through a smaller number of steps. A starting material different from those used in the conventional manufacturing methods is chosen to eliminate use of highly toxic or carcinogenic substances, thus allowing improvement of working conditions and safer environment.
SUMMARY OF THE INVENTION
[0022] The present inventors have earnestly studied to address the above problems and found a manufacturing method of 3,3′,4,4′-tetraaminobiphenyl, which includes protection of the amino groups of a 1,2-diamino-4-halobenzene as a starting material, a subsequent coupling reaction to form a carbon-carbon bond and deprotection of the amino groups to yield 3,3′,4,4′-tetraaminobiphenyl, completing the present invention.
[0023] That is, the present invention relates to following terms [1] to [4].
[1] A method of manufacturing 3,3′,4,4′-tetraaminobiphenyl, comprising:
reacting amino groups of a phenylenediamine compound represented by the following formula (1) with an inorganic sulfur compound,
[0000]
[0000] (in which X represents a chlorine, bromine or iodine atom) to form a benzothiadiazole compound represented by the following formula (2),
[0000]
[0000] (in which X represents a chlorine, bromine or iodine atom); coupling two molecules of the compound (2) together to yield 5,5′-bis(2,1,3-benzothiadiazole) represented by the following formula (3); and
[0000]
[0000] deprotecting the amino groups to obtain 3,3′,4,4′-tetraaminobiphenyl represented by the following formula (4).
[0000]
[2] The manufacturing method according to above term 1, wherein the coupling reaction is carried out in the presence of metallic copper.
[3] The manufacturing method according to above term 1 or 2, wherein the deprotection of the amino groups is carried out under a reductive condition.
[4] The manufacturing method according to above term 1 or 2, wherein the deprotection of the amino groups is carried out by reduction with a metal.
EFFECT OF THE INVENTION
[0028] The manufacturing method of the present invention enables efficient manufacture of 3,3′,4,4′-tetraaminobiphenyl using a smaller number of steps. No need to use highly toxic starting materials enables improvement of working conditions and safer environment.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0029] The present invention is detailed in the following.
[0030] A 4-halo-o-phenylenediamine is used as a starting material in the method of manufacturing 3,3′,4,4′-tetraaminobiphenyl of the present invention. Examples of the 4-halo-o-phenylenediamine include 4-chloro-o-phenylenediamine and 4-bromo-o-phenylenediamine.
<Protection of Amino Groups in the 4-Halo-o-phenylenediamine>
[0031] In the present invention, the amino groups are first protected by reacting the 4-halo-o-phenylenediamine represented by the above formula (1) with an inorganic sulfur compound to yield a 5-halo-2,1,3-benzothiadiazole represented by the above formula (2). In the 4-halo-o-phenylenediamine used in the present invention, the halogen is chlorine, bromine or iodine.
[0032] In the present invention, a coupling reaction of the 4-halo-o-phenylenediamine is used to build the benzidine skeleton. When the coupling reaction is carried out without protecting the amino groups of the 4-halo-o-phenylenediamine, diphenylamine may be formed as a byproduct. Accordingly these amino groups are protected prior to the coupling reaction with a functional group/functional groups which is/are not removed in the coupling reaction.
[0033] An amide group, a carbamoyl group, an N-sulfonyl group, a sulfonamide group or the like may be used here as such a protective group. It is preferred to derive a thiadiazole ring from the amino groups for their protection. For example, a method based on the method according to the above Non-patent Document 2 is preferred to protect the amino groups.
[0034] That is, an inorganic sulfur compound is used when the above amino groups are converted to the thiadiazole ring. The inorganic sulfur compounds employable in the invention include inorganic divalent sulfur compounds such as sulfur dichloride and inorganic tetravalent sulfur compounds such as thionyl chloride. Among them, thionyl chloride is preferred. At least an equivalent mole of the above sulfur-containing compound relative to one mole of the 4-halo-o-phenylenediamine should be used, but the sulfur-containing compound is preferably used in excess so that the reaction will complete.
[0035] A solvent may be used in the present reaction if necessary. The solvent may serve to dissolve or disperse the 4-halo-o-phenylenediamine for effective contact with the inorganic sulfur compound, to prevent rapid and drastic reaction by dilution effect, and to absorb liberated heat by reflux. In the present invention, hydrocarbon solvents such as hexane, cyclohexane, methylcyclohexane, heptane and octane; aromatic hydrocarbon solvents such as benzene, toluene, xylene and ethylbenzene; and halogenated solvents such as dichloromethane, chloroform, dichloroethane, trichloroethane, tetrachloroethane, chlorobenzene and dichlorobenzene may be used. Among them, the aromatic hydrocarbon solvents are preferably used. The amount of the solvent used is preferably 2 to 50 times by weight, more preferably 5 to 30 times by weight that of the 4-halo-o-phenylenediamine.
[0036] However, when thionyl chloride is used as the inorganic sulfur compound, it can serve also as the solvent. In this case, the amount of thionyl chloride used is 1.5 to 10 times by weight that of the 4-halo-o-phenylenediamine.
[0037] An acid may be used to accelerate the present reaction if necessary. In the present invention, nonvolatile protonic acids are preferably used. Among them, sulfuric acid is particularly preferred. The amount of the acid used is 0.01 to 1.0 times by weight, preferably 0.1 to 0.3 times by weight that of the 4-halo-o-phenylenediamine.
[0038] The present reaction is performed under air or an inert atmosphere such as nitrogen.
[0039] The present reaction is generally carried out by mixing the 4-halo-o-phenylenediamine and the inorganic sulfur compound, adding the solvent and the acid if necessary, and heating and stirring. When a gas such as hydrogen chloride is generated in the reaction, the gas is preferably collected with an alkali trap outside a reaction vessel. The present reaction is generally carried out at a temperature of from 80° C. to a reflux temperature of the reaction solution. In the present invention, the reaction is preferably carried out at a reflux temperature of the reaction solution.
<Coupling Reaction>
[0040] Next, in the present reaction, two molecules of the 5-halo-2,1,3-benzothiadiazole (2) obtained in the above protective reaction are coupled together to yield 5,5′-bis(2,1,3-benzothiadiazole) (3). The 5,5′-bis(2,1,3-benzothiadiazole) (3) is a precursor compound for 3,3′,4,4′-tetraaminobiphenyl.
[0041] Although various known methods for such coupling reaction maybe used so long as a desired purpose is achieved, in the present invention, the Ulmann reaction, which uses metallic copper as a coupling agent, is preferred in the coupling reaction from a perspective of reaction simplicity and economy.
[0042] Copper used in the present invention is preferably in a form of granular copper, specifically copper shavings, copper dust, copper powder, and the like from a perspective of reaction efficiency. Copper should be used at least in an equimolar amount to the 5-halo-2,1,3-benzothiadiazole compound has to be used. However, excess amount of copper relative to that of the 5-halo-2,1,3-benzothiadiazole compound is preferably used to ensure completion of the reaction. On the other hand, considering the balance between promotion of the coupling reaction and removal of unreacted copper at the end of the reaction, copper is preferably used in slight excess over the 5-halo-2,1,3-benzothiadiazole compound. Based on this, the amount of copper used in the present coupling reaction is 1.01 to 2 moles, preferably 1.1 to 1.6 moles relative to one mole of the 5-halo-2,1,3-benzothiadiazole compound.
[0043] Amide solvents such as dimethylformamide, diethylformamide, dimethylacetamide and N-methylpyrrolidone, and nitrobenzene solvents such as nitrobenzene and nitrotoluene may be used for the coupling reaction in the present reaction. In the present invention, the amide solvent is preferably used and dimethylformamide is particularly preferred. The amount of the solvent used is 2 to 50 times, preferably 3 to 30 times by weight that of copper used.
[0044] The present reaction is generally carried out under an inert atmosphere such as nitrogen or argon.
[0045] The above coupling reaction is generally carried out by mixing the solvent such as dimethylformamide with the 5-halo-2,1,3-benzothiadiazole compound and copper and heating the mixture. The reaction temperature generally ranges from 100° C. to a reflux temperature of the reaction solution.
<Deprotection>
[0046] 5,5′-bis(2,1,3-benzothiadiazole) thus obtained is deprotected to yield 3,3′,4,4′-tetraaminobiphenyl. Various methods may be used for deprotection of the amino groups in the benzothiadiazole. Deprotection is preferably carried out under a reductive condition in order not to impair the amino groups formed.
[0047] Hydrogen reduction with a metal catalyst, reduction with a metal and the like may be used as the reduction method. Reduction with a metal is preferred. Example of the metals include typical metals such as sodium, potassium, magnesium, aluminum and transition metals such as iron, zinc and tin. Magnesium and zinc are preferred. A source to supply protons is required for this reaction and a protic solvent such as water or alcohol, or an acid such as hydrochloric acid is added to supply protons. Twelve electrons are herein required to reduce 5,5′-bis(2,1,3-benzothiadiazole) and the electrons used in this reaction are supplied from the metal (the following formula (A)). For example, when zinc or magnesium, which is a divalent metal, is used, at least 6 moles of such metal relative to one mole of 5,5′-bis(2,1,3-benzothiadiazole) have to be used. However, excess amount of such metal relative to a theoretical quantity is preferably used to ensure completion of the reaction. Accordingly, 6 to 80 moles of such metal relative to one mole of 5,5′-bis(2,1,3-benzothiadiazole) is preferably used.
[0000]
[0048] The metal used in the present invention is preferably in a form of granules, shavings, dust, powder, and the like from a perspective of improving reaction efficiency.
[0049] In the deprotection, a solvent may be used without limitation. Suitable solvents include protic solvents such as water, alcohols and organic acids. Methanol, ethanol, propanol, butanol, and the like are used as the alcohols, while formic acid, acetic acid, propionic acid, and the like are used as the organic acids. The amount of the solvent used is 2 to 50 times, preferably 5 to 30 times by weight that of 5, 5′-bis (2,1,3-benzothiadiazole).
[0050] The present reaction is carried out under air or an inert atmosphere such as nitrogen or argon.
[0051] The reaction is generally carried out by dissolving 5,5′-bis(2,1,3-benzothiadiazole) in the solvent such as an alcohol, adding the acid if necessary and further adding and mixing the metal. The reaction temperature generally ranges from 0° C. to a reflux temperature of the reaction fluid.
EXAMPLES
[0052] The present invention is specifically described with illustration of the following Examples, but not limited in any way by these Examples.
[0053] Gas chromatography (analytical instrument: model 6890N manufactured by Agilent Technologies, Ltd., analysis column: DB-1 column manufactured by J&W Scientific Inc.) was in principle used for analysis of each component in the Examples. High performance liquid chromatography (analytical instrument: model LC-2010HT manufactured by SHIMADZU Co., analysis column: RP-18 (ODS) column with endcapping treatment manufactured by Kanto Chemical Co. Inc.) was used for analysis of low volatile substances.
Example 1
Synthesis of 5-chloro-2,1,3-benzothiadiazole
[0054] A mixture was prepared by mixing 4.0 g (28 mmol) of 4-chloro-o-phenylenediamine, 14 mL of thionyl chloride and 0.62 mL of concentrated sulfuric acid and was refluxed for one hour. This mixture was cooled and then poured onto ice, and a resultant precipitate was filtered and collected. This precipitate was washed with water till the waste water became neutral and then thoroughly dried to yield 4.6 g of 5-chloro-2,1,3-benzothiadiazole as a crude product (melting point, 50 to 54° C.; yield, 96%). This crude product was vacuum-distilled to yield a pure product of 5-chloro-2,1,3-benzothiadiazole (melting point, 54° C.; yield, 85%).
Synthesis of 5,5′-bis(2,1,3-benzothiadiazole)
[0055] A reaction mixture of 2.2 g (12.9 mmol) of 5-chloro-2,1,3-benzothiadiazole and 1.3 g (20.5 mmol) of copper powder was heated in 5 mL of dimethylformamide with stirring at 150° C. for 20 hours. This reaction mixture was cooled and then poured into water (40 mL), and a resulting precipitate was filtered and collected. After this precipitate was dried, it was extracted with benzene (20 mL×3). After combining these benzene extracts, the combined extract was dried under vacuum to complete dryness. A resulting oily residue was triturated with petroleum ether, and a mother liquor was removed to yield 1.45 g of 5,5′-bis(2,1,3-benzothiadiazole) (melting point, 61 to 62° C.; yield, 83%).
Synthesis of 3,3′,4,4′-tetraaminobiphenyl
[0056] A methanol solution (20 mL) containing 1.0 g (3.7 mmol) of 5,5′-bis (2,1,3-benzothiadiazole) was heated to 45° C., to which 1.6 g (65.8 mmol) of metallic magnesium powder was added in one hour with stirring and then the resulting mixture was heated at 60° C. for 20 minutes. After unreacted magnesium was removed by filtration and methanol was distilled off, isobutyl methyl ether (10 mL) and a saturated aqueous ammonium chloride solution (20 mL) were added to the residue. The resulting mixture was stirred for 10 minutes. An organic layer was separated, dried over anhydrous sodium sulfate and then concentrated to dryness. This concentrated residue was dissolved in water (20 mL) containing concentrated hydrochloric acid (5 mL). The resulting solution was cooled to precipitate crystals, which were collected by filtration and dried to yield 1.07 g of 3,3′,4,4′-tetraaminobiphenyl hydrochloride (yield, 80%).
Example 2
Synthesis of 5-bromo-2,1,3-benzothiadiazole
[0057] A mixture was prepared by mixing 4.0 g (21 mmol) of 4-bromo-o-phenylenediamine, 14 mL of thionyl chloride and 0.62 mL of concentrated sulfuric acid and was refluxed for one hour. This mixture was cooled and then poured onto ice, and a resulting precipitate was filtered and collected. This precipitate was washed with water till the waste water became neutral and then thoroughly dried to yield 4.5 g of 5-bromo-2,1,3-benzothiadiazole as a crude product (melting point, 48 to 50° C.; yield, 96.5%). This crude product was vacuum-distilled to yield a pure product of 5-bromo-2,1,3-benzothiadiazole (melting point, 50° C.; yield, 86%).
Synthesis of 5,5′-bis(2,1,3-benzothiadiazole)
[0058] A reaction mixture prepared by adding 4.6 g (21.4 mmol) of 5-bromo-2,1,3-benzothiadiazole and 2 g (31.5 mmol) of copper powder to 10 mL of dimethylformamide was heated with stirring at 150° C. for 6 hours. This reaction mixture was cooled and then poured into water (40 mL), and a resulting precipitate was filtered and collected. After this precipitate was dried, it was extracted with benzene (20 mL×3). After combining these benzene extracts, the combined extract was dried under vacuum to complete dryness. A resulting oily residue was triturated with petroleum ether, and a mother liquor was removed to yield 2.1 g of 5,5′-bis(2,1,3-benzothiadiazole) (melting point, 61 to 62° C.; yield, 73%).
Synthesis of 3,3′,4,4′-tetraaminobiphenyl
[0059] A reaction mixture prepared by adding 2.5 g (38.2 mmol) of zinc suspended in 6 mL of a 20% aqueous hydrochloric acid solution to a 20% aqueous hydrochloric acid solution (6 mL) containing 1.0 g (3.7 mmol) of 5,5′-bis(2,1,3-benzothiadiazole) was refluxed for 1.5 hours with stirring. The reaction mixture was cooled and filtered. While the filtrate was concentrated crystals started precipitating. This concentrated solution was cooled to collect the crystals by filtration to yield 1.0 g of 3,3′,4,4′-tetraaminobiphenyl hydrochloride (melting point, 265 to 267° C.; yield, 75%).
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An object of the present invention is to provide an efficient method of manufacturing 3,3′,4,4′-tetraaminobiphenyl with a smaller number of steps. The manufacturing method of 3,3′,4,4′-tetraaminobiphenyl includes reacting the amino groups of a 4-halo-o-phenylenediamine with an inorganic sulfur compound to lead to a 5-halo-2,1,3-benzothiadiazole, subsequently coupling two molecules of the benzothiadiazole together to form a 5,5′-bis(2,1,3-benzothiadiazole) and then deprotecting the amino groups to yield 3,3′,4,4′-tetraaminobiphenyl.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to tongue and groove joints. These joints are particularly useful for joining pieces of laminate flooring. Glue in these joints resists penetration of moisture.
2. Description of the Related Art
Commercially available laminate flooring generally includes a wear surface glued to a substrate. The wear surface generally is high-wear resistant decorative laminate. The substrate generally is fiber board or particle board. Each piece of laminate flooring generally has a groove along one end and one side suitable for joining with a tongue along one side or end of an adjacent piece of laminate flooring.
While such laminate flooring has found wide acceptance in Europe as flooring, it is not substantially used in the United States. In part the reason may be due to installation difficulties and the lack of moisture resistance in the joint areas.
Laminate flooring is assembled by placing glue in the groove and inserting the tongue of one piece into the groove of an adjacent piece. A substantially complementary fit of a tongue and groove results in difficulty in aligning the tongue and groove. Additionally, as the glue is absorbed into substrate, the substrate swells, causing the groove to tightly squeeze the tongue. This can make full insertion of the tongue into the groove extremely difficult. Furthermore, as the tongue and groove are moved together, glue can be compressed in the groove by the tongue in a piston fashion. This can increase the difficulty in abutting the wear surfaces of adjacent laminate flooring pieces.
To overcome this assembly problem, laminate flooring manufactures offer special tools for assembling pieces of laminate flooring.
One such special tool is a hammering aid that has a flat surface and complementary tongue and groove engaging surfaces. When difficulty is encountered in abutting the wear surfaces of adjacent pieces, the hammering aid is placed along the edge of the laminate. The flat surface of the hammering aid is then struck with a hammer repeatedly to apply a force to the joint and force the tongue and groove together.
However, even with the use of a hammering aid, a gap can remain between adjacent pieces. The gap is unsightly and allows for damaging penetration of moisture to the substrate. The problem with moisture penetration into the joint is that it can cause the substrate to swell. Excess swelling damages laminate flooring.
Laminate flooring with tongue and groove joints are difficult to manufacture. The tight complementary fit between the tongue and groove requires attention be paid to cutting tolerances for the widths of the tongue and groove. An interesting yet problematic phenomenon occurs during the process of cutting the tongues and grooves. The cutting process itself progressively dulls and wears the cutting blades. As the blades progressively wear, grooves of later cut articles are progressively narrower than grooves of earlier cut articles. Likewise, tongues of later cut articles are progressively wider than tongues of earlier cut articles. Unfortunately, at some point, the widths of the tongues and grooves are not within acceptable tolerances.
Thus there is a need in the art for an improved tongue and grooved joint. There is a need for a tongue and groove joint that does not require special tools for installation. There is a need for a moisture resistant tongue and groove joint. These and other needs will become apparent to those of skill in the art upon review of this specification, including its claims and drawings.
SUMMARY OF THE INVENTION
It is one object of the present invention to provide for an improved tongue and grooved joint.
It is even another object of the present invention to provide for a tongue and grooved joint that does not require special tools for installation.
It is yet another object of the present invention to provide for a moisture resistant tongue and groove joint.
These and other objects of the present invention will become apparent to those of skill in the art upon review of this specification, including its claims and drawings.
An article of the present invention has a planar, decorative wear surface, a grooved edge and a tongued edge. The tongued edge has a tongue with a planar lower surface positioned an index distance from and parallel to the planar decorative surface. The grooved surface has a groove with a planar lower surface positioned the index distance from and parallel to the planar decorative surface. The upper surfaces of the tongue and groove are shaped and sized such that upon joining two pieces of the article by positioning the lower surfaces of the tongues and grooves together and moving the tongue of one piece into the groove of another piece, liquid glue placed in the groove will be squeezed out between the upper surfaces of the tongue and groove and upwardly between the tongued and grooved edge toward the decorative surfaces of the two pieces. This joint can be assembled without the use of special tools and the glue acts as a barrier to water damage to substrate of laminate flooring.
The tongue has a beveled surface extending from the end surface to the upper surface of the tongue. The beveled surface can form an oblique angle to the upper surface of the tongue. Preferably more than about one half and most preferably more than about two thirds of the length of upper surface of the tongue remains after the beveled surface is cut. A space for glue to be squeezed through is provided between the upper surfaces of tongues and grooves upon joining pieces of the article. A space for glue to be squeezed through is also provided between a planar surface above the tongue and a planar surface above the groove. The planar surface above the tongue forms a right angle to the decorative surface. The planar surface above the groove forms an acute angle to the decorative surface The acute angle can be about 82.5 to 87.5 degrees. A space is provided between a planar surface below the tongue and a planar surface below the groove. The planar surface below the tongue forms a right angle to the decorative surface. The planar surface below the groove forms an acute angle to the decorative surface The acute angle can be about 82.5 to 87.5 degrees.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side-view of the tongue and groove joint of the present invention.
FIG. 2 is a side-view of an assembly step of the tongue and groove joint of the present invention showing glue placed in the groove and the tongue entering the groove.
FIG. 3 is a side-view of an assembly step of the tongue and groove joint of the present invention showing the tongue in contact with glue in the groove and the glue being squeezed out.
FIG. 4 is a side-view showing the tongue and groove of the present invention being fully joined and glue squeezed out to the wear surface.
FIGS. 5-8 show the dimensions of an embodiment of the tongue and groove joint of the present invention in English and Metric units.
DETAILED DESCRIPTION OF THE INVENTION
The tongue and groove joint of the present invention is described with reference to laminate flooring. However, the present invention is applicable to other articles that can be joined with tongue and groove joints.
Features and functions of the tongue and groove joint of the present invention are shown in side views of pieces of laminate flooring 10 on FIGS. 1-4. A piece of laminate flooring 10 is shown on FIG. 1 with a rectangular tongue 26 on a planar tongued edge 25. Another piece of laminate flooring 10 is shown on FIG. 1 with a rectangular groove 16 on a planar grooved edge 15.
Additional features of laminate flooring are decorative laminate 11, substrate 13, and backer 14. The decorative laminate provides a wear surface 12. The tongue 26 and groove 16 are cut in the substrate. It is believed that particle board, fiberboard or plywood can be suitable substrates 13 for laminate flooring. A backer 14 is believed to be required when laminate flooring is to be installed on a flexible pad. The backer 14 provides dimensional stability to the laminate flooring and can be a moisture barrier. It is believed that a backer is not required for laminate flooring that will be glued to an existing floor.
The tongue 26 and groove 16 are shown on FIG. 1 as having planar lower surfaces, 28 and 18 respectively. These planar lower surfaces are parallel with and an indexing distance from planar wear surface 12. Abutment of the planar lower surface 28 of tongue 26 and the planar lower surface 18 of groove 16 during the joining of the tongue and groove, as shown on FIGS. 2 through 4, causes indexing of wear surfaces 12 of pieces of laminate flooring 10.
The tongue 26 and groove 16 are shown on FIGS. 3 and 4 as having planar upper surfaces, 27 and 17 respectively. These planar upper surfaces are parallel and spaced apart. This space provides a flow path for glue to flow during the joining of the tongue and groove joint of this invention.
The planar tongued and grooved edges, 25 and 15 respectively, above and below the tongue 26 and groove 16 are shown on FIG. 4 as not being parallel. The planar tongued edge 25 is cut at a right angle (90 degrees) to the wear surface. The planar grooved edge 15 is cut at an acute angle (less than 90 degrees) to the wear surface. This provides a space above tongue 26 and groove 16 for glue 20 to flow to the wear surface 12 of laminate flooring 10. It is believed that this acute angle should be about 82.5 to 87.5 degrees. An acute angle above about 87.5 degrees will not provide sufficient space for viscous glue to flow to the wear surface 12. An acute angle of less than about 82.5 degrees will result in a larger space than required. Water absorbed by the substrate from the excess glue could swell the substrate and separate the planar tongued and grooved edges, 25 and 15 respectively. This also provides a space below the tongue 26 and groove 16 for the substrate to absorb moisture and swell without damaging the laminate flooring. It is believed that this swelling will not apply pressure for separating the planar tongued and grooved edges, 25 and 15 respectively.
Tongue 26 is shown as having a beveled surface 30 extending from its end surface 29 to its upper surface 27. The bevel is shown as cut at an oblique (45 degree) angle to the upper 27 and end 29 surfaces of the tongue 26. The beveled surface 30 can serve as a guide during the joining of tongue 26 and groove 16.
Glue 20 is shown on FIG. 2 in the end 19 of groove 16. Glue 20, after curing, adheres the tongue and groove joint together and acts as a barrier against moisture penetration to the substrate 13. Commercially available wood glues are suitable to adhere the tongue and groove joint together. Franklin Titebond II Wood Glue, which is available from Franklin International of Columbus, Ohio is believed to be suitable for joining laminate flooring. Franklin Titebond II Wood Glue is believed to be a polyvinyl acetate emulsion adhesive. When laminate flooring is installed on a flexible pad, it is believed to be desirable for the glue to be somewhat flexible. It is thought that flexibility of the glue, after curing, can better accommodate depression of laminate flooring at the tongue and groove joint of this invention.
Additional features and functions of the tongue and groove joint of this invention are shown on FIGS. 2 through 4. As the tongue and groove of two pieces of laminate flooring 10 are joined, tongue 26 applies pressure to liquid glue 20 in groove 16. Glue 20 flows past beveled edge 30 and through space 31 between the upper surface 27 of tongue 26 and the upper surface 17 of groove 16. The lower surfaces 28 of tongue 26 and the lower surface 18 of groove 16 are abutted, thereby providing an impediment to glue flowing between the lower surfaces 28 and 18 of the tongue and groove.
The beveled surface 30, as shown of FIG. 4, reduces the length of the upper surface 27 of tongue 26 and the upper surface 17 of groove 16 as compared to the lengths of the surfaces of a rectangular tongue. This is believed to aid in glue 20 flowing, preferentially, between the upper surfaces of tongue 26 and groove 16 during the joining of pieces of laminate flooring 10. The abutment and length of the lower surfaces, 28 and 18 respectively, of tongue 26 and groove 16 is also believed to aid in glue 20 flowing, preferentially, between the upper surfaces of tongue 26 and groove 16 during the joining of pieces of laminate flooring 10. Additionally, it is believed that pressure created on the glue 20 during the joining of the tongue 26 and groove 16, as shown on FIGS. 3 and 4, will be transmitted, in part, downwardly on upper surface 27 and beveled surface 30 of tongue 26. This pressure can also aid in glue 20 flowing, preferentially, between the upper surfaces of tongue 26 and groove 16 during the joining of pieces of laminate flooring 10.
The curing of the glue 20 involves the loss of solvent, water in the case of Franklin Titebond II Wood Glue, to the substrate 13. Water causes swelling of the substrate. It is believed necessary to limit the volume of glue 20 that will cure by losing water or other solvent to the substrate 13. This is accomplished in the embodiment of this invention as shown on FIGS. 1-4 by limiting the distance between (1) the end 19 of groove 16 and the end 29 of tongue 26, (2) the amount of the tongue that is cut off in making beveled surface 30, (3) the space 31 between the upper surface 27 of tongue 26 and the upper surface 17 of groove 16 and (4) the space 32 between planar tongued edge 25 and planar grooved edge 15 above tongue 26 and groove 16, respectively.
It is believed that swelling of the substrate at the upper surfaces of the tongue and groove, 27 and 17 respectively, aids in holding the tongue and groove joint of this invention together. Therefore, it is believed that no more than one half and preferably no more than one third of the upper surface 27 of tongue 26 should be removed in cutting the beveled surface 30 on tongue 26. The space between the upper surfaces of the tongue and groove should be limited to the space required for glue to preferentially flow to the wear surface 12 when tongue 26 and groove 16 are joined. It is believed that excess space can result in damage to laminate flooring. Glue loses water to the substrate 13 adjacent space 31 during the curing of the glue. Some swelling is beneficial for producing a tight tongue and groove joint. However, excess swelling damages laminate flooring.
Sufficient glue 20 should be placed in the end 19 of the groove 16 such that a portion of the glue will flow to the wear surface 12 as the tongue and groove joint of this invention is joined. Additional glue is not beneficial and increases the cleanup efforts.
A laminate flooring embodiment of the tongue and groove joint of this invention shown on FIGS. 5 through 8. The dimensions of the features of laminate flooring are preferred dimensions for the embodiment shown. The tolerances are preferred tolerances for the embodiment shown. Dimensions and tolerances are shown on FIGS. 5 and 6 in inches. Dimensions and tolerances shown on FIGS. 7 and 8 in millimeters.
The tolerances for cutting the upper and lower surfaces of the tongue and groove are different. It is shown on FIGS. 5-8 that the lower surfaces, 28 and 18 respectively, of the tongues and grooves are cut to be 0.2±0.0015 inches (5.08±0.0381 millimeters) from the wear surface 12. The upper surface 27 is cut for the tongue 26 to have a minimum width of 0.09 inches (2.286 millimeters) and to increase in width by up to 0.003 inches (0.0762 millimeters) during the cutting of the tongue. The upper surface 17 is cut for the groove to have a maximum width of 0.1 inches (2.54 millimeters) and to decrease in width by up to 0.003 inches (0.0762 millimeters) during the cutting of the groove. This provides a minimum space 31 between the upper surface 27 of tongue 26 and the upper surface 17 of groove 16 of 0.004 inches (0.1016 millimeters).
While the illustrative embodiments of the invention have been described with particularity, it will be understood that various other modifications will be apparent to and can be readily made by those skilled in the art without departing from the spirit and scope of the invention. Accordingly, it is not intended that the scope of the claims appended hereto be limited to the examples and descriptions set forth herein but rather that the claims be construed as encompassing all the features of patentable novelty that reside in the present invention, including all features that would be treated as equivalents thereof by those skilled the art to which this invention pertains.
Additionally, while the present invention has been illustrated with respect to laminate flooring, it is to be understood that the tongue and groove of the present invention may be utilized in any application in which it is desired to have a tongue and groove joint, including but not limited to flooring in general, furniture, cabinets, countertops and wall paneling.
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Disclosed is laminate flooring and other articles with tongues and grooves for joining sections of the flooring or articles and a method of making the tongue and groove joints. The lower surfaces of the tongues and grooves are indexing surfaces for aligning the wear surfaces of the flooring sections. The tongues and grooves are made such that when the tongue is fully inserted into the groove, a continuous space is formed between the upper surface of the tongue and groove. The grooved edges are cut at an acute angle to the surface. This provides a space between the upper surfaces of the tongue and groove and between the edge surfaces above the tongues and grooves toward the wear surfaces of the flooring sections. Glue in the joint, upon curing, resists penetration of moisture and increases the strength of the joint.
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This is a continuation-in-part of U.S. patent application Ser. No. 08/176,953 filed Jan. 3, 1994, and now issued as U.S. Pat. No. 5,392,572, which in turn is a continuation of U.S. patent application Ser. No. 07/935,895, filed Aug. 28, 1992, now issued as U.S. Pat. No. 5,274,971.
BACKGROUND OF THE INVENTION
This invention is generally concerned with wall erection systems and methods, and is specifically concerned with a rapidly erectable, removable, reusable and raisable post and panel-type acoustical wall system.
Acoustical wall systems for obstructing highway noises from residential areas are known in the prior art. Such wall systems generally take three different forms, including self-supporting walls, monolithic post and panel precast walls, and separate steel/concrete or wood post and panel precast walls. When viewed from above, self-supporting wall systems have an undulating profile which resembles a square or trapezoidal wave function which makes them self-supporting without the need for deep underground foundations. They are used where a flat and wide right-of-way is available on either side of the noise-generating highway, and where the ground provides good foundational support. Unfortunately, the larger amount of panel surface caused by the square or trapezoidal-wave profile of these walls necessitates 10% to 30% more structural and sound obstructive materials for their construction, which in turn causes them to be relatively expensive. Additionally, self-supporting wall systems are not compatible with certain desirable architectural wall finishes, and are difficult to install in terrain having significant relief. While self-supporting walls can be removed and reused, such removal and reuse is labor and equipment intensive. Finally, because of the section required to develop the weight required to be self-supporting, the economical height to which the wall can be raised is limited.
Monolithic precast wall systems employ single-monolithic panels supported by concrete support columns integrally cast into the side edges of the panels. They are erected by tongue and groove connections between adjacent panels, and connections between the bases of the columns and a structural foundation is normally welded or bolted. While monolithic precast walls advantageously employ fewer amounts of wall panel materials than self-supporting walls, they are permanent structures which would be removable only with great difficulty with the help of large equipment requiring large amounts of working space. Additionally, these walls are not raisable or otherwise height-adjustable. Moreover, because the alignment of the joints between adjacent panels is dependent upon the grade of the specific terrain that the wall is initially erected on, it is difficult to re-use the same panels in a location having a different grade.
Post and panel acoustical wails employ panels that are slidably mounted between and supported by structurally independent support posts. The support posts are typically steel or concrete columns having opposing pairs of flanges which slidably receive the side edges of wall panels upon the raising of a panel by a crane above two adjacent support posts, and the subsequent lowering of the panel between the posts after the side edges are aligned between the flange pairs. Either a single panel or a stack of panels may be mounted between two adjacent posts. While post and panel walls have certain installation advantages over monolithic precast walls, they also have their disadvantages. One major disadvantage stems from the necessity of having to leave some amount of slack in the distance between the flanges of the support posts and the thickness of the side edges so that the panels may be quickly aligned between the flanges of the beams prior to slidably lowering them between two flange pairs of adjacent posts. As a result of this slack, the front side edges of the panels cannot snugly engage the front flanges of their respective support posts, which if not corrected will create substantial acoustical leaks in the resulting wall, and poor structural alignment of the panels.
In the past, this slack has been eliminated by the installation of steel angle members between the back flanges of the support posts and the back side edges of the panels to take up the unwanted slack in combination with the application of caulking between the panels and the posts. However, the installation of such steel angles has proven to be an expensive and time consuming step in the assembly of such wall systems, as it requires the drilling of a specific pattern of holes through the flanges of the I-beams forming the support posts, the regalvanization of the I-beams, as well as the tedious installation of several nuts and bolts for every angle in such a way that they continuously apply pressure to the back side edges of the panel. The materials cost is also substantial, not only with respect to the steel angles themselves, but the nuts and bolts necessary to mount them as well. Moreover, the use of such steel angle members sometimes fails to permanently remove unwanted slack between the front side edges of the panels and the flanges of the posts because of the constant vibration that such wall systems are subjected to due to their proximity to a heavy flow of road traffic. Vandals have occasionally been known to remove the nuts and bolts that secure the angle members in their place, which of course necessitates their replacement with its attendant expenses. Both the caulking of the panels and the posts and the installation of the numerous nuts and bolts used to mount the angle members substantially slows down both the raising and the disassembly of the wall system (should removal of the wall become desirable). Additionally, the custom pattern of bolt holes that must be drilled or molded in the flanges of each of the I-beams forming the posts makes it difficult, if not impossible, to reuse the same post structures should it become desirable to rebuild the wall system at a different location. The raising would require substantial reengineering of the post which has holes punched in the structural flanges.
Clearly, there is a need for an improved post and panel type acoustical wall system which overcomes all of the aforementioned disadvantages associated with the angle members used in prior art wall systems, and which provides an alternate means for removing unwanted slack between the back side edges of the panels and the flanges of the posts which does not impede the raising, disassembly or removability of the wall system. Ideally, such an alternative slack-removing means would not necessitate the drilling of a custom pattern of holes in the I-beams forming the posts so that the posts could be easily reused to build another wall system should it ever become desirable to remove or relocate the original wall system. The slack removing means should also be durable, inexpensive, versatile, and not easily prone to destruction by either weather conditions or vandalism. The resulting wall systems should also be rapidly erectable, removable, easily reusable, and raisable beyond the height of the originally-used posts to accommodate changes in the acoustical conditions surrounding the highway (which might occur, for example, if the highway were widened).
SUMMARY OF THE INVENTION
Generally speaking, the invention is a rapidly erectable, removable, reusable, and raisable post and panel-type acoustical wall system which overcomes all the aforementioned disadvantages by the use of wedging members which wedgingly and removably secure the side edges of the wall panels into acoustically obstructing engagement with the panel support posts. In the preferred embodiment, the wall panels are precast panels formed from a moldable material such as concrete, and each of the panels may include a front face over which a layer of acoustically obstructive material is placed. For a sound reflective wall system, this layer may simply be a finished concrete face. For a sound absorptive wall system, this layer may be a commercially available sound absorbing medium such as Durisol or Soundtrap/Soundlock. The wall panels may also be panel assemblies formed from a plurality of plank-like panel members extruded from a polymeric material that interfit with one another by tongue and groove joints. Each of the side edges of the wall panels may include a planar front edge and a back edge, and the panel support posts are preferably formed from galvanized steel I-beams having two pairs of parallel flanges extending from a centrally disposed web. Each of the pairs of parallel flanges receives one of the side edges of the wall panels, and wedging members are inserted between the back side edges of the panels and the back flange of the beam forming the support post in order to snugly secure the planar from edges of each of the panels into acoustically obstructing engagement with the front flange of the beam.
The upper and lower ends of each of the back side edges of the panels includes a means for retaining one of the wedging members. In the case of precast panels, such a retaining means preferably takes the form of a recess that is complementary in shape to the wedging member. In the case of panel assemblies formed from a plurality of interfitting plank-like members, the retaining means may take the form of the recesses that are inherently present around the tongue and groove joints that join the panel members. In either case, these wedge-receiving recesses are positioned on the top and bottom ends of each of the back side edges such that they interconnect when one wall panel is slidably stacked over another wall panel between the same two I-beams, which advantageously allows a single wedging member to simultaneously force the front side edges of two different wall panels into acoustically obstructing engagement with the front flanges of the I-beams.
Preferably, the wedging members are formed from wood having compressive properties commensurate with the compressiveness of the sound-obstructing layer of material applied over the front faces of the wall panels. For example, if the from faces of the panels are covered with a relatively soft and compressible sound-absorbing material such Durisol, the wedging members are preferably formed from a relatively soft wood such as pine, which is capable of partially yielding when forced in the recess of the wall panel between the back side edge and the back flange of the I-beam. Such properties will apply a continuous pressure on the Durisol which will effectively seal out sound without crushing the sound-absorbing material. On the other hand, when the front face is merely finished concrete as would be the case with a sound reflective wall, a harder wedging member formed from oak or other hard wood may be used. All wooden wedging members are preferably pressure-treated to resist decay and insect attack. Alternatively, wood-polymer composites or plastic elastomers of varying hardness may be used to form the wedging member. Finally, a wedging assembly may be used whose width is adjustable to accommodate different amounts of slack spaces between the flanges of the post and the thickness of the wall panels. Such a wedge assembly may include a wedging member that may be interconnected with any one of a number of different sized width extender members.
In the operation of the invention, a plurality of vertical-oriented support posts in the form of I-beams or precast columns are erected, these beams being spaced apart approximately the same distance as the width of the wall panels. Next, half-size wedging members are placed at the bottom of the beams between the two opposing flanges thereof. A wall panel as heretofore described is then lifted above the ends of two adjacent I-beams, and the side edges are slidably inserted between the opposing pairs of flanges of each of the beams. Wedge-retaining recesses located on the bottom of the panel are aligned with and lowered over the half-size wedging members. After the panel lowering operation is completed for this first panel, a pair of full-size wedging members is forcefully inserted into the wedge retaining recesses located at the top ends of each of the back side edges of the panel. The lowering operation and insertion operation wedgingly presses the front side edges of the wall panel into acoustically obstructing engagement with the front flanges of the two adjacent I-beams supporting it. As the length of each full-size wedging member is approximately twice the length of the recess in which it is inserted, the top ends of the two wedging members protrude upwardly above the top edge of the lowered panel. A second wall panel is then raised above the upper ends of the two adjacent I-beams, and lowered over the top edge of the bottommost wall panel. Because the topmost wall panel has wedge-receiving recesses on the bottom ends of its two back side edges which register with the recesses of the bottommost panel when the two are stacked together between the two support beams, the upper ends of the wedging members already present in the recesses of the lower panel become forcefully inserted in the lower recesses of the topmost panel due to the weight of the topmost panel as it is being lowered. This mechanical action automatically causes the front face of the topmost panel to be forced into the front flanges of the two supporting I-beams in acoustically obstructing engagement. The two mutually registering recesses, in combination with the overlying back flange of the I-beams, positively capture the wedging member in such a manner that it will not fall out when the resulting wall is rattled from highway sound or wind, and affords so little access to the wedging member that it is impossible for vandals to remove them from an assembled wall.
To complete the assembly of the wall, the panel stacking and wedging member insertion operations are repeated until the wall is raised to a desired level.
To remove the resulting wall structure, all that is necessary to do is to reverse the assembly steps, i.e., remove the topmost wedging members located on the top side edges of the topmost wall panel, slidably remove the topmost wall panel from between the two adjacent I-beams by means of a crane, and then repeat the same steps until all of the panels and wedging members are removed. Preferably, I-beams that form the support post of the system are bolted onto pedestals by means of studs so that they can be conveniently removed and used in conjunction with the same wall panels and wedging members to rebuild the wall at a different location.
Because the use of the wedging members obviates the need to drill customized patterns of holes in the beams, beams from disassembled walls may be easily reused and even spliced together to raise the height of the reassembled wall.
BRIEF DESCRIPTION OF THE SEVERAL FIGURES
FIG. 1A is a side view of the acoustical wall system of the invention as it appears assembled into a wall, with the base assemblies of the post shown uncovered;
FIG. 1B is a cross-sectional side view of the base assembly circled in phantom in FIG. 1A;
FIG. 2 is a plan view of the wall system illustrated in FIG. 1A along the line 2--2;
FIG. 3 is a partial back view of the wall system illustrated in FIG. 1A with part of the back flange of the post broken away so that the wedging member of the system may be more plainly seen;
FIG. 4 is a side, cross-sectional view of the partial wall section illustrated in FIG. 3 along the line 4--4, illustrating how a single wedging member is received within adjacent, wedge-receiving recesses in different wall panels;
FIG. 5 is a back view of the wall system of the invention illustrating the method of assembly;
FIG. 6 is a perspective side view of one of the panels of the system, illustrating how the wedging member may be inserted into a complementarily shaped wedge-receiving recess in order to snug the front side edge of the panel into acoustically obstructing engagement with the front flange of one of the posts, and
FIG. 7 is a side perspective view of one panel being lowered in stacked relationship on top of another panel, illustrating how the protruding top end of the wedging member will automatically be received within the recess of the topmost panel in order to force its front side edges into engagement with the front flanges of the posts merely by lowering the upper panel on top of the lower panel;
FIG. 8 is a side view of the wall system of the invention, illustrating how the posts may be extended in order to raise the height of a reassembled wall;
FIG. 9 is a side view of one of the posts illustrated in FIG. 8 along the line 9--9, illustrating how extensions to the posts may be spliced on,
FIG. 10 is a front view of a sound-reflective panel assembly which may be used in the wall system of the invention;
FIG. 11 is a side view of the panel assembly illustrated in FIG. 10 along the line 11--11;
FIG. 12 is an enlargement of the area surrounded by the dotted circle in FIG. 11, illustrating how the panel members forming the panel assembly interfit in tongue-and-groove fashion;
FIG. 13 is a front view of an alternate embodiment of the wall system that uses the sound reflective panel assemblies of FIGS. 10 through 12, illustrating one panel assembly being lowered in stacked relationship on top of another panel assembly between two posts mounted on a concrete parapet or traffic barrier, illustrating how half-wedging members are placed at the bottom of the post and full-sized wedging members are placed between the panel assemblies in order to wedgingly press the panel assemblies into engagement with the front flange of the posts;
FIG. 14 is an enlarged side view of FIG. 13 along the line 14--14 illustrating how a half-wedging member presses the bottom of the lower panel assembly against a flange;
FIG. 15 is an enlarged side view of the wall system illustrated in FIG. 13 along the line 15--15 after the upper panel assembly has been stacked on top of the lower panel assembly illustrating how a full-size wedging member engages both the upper and lower panel assembly;
FIG. 16 is a plan view of the wall system illustrated in FIG. 13 along the line 16--16;
FIG. 17A, 17B, and 17C are side, front, and perspective views of the full-size wedging member used to apply wedging forces in the embodiment of the wall system illustrated in FIG. 13;
FIG. 18 is a back view still another embodiment of the wall system that utilizes single, unstacked panels to form the acoustical wall;
FIG. 19 is a side view of the embodiment of the wall system illustrated in FIG. 18 along the line 19--19;
FIG. 20 is a back view of a further embodiment of the wall system wherein a single panel is used in combination with reversed wedging members;
FIG. 21 is a side view of the embodiment of the wall system illustrated in FIG. 20 along the line 21--21;
FIG. 22 is an enlargement of the portion of FIG. 21 enclosed by the dotted circle;
FIG. 23 is a perspective view of the width-adjustable wedging assembly of the invention being used to press the top portion of a concrete panel against the front flange of a post, and
FIG. 24 is an exploded, perspective view of the wedging assembly of FIG. 23, illustrating how its two components are interconnected by means of a dovetail joint.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference now to FIGS. 1A, 1B and 2, the acoustical wall system 1 of the invention generally comprises a plurality of post assemblies 3 vertically mounted in the ground 4, as well as a plurality of precast panels 5 which are stacked between the post assemblies 3 to a height 6 which is great enough to prevent unwanted noise from a highway from directly impinging a group of residences or other buildings (not shown). As will be discussed in more detail hereinafter, slack between side edges of the panels 5 and the space between the parallel flanges of the beams forming the post assemblies 3 is expeditiously taken out by a plurality of wedge members 7 which serve to snug the front faces of the panels 5 into acoustically obstructing engagement with the front flanges of the posts 3.
With specific reference now to FIG. 2, each of the post assemblies 3 is formed from an I-beam 10 having two pairs of opposing flanges 12a,b and 13a,b extending from a center web 14. The I-beam 10 may be galvanized steel, core 10 weathered steel or concrete. The top of the flanges of each of the beams 10 includes a taper 16 to facilitate the alignment of the side edges of the panels 5 within the flange pairs 12a,b and 13a,b. With specific reference now to FIG. 1B, the bottom ends of each of the beams 10 includes a base assembly 17. The base assembly 17 is formed from a square base plate 18 welded to the bottom of the beams 10, which includes four stud holes 20a-d, of which only holes 20a and 20b are shown. The holes 20a-d receive studs or anchor bolts 22a-d, and the base plate 18 is secured onto the studs by means of upper and lower nuts 23a-d and 24a-d as shown. The studs 22a-d extend down into and are secured within a pedestal 25 formed from a rectangular block of concrete 26 reinforced by a network 28 of steel bars. The use of studs and nuts to secure the bottom ends of the beams 10 onto the pedestal 25 not only allows the beams to be easily secured to and removed from the pedestals 25 incident to wall assembly and removal operations, but further provides a means for adjusting the vertical orientation of the beams 10 so that they are substantially plumb prior to the lowering of the wall panel 5 into the flange pairs 12a,b and 13a,b.
With reference now to FIGS. 2, 3, and 4, each of the panels 5 of the wall system 1 includes a support layer 30 of precast concrete strengthened by a network of reinforcing steel 32. The back surface 34 may have a rough or rake finish, while the from surface 36 is substantially flat. In the preferred embodiment, the front surface 36 of the support layer 30 is covered by a layer 38 of sound absorbing material such as Durisol (available from The Reinforced Earth Company located in Vienna, Va.), or Soundtrap (available from Smith Midland Corporation located in Midland, Va.). Both materials are porous, compressible compositions formed in part by concrete having large amounts of air void spaces. The sound absorbing layer 38 includes a flat back surface 40 which overlies the flat front surface 36 of the support layer 30 as well as a fluted front surface 42 for absorbing sound. The front surface 42 of the sound absorbing layer 30 is circumscribed by a bevel 43 as shown. Each of the panels 5 includes a pair of opposing side edges 44a,b having a generally planar back side edge 46, and planar front side edge 48. The top edge 50 of each of the panels 5 includes a sound obstructing key 52 which fits into a keyway 56 located at the bottom edge 54 of another panel 5 when two panels are stacked together as shown in FIG. 4. In addition to sound obstruction, the interfitting key 52 and keyway 56 further help to rigidify the wall resulting from the assembly of the wall system 1.
With reference now to FIGS. 3, 4, 5, and 6, both the top and bottom ends of each of the planar back side edges 46 of every panel 5 includes recesses 60a,b whose general locations are best seen with respect to FIG. 5. Each of the recesses 60a,b includes a flat upper section 62 bordered by a tapered wall 64 which are generally complementary to the lower half of a wedging member 7. The recesses 60a located on the upper ends of the planar back side edges 46 terminate in a bottom wall 66 which is slightly inclined relative to the horizontal so as to allow rain water which could otherwise soak the wooden wedge 7 and collect and freeze and break the panel 5 to drain out of the recess 60A.
As best seen in FIGS. 4 and 5, each of the wedging members 7 includes upper and lower tapered wedging surfaces 68a,b which are complementary in shape to the tapered walls 64 of upper and lower recesses 60a,b. The front portion of each of the wedging members 7 further includes a flat surface 69 which is approximately twice as long as the flat section 62 of either of the upper or lower recesses 60a,b. Finally, the back of the wedging member 7 includes a spacer portion generally indicated at 70 which is dimensioned to insure that when the wedging member 7 is inserted between the back flange 12B of a beam 10 and two mutually registering upper and lower recesses 60a,b of two different panels, the member 7 will apply a force sufficient to snug the planar front side edges 48 of the panel 5 into acoustically obstructing engagement with front flange 12a of the beam 10. The wedging member 7 is preferably formed from a material with similar compressive properties as the material forming the front face of the panel 5. Hence, when a layer of relatively soft and brittle sound absorbing material 38 is applied over the front of the panel 5, the wedging member 7 is preferably formed from a soft and yielding wood, such as pine. Alternatively, if the front face of the panels 5 is formed from a relatively hard, sound reflective material such as smoothly finished concrete (as would be the case if the wall system 1 were used to erect a sound reflective wall) the wedging member 7 is preferably formed from a hardwood such as oak or maple. In all cases where wood is used to form the wedging member 7, the wood is preferably pressure treated with aluminum salts to increase the members resistance to insects or fungi. In all instances, the spacer portion 70 of the wedging member 7 is dimensioned to provide a snug engagement between the front side edges 46 of the panels 5 and the front flanges 12a of the beams 10 forming the post assemblies 3. Specifically, as is shown in FIG. 4, if the distance between flanges 12a,b is d1, and the distances between the front and back side edges 46 and 48 of the panel is d2, then the spacer portion 70 of the wedging member 7 will be dimensioned so that it is slightly larger than d3, the difference between d1 and d2.
The method or operation of the invention is best understood with reference to FIGS. 5, 6, and 7. In the first step of the method of the invention, the pedestals 25 of the base assembly 17 of each of the post assemblies 3 are constructed by first auguring an appropriately dimensioned hole in the earth 4, and then casting the previously described steel-reinforced, cylindrical block of concrete 26 with the studs 22 extending slightly above the ground. Next, the beams 10 of the post assemblies 3 are secured onto the pedestals 25 by means of the previously described upper and lower nuts 23a-d and 24a-d. During this step, each of the beams 10 is accurately vertically positioned until it is plumb with respect to the surrounding ground. The pedestals 25 are spaced apart such that when the beams 10 are plumbly installed, the distance between the center webs 14 of adjacent beams 10 is only slightly wider than the width of the panels 5.
In the next step of the method, the side edges 44a,b of a first panel are aligned between opposing parallel flanges 12a,b of two adjacent beams 10 and then slid down to the bottom of the beams 10 as shown by means of a crane (not shown). This step is facilitated by the tapered end 16 of the flanges present at the top ends of each of the two adjacent beams 10.
Next, the bottom portions of two wedging members 7 are inserted in the upper recesses 60a existing on either side of the top edge of the lower panel 5, as shown in FIGS. 6 and 7. Such insertion of each of the wedging members 7 has the effect of snuggling the front side edge of the panel 5 against the front flange 12a in the manner previously described, while at the same time securely capturing the lower half of the wedging member 7 between the tapered wall 64 of the recess 60a and the back surface of the back flange 12b (as is best seen in FIG. 4).
A second panel 5 is next raised above the upper ends of the beams 10 of the adjacent post assemblies 3, as is shown in FIG. 5. The side edges 44a,b are again aligned between the pairs of adjacent flanges 12a,b of the two adjacent beams 3 with the help of the previously described tapers 16, and a second panel 5 is slid on top of the first installed panel 5. Just before the bottom edge 54 of the second panel 5 engages the top edge 50 of the bottommost panel 5, the upper portion of the wedging member 7 is received by the bottom recess 60b of the topmost panel, which automatically creates a wedging action which in turn snugs the front side edge 48 of the topmost panel 5 into engagement with the back surface of the top flange 12a as is best seen in FIGS. 4 and 7. All of the aforementioned panel raising and lowering steps are repeated until the wall created by the wall system 1 is complete.
With reference now to FIGS. 8 and 9, the wall of the system 1 can be conveniently raised at another location in response to changing acoustical conditions which may happen if, for example, the highway that the wall is next to is widened. It would further be possible to raise the wall system at the same location so long as the load capacity of the existing pedestals 25 and studs or anchor bolts 22a-d would not be exceeded. To raise the wall, post extensions 71 may be connected over the top ends of the beams 10 by splicing plates 73, which are secured to both the beam 10 and extension by means of welds 74. The extensions 71 may be formed from portions of steel beams which are identical in structure to the beams 10 initially erected, but the bottom beam may be larger in section if required to meet the structural requirement need for the additional height. Additional panels 75 may then be stacked over the former topmost panel 5 in the same manner as previously described.
To remove the wall created by the system 1, all of the aforementioned method steps are repeated in reverse. The resulting plurality of beams 10, wedging members 7, and panels 5 can then be conveniently reused to build another wall at another location.
With reference now to FIGS. 10, 11, and 12, the wall system 1 of the invention is not confined to the use of precast panels 5, but may also be used in conjunction with light-weight reflective acoustical wall panel assemblies 80 formed from a plurality of interconnected panel members 82 that may be easily installed on the tops of parapets 109 or traffic barriers. Such panel members 82 are extruded from a fiber reinforced, polymeric material with a tongue portion 84 along their top edges, and a groove portion 86 along their bottom edges. These tongue and groove portions 84, 86 allow the plank-like panel members 82 to be stacked in interfitting relationship as is illustrated in FIGS. 10 and 11. To secure these panel members 82 into a single panel assembly 80, U-shaped channel members 88 (which also may be formed from a fiber reinforced polymeric material) are provided which capture the end portions 90 of the stacked members 82 as shown. The channel members 88 are fastened to each of the panel members 82 by means of rivets (not shown). In order to add compressive strength to the end portions 90 of the panel members 82, each of the panel members 82 (which is hollow) is preferably filled with a resilient filling material 92 at its end portions 90 (as may best be seen in FIG. 16). In the preferred embodiment, the resilient filling material 92 is ground out automobile tires, and the panel members 82 are Carsonite® panels made from fiberglass available from Carsonite International, located in Carson City, Nev.
With reference now to FIGS. 13, 14, and 15, such panel assemblies 80 also include recesses 94 which interfit with wedging members 95 to press the back side edges of each panel assembly 80 into sound-right engagement with the flange 111 of a spacing angle 110. However, unlike the wedge-receiving recesses 60a,b associated with the precast panels 5, the recesses 94 formed between adjacent panel assemblies 80 are formed from the contours associated with the tongue portion 84 located on the upper edge of each panel assembly 80, and the groove portion 86 located along the bottom edge of each such panel assembly 80. As may best be seen with respect to FIG. 15, a recess 94 is formed at the interface of these tongue-and-groove portions largely as a result of the tapering of the upper edge of the tongue portion 84 of the topmost panel member 82. As is best seen in FIGS. 15 and 17a-17c, the wedging member 95 used in combination with the panel assemblies 80 has a contour which is complementary to the naturally occurring recess 94 created by the tapered tongue portion 84 and interfitting groove portion 86 between adjacent panel assemblies 80. Specifically, each wedge member 95 includes an upper inclined portion 97 (which may be used to form an upper half wedge 98), a lower inclined portion 99 (which may be used to form a lower half wedge 100), and a recess fitting portion 101 which is complementary in shape to the recess 94 in the vicinity of the tongue portion 84.
The operation or method of a wall system utilizing such panel assemblies 80 may best be understood with respect to FIGS. 13 and 16. Prior to installing any of the panel assemblies 80 between a pair of adjacent posts 3, a spacing angle 110 is welded or bolted onto the web 14 of the post 3 in the position illustrated in FIG. 16 in order to compensate for the much thinner thickness of such panel assemblies 80 relative to the thickness of precast panels 5. Next, upper half wedging members 98 are placed against the first flanges 13b, and on the base plates of the posts 3 in the position illustrated in FIG. 13. The lowermost panel assembly 80 is then lowered into the position illustrated in FIGS. 13 and 14. The interaction between the weight of the panel assembly 80 and the inclined surface of the half wedging members 98 causes the back side edge of the panel assembly 80 to firmly engage against the flange 111 of the spacing angle 110. Full-sized wedging members 95 are next placed in the positions illustrated in FIG. 13 against the flanges 13b of the posts 3. The topmost panel assembly 80 is then slid on top of the bottommost panel assembly 80 in the position illustrated in FIG. 15. The weight of the topmost panel assembly 80 interacts with the inclined surfaces of the full-size wedging members 95 to snug the upper and lower back side edges of the stacked panel assemblies 80 against the flange 111. After the last panel assembly 80 has been stacked in place, lower half wedging members 100 are forcefully inserted in the recesses 94 between the upper side edges of the topmost panel assembly 80 and the front flanges 13b of the posts 3 to snug the topmost panel assembly 80 against the flange 111. Holding screws 104 are then used to secure the wedging members 95, 98, and 100 in place so that they will not move laterally from under the front flange 13b of the post 3.
Alternatively, a flange 104.5 (shown in phantom in FIG. 16) may be integrally molded or separately connected to one side of the wedging members 95, 98, and 100 to prevent lateral movement once they have been installed in the wall system.
FIGS. 18 and 19 illustrate still another embodiment of the system 1 of the invention wherein only a single, full-height precast panels 105 are used to form an acoustical wall. In this embodiment, both the lower and upper corners of the panel 105 include recesses 60a,b that are complementary in shape to upper half wedging members 107 and lower half wedging members 108, respectively. In operation, this particular embodiment of the invention is assembled in the same manner as previously described with respect to the system illustrated in FIGS. 10 through 17C, the only difference being that no full-sized wedging members are used. After the single precast panel 105 has been lowered over upper half wedging members 107, lower half wedging members 108 are forcefully pushed or hammered into the upper recesses 60a so as to snugly secure the front of the side edges of the panel 105 against the front flanges 13a of the posts 3. In this particular embodiment, the half wedge members 107 and 108 are preferably formed from pressure-treated wood.
FIGS. 20, 21, and 22 illustrate still another embodiment of the system 1 which utilizes full-height precast panels 105 that are not stacked on top of one another. However, reversed full-sized wedging members 112 are integrally molded into recesses 113 at each of the corners of the panel 105 as shown. The 180° reversal of the position of the wedging members 112 allows their lower inclined surface to provide a lead-in or guide surface that allows the panel 105 to be inserted in the space between the flanges 13a and 13b of the posts 3. The inclined surfaces further act to snug the front of the side edges of the precast panel 105 against the front flange 113a after the panel 105 has been lowered to a rest position between the post 3 such that both the upper and lower reversed, full-sized wedging members 112 engage the post flange 13b. This embodiment of the system of the invention has the advantage of reducing the assembly time of the completed acoustical wall.
Finally, FIGS. 23 and 24 illustrate an adjustable width wedge assembly 115 that also forms part of the invention. The wedge assembly 115 is comprised of a wedging member 117 having inclined surfaces as previously described, in combination with a plurality of extender members 119 (only one of which is shown) which function to incrementally increase the width of the wedging member 117. To this end, one of a plurality of extender members 119, each of which has a different width (as indicated in phantom in FIG. 24) is selected to be used in combination with the wedging member 117 to adjust the width of the resulting wedge assembly 115 to a desired dimension. A dovetail joint 121 formed from a dovetail 122 in the extender member 119 and a complementarily shaped recess 123 in the wedging member 117 is advantageously used to firmly secure the members 117 and 119 together into a integral assembly 115. Providing the recess portion 123 of the joint 121 in the wedging member 117 (as opposed to the dovetail 122) advantageously allows the wedging member 117 to be used without an extender member 119 if desired. While the wedge assembly 115 is illustrated as being formed from wood (which is preferably pressure treated), it should be noted that it may be formed from any one of the materials previously mentioned in this specification. Additionally, while a dovetail joint 121 is illustrated in FIGS. 23 and 24, any one of a number of different types of joint may be used to the same advantage. Finally, while only one extender member 119 is illustrated in FIG. 24, this invention contemplates the use of a plurality of different sized extender members 119, each of which may easily and conveniently connected to a wedging member 117, so that a wedge assembly 115 of a specifically desired width may be easily assembled.
While both the system and method of this invention has been described with respect to a preferred embodiment, a number of substitutions of equivalent components and variations of similar method steps will become evident to the person of ordinary skill in the construction arts. All such substitutions and variations and equivalents thereof are encompassed within the scope of this invention, which is limited only by the claims appended hereto.
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A rapidly erectable, removable, reusable, and raisable acoustical wall system is provided that comprises a plurality of wall panels, each of which has opposing side edges which include a front edge and a back edge, a plurality of panel support posts having pairs of parallel flanges for receiving the side edges of the wall panels to form a wall, and a plurality of wedging members for forcefully securing the front side edges of the panels into an acoustically-obstructing engagement with the front flanges of the panel support posts. Wedge-receiving recesses are provided at the top and bottom of each of the back side edges of the panels, the top recesses of one panel being registrable with the bottom recesses of another panel when two panels are stacked between the same support posts. Each wedging member is about the shine length as two aligned wedge-receiving recesses so that a single wedging member may be used to forcefully engage the front side edges of two different panels against the front flanges of their respective support posts. In the apparatus of the invention, the erection of the walls is expedited by the wedging members, which function to forcefully engage the bottom half of a wall panel into acoustically-obstructing engagement with its respective support post simply by the act of stacking one wall panel over another. Additionally, the resulting wall may be easily raised at another location by mounting extension members on the tops of the support posts, and sliding additional wall panels between the heightened posts.
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This application is the national phase under 35 U.S.C. § 371 of PCT International Application No. PCT/DE02/00151 which has an International filing date of Jan. 18, 2002, which designated the United States of America and which claims priority on German Patent Application number DE 101 04 892.0 filed Feb. 1, 2001, the entire contents of which are hereby incorporated herein by reference.
FIELD OF THE INVENTION
The invention generally relates to a marine electrical system. Preferably, it relates to a system having generators, electrical loads, such as electric motors and an on-board power supply system with switchgear assemblies etc. as system components, with the electrical system ensuring that adequate electrical power is provided in all operating states of the ship.
BACKGROUND OF THE INVENTION
Until now, measurement, control and regulation devices which operate on an analog basis have normally been used in maritime vessels, if appropriate with an associated digital control and observation level. A mixed system such as this has admittedly been proven, but has design disadvantages. Surprisingly, it has been found that a completely digitized version can be more advantageous and, in particular, more cost-effective. This is particularly true when it is intended to carry out continual optimization, by reconfiguration, that is to say by external actions, or by way of an automatic system.
SUMMARY OF THE INVENTION
According to an embodiment of the invention, the known hybrid system is produced by digital control and regulation based on standard modules.
BRIEF DESCRIPTION OF THE DRAWINGS
The design of the system will become evident from all of the detail of the attached system description, with the figures contained in this description.
FIG. 1 illustrates the system configuration;
FIG. 2 illustrates a bar graph;
FIG. 3 illustrates a profile of the power supply system frequency in response to load changes in the power supply system (frequency regulation with droop);
FIG. 4 illustrates the GENOP 71 connections;
FIG. 5 illustrates the Genop 71 integrated in the PMA 71 system;
FIG. 6 illustrates the Genop 71 used as an individual device;
FIG. 7 illustrates the functional relationship for generator protection;
FIG. 8 illustrates the functional relationship for disturbance evaluation;
FIG. 9 illustrates the functional procedures for synchronization;
FIG. 10 illustrates the principle of synchronization; and
FIG. 11 illustrates the standard OP7 control panel (BT).
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
General Object of a Power Management System
The major task of the SIMOS PMA 71 power management system is to ensure that adequate electrical power is provided for all the operating states of the marine vessel. As the power demand on marine vessels increases, economic generation of power is, however, becoming virtually just as important as freedom from interruption.
The SIMOS PMA 71 automatic power generator system is based on the requirement of maintaining electrical power automatically during the various operating modes. In the event of faults in the on-board power supply system, all the necessary measures are initiated in order to supply the loads with electrical power with as little interruption as possible, while at the same time preventing damage.
SIMATIC-S7 standard components are used for each machine unit, plus a generator protection device/measurement transducer and an OC 24V/DC 24V isolating transformer. The generator protection device/measurement transducer, DC 24V/DC 24V isolating transformer and SIMATIC S7 for each individual machine set controller form an independent system. This ensures that only one machine unit is also affected if one system fails.
In addition to the 24V supply from the marine vessel's battery, the generator protection device has an internal voltage supply from the generator voltage. If the SIMATIC-S7 is likewise to be supplied by a redundant power supply, this must be provided by the switchgear assembly manufacturer (for example a DC 24V power supply, fed from the busbar voltage) in order that the operation of the PMA is ensured even if the higher-level battery power supply fails.
The generator protection device can also be used on its own, without SIMATIC-S7, in which case it then provides only some of the functions (generator protection, synchronization). A PMA coupling switch, a PMA land connection and a PMA emergency diesel can be supplied in addition to the PMA generator. These have particular functions which differ from the PMA generator.
Some classification organizations require an additional, independent diesel protection system (overspeed, lubricating oil pressure). The PMA 71 diesel protection has only second-priority functions. The main diesel protection is not part of the PMA 71.
Power and Functional Scope
On-board power supply system monitoring (black-out, underfrequency, overfrequency, undervoltage, overvoltage) Load-dependent starting of machine sets (overcurrent, overload) Fault-dependent starting of machine sets Overcurrents and reverse power protection of the generator Disconnection of unimportant loads in three stages Automatic stopping of machine units taking into account the available power (underload) Manual starting of machine sets (with two or more start attempts, if set), and manual stopping (with previous reduction in the load of the machine set, provided that another machine set is also connected to the busbar) Automatic synchronization of machine sets Automatic regulation of the on-board power supply system frequency Automatic real load matching between the machine sets Short-circuit protection Fault indication integrated in the control panel Load demand automatic system (option)
Special Features
High availability by structured design (fault in one PMA 71 does not influence the operation of the other machine sets) Simple servicing and fault localization by virtue of modular design Light-emitting diodes on all binary SIMATIC-S7 inputs and outputs Easy replacement of the assemblies in the SIMATIC-S7 by plug-in technology Easy matching of the system to different machine sets by way of the generator protection device/measurement transducer Little wiring complexity through the use of prefabricated plug-in technology
General information:
Operational messages and fault messages are indicated on the control panel in the form of text.
Abbreviations may be necessary, depending on the space in the control panel display.
The type of message (operational or defect message) is shortened in this description, in abbreviated form, using
BM (Operational message)
SM (Fault message)
The following abbreviations are used
DG (Diesel generator)
WG (Shaft generator)
HATA (Main switch panel)
B&B (Control and observation)
System Design
Individual Machine Set Components
The components of the SIMOS PMA 71 automatic power generator system are intended for decentralized installation using standard switch panels (associated with the generator panel) or for central installation in standard cabinets. For central installation, the generator protection device must be installed in the respective generator panel, while the other components can be installed together, centrally, in one cabinet.
Each machine set has the following associated components, as standard:
Programmable logic controller (PLC, SIMATIC S7-300) Generator protection/synchronization device/measurement transducer (GENOP 71) DC 24V/DC 24V isolating transformer Control panel (OP).
If the PMA is installed in a central cabinet, then the GENOP 71 generator protection device must be installed in the corresponding generator panel in the main switch panel. Other components can be installed in the central cabinet.
Plug Connections/Connections
Bus Couplings
The components of a machine set (PLC, GENOP 71, OP) are connected to one another via Profibus DP. The PLCs for the various machine sets are connected via MPI coupling.
Peripherals
The external lines are connected via connecting modules (with screw connections). The modules for digital output signals are fitted with relays. (DC isolation between the output signals). These connecting modules are connected to the input and output assemblies of the SIMATIC-S7 via front plugs and plug-in cables.
Generator Protection Device/Measurement Transducer
The following signals must be supplied to the generator protection device/measurement transducer
3-phase generator voltage, (100V AC signal)
3-phase power supply system voltage, (100V AC signal)
one current transformer for each phase (1A AC signal)
These cables must be routed separately from the control cables (separate cable duct) within a cabinet or within a switch panel when they are laid.
Shielding of the Cable and Lines
When laying signal lines and/or supply lines outside a cabinet/switch panel, lines and cables which carry a voltage of 230 V or more must be separated by a minimum distance of 10 cm.
FIG. 1 illustrates the system configuration.
Machine Set Control
The following operating modes are possible:
Local manual
Local semiautomatic
Automatic operation
Operation in the “Local Manual” Mode
The Local manual mode is normally selected for servicing tasks and for starting and stopping machine sets “locally”. In this operating mode, the machine set is started and stopped with the PMA 71 being bypassed. The manual/automatic selector switch is switched to the “manual” position for switching.
The operating mode is indicated as “MANUAL” on the control panel.
The “manual/automatic” selector switch is arranged in the HATA.
In the Local manual mode, the automatic functions and operation via the control panel are inhibited. The display functions are operative. Speed adjustments and the switching on of the generator switch can be carried out only manually. The required devices for speed adjustment and control of the generator switch must be supplied by the switch panel manufacturer. Safety functions (disconnection in the event of overspeed, minimum lubricating oil pressure, maximum cooling water temperature etc. are still operative. When the generator switch is switched on, the generator protection is also operative.
Synchronization
Manual synchronization is carried out by way of a check synchronization aid. Once the machine set has been started manually, the generator frequency is matched to the power supply system frequency by manual adjustment (from the switch panel). The “ENABLE KEY” must be pressed in order to switch on the generator switch. The switch is switched on by the synchronization aid at the next zero crossing. In the event of a blackout, the generator switch can be switched on directly by way of the “SWITCH ON” key.
Operation in the “Local Semiautomatic Mode”
Precondition: the “manual/automatic” selector switch is in the “automatic” position. Local semiautomatic is selected by pressing the “SEMI” key on the control panel. The operating mode is indicated as “SEMI” on the control panel. The following functions can be carried out from the control panel in the semiautomatic mode:
Starting of the machine
Stopping of the machine
Starting of synchronization
In order to avoid incorrect selections, additional confirmation with the “CONFIRM” key is required for important functions.
The safety functions (disconnection in the event of overspeed, minimum lubricating oil pressure, maximum cooling water temperature and generator protection) are operative. In the event of a fault, the diesel set is stopped as in the automatic mode, but no start command is issued to the standby machine set.
Starting of the Machine Set
When the “START” key is operated, the “PRESS TO CONFIRM” message is displayed for an adjustable time on the control panel. However, the command is not carried out unless the “CONFIRM” acceptance key is operated within this time. If this is not done, the request is rejected.
The start command can be given only if the motor is stationary, that is to say it has not reached self-sustaining speed and the generator voltage. If the “CONFIRM” key is operated during this time period, the start command is given. At the same time, the BM “START VALVE” appears on the display. The start command is canceled by the signal “self-sustaining speed reached” or “generator voltage>85%”. The start command is given only for an adjustable time (start time).
The “self-sustaining speed” or “generator voltage>85%” signal results in BM “OPERATION” being displayed. If the “self-sustaining speed” or “generator voltage>85%” signal is not produced after two or more start attempts, then a further start command is issued.
Starting of Synchronization
The synchronization process can be carried out in two different ways:
without load distribution after synchronization
with load distribution after synchronization
Synchronization without Load Distribution
On operation of the “GEN. SWITCH ON” key, the “PRESS TO CONFIRM” message appears on the control panel for an adjustable time. However, the command is not carried out unless the “CONFIRM” acceptance key is operated within this time. If this is not done, the request is rejected.
The automatic synchronization process is now started, and the generator switch is switched on. The present mode of operation and the real power being emitted from the machine set are now displayed on the control panel. No automatic load distribution is carried out. The load distribution can be changed manually.
Synchronization with Load Distribution
This function can be used only in the automatic mode. Operating the “AUTO” key results in a change to AUTO. After the change, the automatic synchronization is started, and the generator switch is switched on. Automatic load adjustment starts after switching on.
Switching on the Generator Switch in the Event of a Blackout
In the event of a blackout, the generator switch is switched on as follows:
by pressing the “GEN. Switch ON” key and “CONFIRM” or
by switching to automatic
Stopping the Machine Set
When the “STOP” key is operated, the “PRESS TO CONFIRM” message is displayed on the control panel for an adjustable time. However, the command is not carried out unless the “CONFIRM” acceptance key is operated within this time. If this is not done, the request is rejected.
During parallel operation, a “Stop with load reduction” is carried out first of all. The BM “LOAD RED” is displayed. “Lower” adjustment pulses are emitted until the machine set load has been reduced to below the “Gen Power Minimum” limit value. The generator switch is then switched off. When the generator switch has been switched off, the machine set continues to run for a certain time, for cooling. The “NO-LOAD RUN-ON” message is displayed on the control panel. Once the no-load run-on time has elapsed, the machine set is stopped. When the stop command is emitted, the BM changes from “NO-LOAD RUN-ON” to “STOP”. After completion of the stop command, the machine set is ready to be started once again.
The “NO-LOAD RUN-ON” can be switched off (this is defined in the configuration section). In this case, the machine set is stopped immediately after the generator switch is switched off.
Switching off the Generator Switch
The operation of the “GEN. SWITCH OFF” key results in the “PRESS TO CONFIRM” message being displayed for an adjustable time on the control panel. However, the command is not carried out unless the “CONFIRM” acceptance key is operated within this time. If this is not done, the request is rejected. In the parallel mode, a “Stop with load reduction” is carried out first of all. The BM “LOAD RED” is displayed. “Lower” adjusting pulses are emitted until the load on the machine set is below the “Gen. Power Minimum” limit value. The generator switch is then switched off.
Operation in the “Automatic Mode”
The automatic mode is selected by pressing the “AUTO” key on the control panel. The operating mode is displayed as “AUTO” on the control panel.
In the automatic mode, starting (standby start) and stopping (emergency stop, underload etc.) are carried out automatically or on request via a control and observation system.
Starting in the Automatic Mode
In the automatic mode, the starting process is initiated when the machine set is at “Standby” and a request is made by another machine set or by the higher-level control system.
The BM “START” appears on the display.
The start command is canceled in response to the “Self-sustaining speed reached” or “Generator voltage>85%” signal. The start command is issued only for an adjustable time (start time).
The “self-sustaining speed” signal results in the BM “OPERATION” being displayed.
If the “self-sustaining speed” or “generator voltage>85%” signal is not produced after two or more start attempts, then a further start command is issued.
Stopping in the Automatic Mode
An undelayed stop command (emergency stop, short circuit, reverse power etc.) results in the generator switch being switched off immediately. If the machine set is stopped by an underload or by a remote stop via the control and monitoring, and is being operated in the parallel mode, then a “Stop with load reduction” is carried out first of all.
The BM “LOAD RED” is displayed. “Lower” adjusting pulses are emitted until the load on the machine set has been reduced below the “Gen. Power Minimum” limit value. The generator switch is then switched off. When the generator switch is switched off, the machine set continues to run for a certain time for cooling. The “NO-LOAD RUN-ON” message appears on the control panel. Once the no-load run-on time has elapsed, the machine set is stopped. When the stop command is emitted, the BM changes from “NO-LOAD RUN-ON” to “STOP”. After completion of the stop command, the machine set is ready to be started again.
The “NO-LOAD RUN-ON” can be switched off (this is defined in the configuration section). In this case, the machine set is stopped immediately after switching off the generator switch.
Start Fault
The starting process with one or more starting attempts is the same in the automatic and semiautomatic modes. If the “self-sustaining speed” or “generator voltage>85%” signal is not produced after two or more start attempts, then a stop command is issued. The following messages are issued:
“BLOCKED” (BM)
“START FAULT” (SM)
An additional command is issued in the automatic mode. Once the “STOP” command has disappeared, the defect message is acknowledged, and the machine set is ready to be started again. Resetting is not possible in the automatic mode.
Adjustment of the Start and Stop Times
The start time, the pause time between the start attempts and the stop time must be adjusted in accordance with the requirements for the machine set. The same time values are set for the automatic and semiautomatic modes. The adjustment is carried out from a control panel. The number of start attempts can also be adjusted.
Standard settings:
Start time
5 s
Pause time
5 s
Stop time
30 s
Number of start attempts
3
No-Load Run-on
A no-load run-on is recommended for some types of machine set in order to cool the machine set before stopping it. The no-load run-on is controlled by the PMA 71. The control panel can be used to set the time for which the no-load run-on is carried out. The no-load run-on is active in the local semiautomatic mode and in the automatic mode. The BM “NO-LOAD RUN-ON” is displayed during this time.
Blocking of the Control Panel
Precondition:
Local semiautomatic mode
Machine set stationary
Blocking of the machine set is envisaged for servicing work. When the “ENTER” key is operated, the control menu is overlaid. The submenu “INPUT COMMANDS” is selected using the arrow key, a “1” is entered in the “block machine set” field, and “ENTER” is pressed for confirmation. The display field can be reselected using the “ESC” key. The following SM is displayed:
“CONTROL PANEL BLOCKING”
Reset Blocking
Select the submenu once again. Instead of “1”, now enter “0” and confirm with “ENTER”. This resets the function.
Blocking Via a Blocking Switch
Most diesel sets have a “BLOCKED/LOCAL/REMOTE” selector switch, which can be switched over for servicing work. The selector switch must be switched for PMA 71. The “BLOCKED/LOCAL” positions block any start capability by the PMA 71. Depending on the selector switch position, either “BLOCKED” or “LOCAL” is displayed on the control panel.
However, the running machine set is not stopped. The monitoring for the machine set (overspeed, lubricating oil pressure, etc.) still remains in action. If a start attempt is made in the local semiautomatic mode, then the following message appears on the control panel:
“MACHINE SET BLOCKED VIA BLOCKING SWITCH”
Acknowledgement of Alarm Messages
Alarm messages are displayed in blinking form in the lower two message lines on the control panel, and they can be acknowledged using the “ACK” key. If the alarm message (for example an overvoltage) is no longer current, then it is deleted from the message buffer by operating the “ACK” key. If the message persists externally, then it changes from a blinking light to a continuous light on acknowledgement, and is still indicated on the display. If the message disappears externally, then it is also deleted from the message buffer, and is no longer indicated on the display.
Existing already acknowledged messages can be displayed using the ↑↓ keys.
Resetting Blockings
Blockings of the machine set (for example initiated by an overspeed or a short circuit on the busbar etc.) are displayed on the control panel by way of the “BLOCKED” operating message, and must be reset by operating the “CONFIRM” key. Resetting can be carried out only when the machine set is stationary.
Initial Lubrication
The PMA 71 provides one output (floating contact) for controlling the initial lubrication. The following functions can be set on the control panel.
No initial lubrication
Continuous initial lubrication
Cyclic initial lubrication
Initial lubrication before start
It is also possible to select whether initial lubrication should be carried out in the standby mode, in the automatic mode, or in the automatic mode and in the local semiautomatic mode.
Continuous Initial Lubrication
If this function is selected, the machine set will be initially lubricated continuously as long as it is not running.
The initial lubrication process is started when the “self-sustaining speed” and “generator voltage>85%” signals have disappeared. The initial lubrication process ends when the “self-sustaining speed” or “generator voltage>85%” signals appear.
If the blocking switch is inserted on the machine set, the initial lubrication is switched off.
Cyclic Initial Lubrication
When this function is selected, the machine set is initially lubricated cyclically, for as long as it is not running.
The times can be set on the control panel.
Standard settings:
Initial lubrication time
2 min
Pause time
2 hours
The initial lubrication is started when the “self-sustaining speed” and “generator voltage>85%” signal have disappeared. The initial lubrication process ends when the “self-sustaining speed” or “generator voltage>85%” signals appear. If the blocking switch is inserted on the machine set, then the initial lubrication is switched off.
Initial Lubrication Before Start
This function provides initial lubrication for the machine set for an adjustable time, with the machine set then being started. However, the time that has passed since the last initial lubrication was carried out is checked. If the time is too long, initial lubrication is carried out. If the time is shorter than set, starting is carried out immediately. The times can be set on the control panel.
Standard settings:
Initial lubrication time
30 s
Longest time for start without
5 min
initial lubrication
A start without initial lubrication is carried out in the event of a “Blackout”.
Initial Lubrication Monitoring (Option)
A contact from an external initial lubrication system is required for this function. The alarm is evaluated with a delay. Once the delay time has elapsed, the machine set is blocked. The delay time can be set on the control panel.
The following messages are output on the control panel:
“BLOCKED”
(BM)
“LUBRICATING OIL PRESSURE FAULT”
(SM)
Blocking is active in the automatic mode and in the local semiautomatic mode. Resetting is usually impossible as long as the alarm is active. The alarm is suppressed in the event of a “Blackout”.
Preheating
The PMA 71 has one output (floating contact) for controlling the preheating. It is possible to select whether the initial lubrication should be carried out in the standby mode, in the automatic mode or in the automatic mode and in the local semiautomatic mode.
The preheating is started when the “self-sustaining speed” and “generator voltage>85%” signals have disappeared. The preheating ends when the “self-sustaining speed” or “generator voltage>85%” signals appear. If the blocking switch is inserted on the machine set, then the preheating is switched off.
Slow Turn (Option)
This function slowly rotates the crankshaft of the diesel set, and then starts it. However, the time which has passed since the machine set was last started is checked. If the time is too long, slow turning is carried out. If the time is shorter than set, starting is carried out immediately. The time can be set on the control panel.
Standard settings:
Time for slow turn
10 s
Longest time for start without
2 hours
slow turn
Starting is carried out without any slow turn in the event of a “blackout”.
“Self-Sustaining Speed” Signal
The PMA 71 requires the “self-sustaining speed” (self-sustaining speed=contact closed) signal for various functions. The speed detection (for example a speed relay) is not part of the PMA 71.
Safety Functions
The PMA 71 allows safety functions to be provided. Four digital inputs with wired discontinuity monitoring can be used as standard. Normally, these are used as follows:
No. 1:
“Overspeed”
No. 2:
“Minimum lubricating oil pressure”
No. 3:
“Maximum cooling water temperature”
No. 4:
Spare (for example “Minimum cooling
water pressure”)
Further inputs may optionally be provided.
The machine set must be equipped with appropriate sensors. For wire discontinuity monitoring, each sensor contact is bridged by a 5.6 kiloohm resistor. The PMA 71 identifies the resistance as follows:
Resistance ~8 kΩ (Wire discontinuity Wire or no resistor in discontinuity parallel): Resistance ~5.6 kΩ (Contact open with No stop resistor in parallel): Resistance ~0 (Contact closed): Undelayed stop
In order to prevent initiation by short interference pulses, the alarms 2 . . . 4 are provided with a delay time. This time can be selected from the control panel. The standard setting is one second. When one of these alarms occurs, the machine set is stopped and blocked immediately. In the automatic mode, a standby machine set is started.
The following messages are displayed on the control panel:
“BLOCKED” (BM)
and the corresponding reason message:
“OVERSPEED”
(SM) or
“MINIMUM LUBRICATING OIL PRESSURE”
(SM) or
“HIGH COOLING WATER TEMPERATURE”
(SM) or
“ALARM NO. 4”
(SM)
Undelayed Stop/Delayed Stop
The safety disconnection can be delayed or undelayed. The maximum cooling water temperature criterion, for example, requires either undelayed or delayed disconnection depending on the machine set type (this is defined in the configuration section). If delayed disconnection is provided, then the BM “DELAYED STOP” is first of all output on the control panel if the cooling water temperature is exceeded. Once a delay time has elapsed, the machine set is then stopped. The delay time can be set on the control panel.
Speed/Time-Dependant Enabling of the Alarms
When the machine set is not running, some values (for example lubricating oil pressure) will be below the alarm point. Whilst the machine set has been started, these values require some time to reach a normal level. For this reason, the alarms can be blocked until a delay time has elapsed. (Delay time 1 or delay time 2). Alarm No. 2 (lubricating oil pressure) is blocked until the delay time 1 has elapsed.
Standard settings: Monitoring time 1 15 s Monitoring time 2 45 s
The monitoring time 1 is started by the “self-sustaining speed” or “generator voltage>85%” signals. Once this time has elapsed the monitoring time 2 is started.
Alarm Blocking
One floating contact is available for alarm blocking. This output is active when the machine set is not running, and until the monitoring time 1 has elapsed after starting of the machine set. This signal makes it possible to block alarms from an external alarm system when stationary or while the machine set is running up.
Emergency Stop
A digital input is provided for the emergency stop function. An “emergency stop” pushbutton can be connected here. This function initiates an immediate stop, and blocking of the machine set. The function is active in the automatic mode and in the local semiautomatic mode, but only when the machine set is running, for example when the signals “self-sustaining speed” or “generator voltage>85%” are present.
The following messages are displayed on the control panel:
“BLOCKED”
(BM)
“EMERGENCY STOP”
(SM)
The “emergency stop” function does not initiate a standby start. It should be remembered that emergency stopping of a machine set can cause a blackout when the corresponding machine set is the only one connected to the power supply system, or when the remaining machine set is overloaded. For safety reasons, the emergency stop valve should also be operated directly, bypassing the PMA 71.
Emergency Stop Valve
Some machine sets also have an emergency stop valve in addition to the normal stop valve. This valve is operated when the machine set is intended to be stopped as quickly as possible (undelayed stop, emergency stop, short circuit, etc.). The PMA 71 has one output for operating this valve.
Suppression Valve
The PMA 71 provides one output for operating a suppression valve. This valve is operated when the machine set is not running, and is deactivated with a delay by the “self-sustaining speed” or “generator voltage>85%” signals. The delay time can be set on the control panel.
Initial Alarm (Option)
Precondition:
Automatic Mode
This function is required to start a standby machine set as a precaution, in order to prevent an undelayed stop being required. The signal can come directly from the machine set as an initial alarm, or as a group alarm from the alarm system. (For example, initial alarm as lubricating oil pressure and cooling water temperature). The control panel can be used to select whether the faulty machine set should be stopped (with a previous load reduction), or should remain connected to the power supply system.
The following messages are displayed on the control panel:
“INITIAL ALARM”
(BM)
The message is acknowledged by operating the “RESET” key.
Remote Control
If the PMA 71 is connected to a higher-level control and observation system, then the following control actions are possible:
Start the machine set
Stop the machine set
Activate/deactivate the connection and disconnection chain
Activate/deactivate the UBL mode
Connect/disconnect the land connections
Connect/disconnect the coupling switches
Furthermore, the actual values such as the machine set real power, currents, voltages and frequency are provided and can be processed further in a standard data module. In order to transfer the control authorization to the control and monitoring system, the “remote” key must be operated on the OP 7.
The operating mode is displayed as “REMOTE” on the control panel. The OP 7 cannot be used for control purposes during remote control. The “semi” or “automatic” key must be operated in order to switch control back to the OP 7. Further information can be found in the operating instructions for the appropriate control and monitoring system.
Control of Shaft Generators
General Note:
The description covers only control of the WGA 23D and the conventional WG.
WGA 23D
The WGA 23D is a shaft generator control system comprising a shaft generator, a static converter and a wattless component machine. The converter is used to convert the frequency of the shaft generator to the busbar frequency. This can be done within a range from 40% to 100% of the machine speed. Parallel operation between the WGA and diesel generators is possible.
The WGA 23D is used in marine vessels with fixed-pitch propellers and variable-pitch propellers. For marine vessels with fixed-pitch propellers, the speed of the vessel can be controlled only via the speed of the main machine. For vessels with variable-pitch propellers, the speed of the vessel is regulated by the speed of the main machine and by the propeller pitch. The WGA 23D thus allows shaft generator operation over a wide speed range.
Standard values:
Speed of the main machine
WGA 23D power margin
100% → 75%
100%
75% → 40%
100% → 50%
WG Control Via Epicyclic Gearing (for Example Renck)
In this case, the shaft generator is coupled to the main machine via epicyclic gearing. Once again, continuous parallel operation is possible in this case, in the range from 70% to 100% of the machine speed.
The generator frequency is in this case matched to the main machine speed via the gearing.
Conventional Shaft Generator (PTO)
This control system is used predominantly for marine vessels with variable-pitch propellers, since the shaft generator frequency is kept constant by switching the main machine to constant speed. The speed of the vessel is in this case regulated by varying the propeller blade pitch. Parallel operation between WG and DG is feasible only for load transfer or in an extremely calm sea.
WGA 23D
Switching on the WGA 23D
The WGA 23D can be switched on only when the on-board power supply system is available. Blackout starting, as in the case of DG is not possible. The WGA 23D is switched on from the PMA 71 control panel in the local semiautomatic mode. A number of preconditions have to be satisfied before the WGA 23D can be switched on.
The speed of the main machine is in the operating range
The coupling must be switched on
The WGA control is switched on
No fault message in the control system
If these preconditions are satisfied, then the WGA 23D passes the “READY TO START” signal to the PMA 71. The following message is displayed on the control panel:
“START”
(BM)
When the “START” key is operated the “PRESS TO CONFIRM” message is displayed on the control panel for an adjustable time. However, the command is not carried out unless the “CONFIRM” acceptance key is operated within this time. If this is not done, the request is rejected. A start command can be issued only when the “READY TO START” signal from the WGA 23D is present. If the “CONFIRM” key is operated within this time, then a start command is issued to the WGA 230 controller. The WGA 23D now starts the start-up process. The following message is displayed on the control panel:
“OPERATION”
(BM)
The generator voltage>85% signal results in the message
“OPERATION” (BM)
being displayed.
After completion of the start-up process (after approximately 60 seconds) the “ready for synchronization” and “enable generator switch” signals are passed from the WGA 23D to the PMA 71. The following messages are displayed on the control panel:
“READY FOR SYNCHRONIZATION”
(BM)
“ENABLE GENERATOR SWITCH”
(BM)
If the PMA 71 is switched to “automatic”, the synchronization is started The paritetic load distribution is carried out once the generator switch has been switched on.
The currently active operating state and the real power being emitted from the generator are displayed on the control panel. The “ENABLE GENERATOR SWITCH” signal is wired directly to the main switch panel. The generator switch cannot be switched on without this signal. The WGA 23D can switch off the generator switch by canceling this signal (in the event of a serious fault).
Start Fault
If the “ENABLE GENERATOR SWITCH” signal does not arrive within a specific time after the start command has been issued, the following message appears on the control panel:
“START FAULT”
(FM)
Manually Switching Off the WG in the Parallel Mode
The WGA 23D can be stopped from the PMA 71 control panel in the local semiautomatic mode. When the “STOP” key is operated, the “PRESS TO CONFIRM” message is displayed on the control panel for an adjustable time. However, the command is not carried out unless the “CONFIRM” acceptance key is operated within this time. If this is not done, the request is rejected.
A stop command is passed to the WGA 23D controller. If the machine set is being operated in parallel on the power supply system, then a “STOP with load reduction” is carried out first.
The BM “LOAD RED” is displayed on the control panel. “LOWER” adjusting pulses are emitted in order to reduce the load on the machine set. The generator switch is switched off when the power falls below the “GEN. POWER MIN.” limit value. Once the generator switch has been switched off, a “STOP” command is passed to the WGA 23D controller.
When the “STOP” command is output, the operation message on the control panel changes from “LOAD RED” to “MACHINE SET STOPPING”.
Manually Switching Off the WG in the Insular Mode
If the WG is the only one connected to the power supply system, then switching it off would result in a blackout. A diesel set must therefore be started and synchronized before this is done. After synchronization of the DG, the rest of the process is as described previously.
Slow Down of Main Machine
The PMA 71 is supplied with this signal via a floating contact from the diesel remote control. In the event of a slow down, the speed of the main machine is maintained by the remote control for a certain time in order to start a standby machine set and to carry out a load transfer.
When this signal arrives, the PMA 71 is blocked and a standby machine set is started. The following message is displayed on the control panel:
“SLOW DOWN OF MAIN MACHINE”
After starting and synchronization of the standby machine set, the PMA 71 controller for the WGA 23D carries out a “stop with load reduction”. “LOWER” adjusting pulses are emitted in order to reduce the load on the machine set. During the process of reducing the load, the BM “LOAD RED” is displayed on the control panel. When the power falls below the limit value “GEN. POWER MIN.”, the generator switch is switched off.
When the generator switch is switched off, the PMA controller for the WGA 23D is switched to the “local semiautomatic mode”. At the same time a “STOP” command is passed to the WGA 23D controller. When the “STOP” command is issued, the operation message changes from “LOAD RED” to “STOP”.
When the generator switch is switched off, the remote control continues with the “slow down” of the main machine. A floating contact must be connected from the switch panel to the diesel remote control for this function (this is not a function of the PMA 71).
Shut Down of the Main Machine
The PMA 71 is supplied with this signal via a floating contact from the diesel remote control. In contrast to the “slow down of the main machine”, the speed of the main machine is in this case not maintained for a specific time. The rate of change of speed of the main machine determines whether there is sufficient time to start a standby machine set, and to carry out a load transfer. Normally, a shut down of the main machine leads to a blackout.
The signal results in a start command being issued to the standby machine set, and in the WGA 23D controller being blocked. If the “start two generators in the event of a fault” function is selected, then two diesel sets are started.
The following message:
“EMERGENCY STOP OF MAIN MACHINE”
is displayed on the control panel.
After starting and synchronization of the standby machine set, the PMA 71 controller for the WGA 23D carries out a “stop with load reduction”. “LOWER” adjusting pulses are emitted in order to reduce the load on the machine set. During the load-reduction process, the BM “LOAD RED” is displayed on the control panel. When the power falls below the “GEN. POWER MIN.” limit value, the generator switch is switched off.
When the generator switch is switched off, the PMA controller for the WGA 23D switches to the “local semiautomatic mode”. At the same time, a “STOP” command is passed to the WGA 23D controller. When the “STOP” command is issued, the operation message changes from “LOAD RED” to “STOP”.
If the speed of the main machine falls below the operating range of the WGA 23D before the load transfer has taken place to the standby machine set, then the generator switch is switched off by the WGA 23D independently of the PMA 71. The standby machine set that has already started is then connected via “blackout”.
Machine Telegraph (MT)<n Min
The PMA 71 is supplied with this signal via a floating contact either via the diesel remote control or from the WGA 23D. The minimum speed for operation of the WGA 23D is normally 40% of the rated speed of the main machine. The minimum speed is, however, dependent on the design of the main machine and of the WGA 23D. If the MT lever is set below this limit, the diesel remote control stops the reduction in the speed at this point in order to allow a standby machine set to be started and a load transfer to be carried out.
If this signal occurs in the automatic mode when the generator switch is closed, a standby machine set is started. The following message is displayed on a control panel:
“MT < N MIN”
(BM)
After starting and synchronization of the standby machine set, the PMA 71 controller for the WGA 23D carries out a “STOP WITH LOAD REDUCTION”. “LOWER” adjusting pulses are emitted in order to reduce the load on the machine set. During the load-reduction process, the BM “LOAD RED” is displayed on the control panel. When the power falls below the “GEN. POWER MIN.” limit value, the generator switch is switched off.
Once the generator switch has been switched off, the diesel remote control continues to reduce the speed. A floating contact must be passed from the switch panel to the diesel remote control for this function (this is not a function of the PMA 71)
Machine Telegraph (MT)>n Min
If the MT lever is once again set to a value above the minimum speed, the “STOP WITH LOAD REDUCTION” function is canceled. The BM “LOAD RED” which may already be displayed on the control panel is extinguished again. The machine set that has already been started is synchronized, and is stopped once again if the load is too low, or manually.
DG Request (Warning)
The PMA 71 is supplied with this signal via a floating contact from the WGA 23D. The signal is produced when the WGA 23D detects an overload. A standby machine set is started.
The following message is displayed on the control panel:
“DG REQUEST FROM THE WG”
(BM).
Load sharing is carried out after starting and synchronization of the standby machine set.
WG Delayed Stop
The PMA 71 is supplied with this signal via a floating contact from the WGA 23D. If the WGA 23D has identified a fault which still allows operation to continue for a short time, then the “WG DELAYED STOP” signal is passed to the PMA 71. Normally, this time is sufficient to start a standby machine set and to carry out a load transfer.
When this signal arrives, a delayed stop of the WGA 23D is carried out, together with blocking of the controller, and a standby machine set is started. The following message is displayed on the control panel:
“WG DELAYED STOP”.
Once the standby machine set has been started and synchronized, the PMA 71 controller for the WGA 23D carries out a “stop with load reduction”. “LOWER” adjusting pulses are emitted in order to reduce the load on the machine set. During the load-reduction process, the BM “LOAD RED” is displayed on the control panel. When the power falls below the “GEN. POWER MIN.” limit value, the generator switch is switched off.
When the generator switch is switched off, the PMA controller for the WGA 23D is switched to the “local semiautomatic mode”. At the same time a “STOP” command is passed to the WGA 23D controller. When the “STOP” command is output, the operation message changes from “LOAD RED” to “STOP”.
WG Undelayed Stop
The PMA 71 is supplied with this signal via a floating contact from the WGA 23D.
If the WGA 23D has identified a critical fault which requires an immediate stop, then this signal is passed to the PMA 71. The WGA 23D is de-energized, and the generator switch is switched off. (“Enable generator switch” signal=Off). If the shaft generator is connected to the power supply on its own, then this signal causes a blackout.
When this signal occurs, an undelayed stop of the WGA 23D is carried out, the generator switch is switched off, the controller is blocked and a standby machine set is started. The following message is displayed on the control panel:
“WG UNDELAYED STOP”.
If the PMA 71 was in the automatic mode, then it is switched to the local semiautomatic mode.
In the event of a blackout, the newly started standby machine set is connected after a short run-up time, or it is synchronized if another machine set perfume to the power supply system.
Reverse Power Protection for the WGA 23D
Reverse power protection for the shaft generator is not necessary, since the WGA 23D does not allow any reverse power flow. However, a small real power flow to the WGA 23D is required in order to operate the wattless component machine when the shaft generator is running on no load. In order to prevent the generator switch from being switched off, the reverse power protection for the shaft generator should be switched off, or the limit value should be set sufficiently high that it cannot be triggered.
Conventional WG (PTO)
The frequency of the shaft generator is dependent on the speed of the main machine. Any change in the speed (for example resulting from a heavy sea) also changes the frequency of the on-board power supply system. During parallel operation with a diesel generator, this leads to severe load shifts. For this reason, PMA 71 does not allow continuous parallel operation between SG and DG.
Switching on the WG when the on-Board Power Supply is Present
The function described here carries out a load transfer from a DG to a WG. The main machine is switched to constant speed by supplying one contact to the remote control for this purpose. When the contact is switched on, the remote control keeps the main machine at a constant speed. When the WG is switched on, the remote control receives the “WG ON” signal. However, the speed can now be reduced only if the WG has previously been switched off again and the “WG ON” signal has disappeared.
The following conditions must be satisfied in order to switch on the WG:
Generator voltage greater than 85%
READY TO SWITCH ON signal
The following BMs are displayed on the control panel
SEMI
READY TO SWITCH ON.
Switch to AUTOMATIC.
When the automatic mode is switched on, the WG controller passes adjusting pulses to the diesel set via the connection for common frequency adjustment, in order to match the frequency of the on-board power supply system to its own frequency (this works only when READY TO SWITCH ON is present). Synchronization is carried out as for a diesel set. After synchronization, the DG receives LOWER adjusting pulses from the WG controller and reduces the load on the DG.
During the load-reduction process, the BM LOAD RED is displayed on the control panel. Once the power falls below the “Gen. power minimum” limit value, the generator switch is switched off. The DG can still carry out a no-load run (depending on the configuration) and is then stopped. When the stop command is emitted, the BM LOAD RED is extinguished.
Switching Off the WG
The function described here carries out a load transfer from SG to a DG. In order to switch off the WG, a DG is started in the local semiautomatic mode. After switching to AUTOMATIC, the synchronization of the DG is started. After switching on the generator switch, a “stop with load reduction” is carried out for the WG. During the load reduction process, the BM “LOAD RED” is displayed on the ST.
The WG controller passes adjusting pulses to the diesel set via a connection between the PMA 71 systems. “High” adjusting pulses are passed to the DG until the load on the WG is reduced below the “Generator power minimum” limit value. The generator switch is then switched off. When the generator switch is switched off, the BM “LOAD RED” is extinguished, and the WG controller is switched to the local semiautomatic mode.
Slow Down of Main Machine
The PMA 71 is supplied with this signal via a floating contact from the diesel remote control. In the case of a slow down, the speed of the main machine is maintained by the remote control for a certain time in order to start a standby machine set and to carry out a load transfer.
When this signal occurs, a delayed stop of the WG, blocking of the controller and starting of a standby machine set are carried out. The following message is displayed on the control panel:
“SLOW DOWN OF MAIN MACHINE”
(SM).
After the DG has been started and synchronized a “Stop with load reduction” is carried out for the WG.
During the load-reduction process, the BM “LOAD RED” is displayed on the ST. The WG controller passes adjusting pulses to the diesel set via a connection between the PMA 71 systems. “Higher” adjusting pulses are passed to the DG until the WG load has been reduced below the “Generator breaker minimum power” limit value. The generator switch is then switched off.
When the generator switch is switched off, the BM “LOAD RED” is extinguished, and the BM “BLOCKED” is displayed. The WG controller is switched to the local semiautomatic mode.
After switching off the generator switch, the remote control continues the slow down of the main machine. A floating contact must be passed from the switch panel to the diesel remote control for this function (that is not the function of the PMA 71).
Emergency Stop of Main Machine, Delayed/Undelayed Step of the WG
The PMA 71 is supplied with this signal via a floating contact from the diesel remote control. In contrast to the “Slow down of main machine”, the speed of the main machine is in this case not maintained for a specific time. The rate of change of speed of the main machine determines whether there is sufficient time to start a standby machine set, and to carry out a load transfer.
The signal results in a start command being passed to the standby machine set, and the WGA 23D controller being blocked. If the function “start two generators in the event of a fault” is selected, then two diesel sets are started. The following message is displayed on the control panel:
“EMERGENCY STOP OF MAIN MACHINE”.
Once the DG has been started and synchronized, a “Stop with load reduction” is carried out for the WG.
During the load-reduction process, the BM “LOAD RED” is displayed on the control panel. The WG controller passes adjusting pulses to the diesel set via a connection between the PMA 71 systems. “Higher” adjusting pulses are passed to the DG until the load on the WG has been reduced below the “Generator breaker minimum power” limit value. The generator switch is then switched off.
When the generator switch is switched off, the BM “LOAD RED” is extinguished, and the BM “BLOCKED” is displayed. The WG controller is switched to the local semiautomatic mode.
If the speed is already below the operating range of the WG (Generator switch trips due to undervoltage or underfrequency), the standby machine set which has already been started is connected via “blackout”.
Reverse Power
While the load is being accepted or transferred, the DG can change to reverse power mode due to severe speed fluctuations in the main machine (because of the marine vessel's propeller surfacing due to the wave height, etc.). Reverse power evaluation of the DG is therefore inhibited during this time. Reverse power evaluation is generally inhibited for the WG, since it always runs on its own.
On-Board Power Supply System Monitoring
The on-board power supply system monitoring has the following tasks:
Start of a standby machine set in the event of a blackout, in order to supply the loads with electrical power as quickly as possible once again, Protection of the on-board power supply system against unacceptable frequency errors (underfrequency), by switching off unimportant loads, Protection of the on-board power supply system against unacceptable frequency disturbances (underfrequency/overfrequency) by switching off the generator switch. If there is a major difference between the busbar frequency and the rated frequency, synchronization is often impossible, because the rated frequency is outside the adjustment range of the speed adjustment device. Switching is therefore carried out via “blackout”. Protection of the on-board power supply system against unacceptable voltage discrepancies (undervoltage/overvoltage) by switching off the generator switch. In this case, no paralleling is carried out, since the different magnitudes of the voltage that is set on the busbar and the voltage that is set on the generator that is to be connected would result in a high reactive current flowing. For this reason, switching takes place via a “blackout”.
Blackout
Busbar monitoring (for example two auxiliary contactors) must be provided by the switch panel manufacturer. These auxiliary contactors can be connected between the phases L1–L2, L2–L3 via a circuit breaker. Each relay requires two auxiliary contacts (1M, 1B), and the circuit breaker requires one auxiliary contact (1B). These auxiliary contacts must be connected such that two signals are provided for the PMA 71.
a) Blackout signal (all auxiliary contactors tripped, B, circuit breaker, M)
b) “Busbar voltage present” signal (all auxiliary contactors connected, M)
This circuit ensures that no blackout is identified as a result of the disconnection of the circuit breaker or as a result of the failure of one of two phases. The following message is displayed on the control panel:
“BUSBAR MONITORING FAULT”
(SM)
The busbar monitoring must be provided separately for each PMA 71. The auxiliary relay contacts are connected to the corresponding connections of the PMA 71.
If “BLACKOUT” is identified, then the next available machine set is started, and is switched on following a short delay time after the generator voltage reaches>85%. Simultaneous connection of the generator switches for two or more machine sets which are started at the same time to the non-live busbar is prevented by way of a simultaneous inhibit
Underfrequency/Overfrequency
Automatic Mode
The frequency of the on-board power supply system is detected via the generator protection device/measurement transducer, and is monitored in the SIMATIC-S7. The limit values and delay times for underfrequency/overfrequency can be changed from the control panel. The function is password-protected.
The following messages are output if the respective limit values are undershot or exceeded:
“Overfrequency”
“Underfrequency 1”
“Underfrequency 2”
“Underfrequency 3”
The initiated functions are listed in the “GENERATOR PROTECTION” table.
Local Semiautomatic Mode
If a machine set is being used in the manual mode and an underfrequency or overfrequency is identified, then the messages which are produced are as described above, although no machine set is added.
Undervoltage/Overvoltage
Automatic Mode
The frequency of the on-board power supply system is detected via the generator protection device/measurement transducer, and is monitored in the SIMATIC-S7. The limit values and delay times for underfrequency/overfrequency can be changed from the control panel. The function is password-protected.
The following messages are output if the respective limit values are undershot or exceeded:
“Overvoltage”
“Undervoltage 1”
“Undervoltage 2”
“Undervoltage 3”
The initiated functions are listed in the “GENERATOR PROTECTION” table in Section 7.
Local Semiautomatic Mode
If a machine set is being used in the manual mode and an underfrequency or overfrequency is identified, then the messages which are produced are as described above, although no machine set is added.
Generator Protection
The generator protection has the following tasks:
Protection of the generator and of the on-board power supply system against the consequences of a short circuit, by disconnection of the generator switches for the generators which feed the on-board power supply system. In this case, the disconnection normally takes place with a short time delay, in order to provide time for lower-level circuit breakers to be disconnected (selectivity). Short-circuit counting, stopping and blocking of the machine set and switching of the other machine sets to manual operation, in order to prevent automatic connection of a standby generator to the busbar. If appropriate, allowing standby start and connection of the generator to the busbar (thus, a second short circuit if the short circuit has not been rectified in the meantime). Protection of the generator against overloading due to disconnection of the generator switch when an overcurrent is flowing. Protection of the generator against overloading due to disconnection of unimportant loads when overcurrent is flowing, overloading. Disconnection of the generator switch in the event of reverse power. In addition, undelayed short-circuit tripping for very large short-circuit currents, or differential protection, is also required. These functions are not included in the PMA 71 but need to be provided separately in the switchgear assembly.
Short Circuit
The generator currents are monitored for short circuits by the generator protection apparatus/measurement transducer GENOP 71. If a short circuit occurs, the output relay for the generator switch is operated. In order to achieve selectivity between the generator switch and the lower-level circuit breakers, the generator switch is normally switched off with a delay.
The limit value and the delay time can be set via the control panel. The function is password-protected.
A stock command is emitted to the relevant diesel engine (or to the shaft generator controller). The following messages are displayed on the control panel:
“GENERATOR SHORT CIRCUIT”
(SM)
“BLOCKED”
(BM)
The following message is displayed on the control panel of the other machine set:
“OTHER MACHINE SET SHORT CIRCUIT” (SM)
It is possible to select whether one or two short circuits is or are allowed.
If only one short circuit is allowed, all the other machine sets are switched to “semiautomatic” after just one short circuit. The other machine sets do not start.
If two short circuits are allowed, one standby machine set is started and connected to the power supply system after the first short circuit. If a second short circuit occurs, this machine set is also stopped and blocked and all the other machine sets are switched to “semiautomatic”. This prevents a third machine set from being started and connected.
The off command for the generator switch is provided directly from the generator protection device/measurement transducer, and still operates even in the event of failure of the PLC or of the 24V DC supply voltage (for supplying the generator protection device from the generator voltage). The other functions are carried out in the PLC.
Short-Circuit Acknowledgement
The short-circuit storage for that particular machine set must be acknowledged manually. Once the stop command has disappeared, the blocking of the machine set can be canceled.
Overcurrent
The three generator currents I L1 /I L2 /I L3 are monitored in the generator protection device/measurement transducer for exceeding various limit values. If at least one of the currents exceeds the limit value, unimportant loads and/or the generator switches are disconnected once the delay time has elapsed. The limit values and delay times can be varied via the control panel. The function is password-protected.
The following signals are emitted:
Disconnection of unimportant loads, level 1
Disconnection of unimportant loads, level 2
Disconnection of unimportant loads, level 3
Disconnection of generator switches
Machine set stop command
Block machine set
Switching to semiautomatic
The association between the individual functions and the limit values as well as the standard settings are shown in Table 7.8.
Depending on the function that is initiated, the following messages are displayed on the control panel:
“DISCONNECTION OF UNIMPORTANT LOADS 1”
(SM) or
“DISCONNECTION OF UNIMPORTANT LOADS 2”
(SM) or
“DISCONNECTION OF UNIMPORTANT LOADS 3”
(SM) or
“OVERCURRENT, STANDBY START”
(SM)
“BLOCKED”
(BM)
“SEMI”
(BM)
“Generator switch case”
(SM)
The off command for the generator switch and for the unimportant loads comes directly from the generator protection device/measurement transducer, and still works even in the event of failure of the PLC or of the 24V DC supply voltage (the supply for the generator protection device from the generator voltage). The other functions are carried out in the PLC.
Overload
The emitted power from the generator is detected in the GENOP 71 generator protection device, and is monitored in the Simatic-S7. The limit values for overloading can be varied from the control panel. The function is password-protected.
The following signals are emitted:
Disconnection of unimportant loads, level 1
Disconnection of unimportant loads, level 2
Disconnection of unimportant loads, level 3
Disconnection of generator switches
Machine set stop command
Block machine set
Switching to semiautomatic
The association between the individual functions and the limit values as well as the standard settings are shown in Table 7.8.
Depending on the function that is initiated, the following messages are displayed on the control panel:
“DISCONNECTION OF UNIMPORTANT LOADS 1”
(SM) or
“DISCONNECTION OF UNIMPORTANT LOADS 2”
(SM) or
“DISCONNECTION OF UNIMPORTANT LOADS 3”
(SM) or
“OVERCURRENT, STANDBY START”
(SM)
“BLOCKED”
(BM)
“SEMI”
(BM)
“Generator switch case”
(SM)
The off command for the generator switch and for the unimportant loads comes directly from the generator protection device/measurement transducer, and still works even in the event of failure of the PLC or of the 24V DC supply voltage (the supply for the generator protection device from the generator voltage). The other functions are carried out in the PLC.
Monitoring of the Current Transformers
The current transformers are monitored when the generator switch is switched on. This is done by comparing the mean value with the extreme value. The following states result in a fault message:
Extreme value (greatest value of the three generator currents (I L1 /I L2 /I L3 ) less than the mean value Mean value less than 75% of the extreme value
When a fault occurs, the following message is displayed on the control panel:
“FAULT IN CURRENT MEASUREMENT”
(SM)
This monitoring presupposes that the single-phase on-board power supply system loads are shared in a largely balanced manner. This makes it possible to identify faults in the current transformer and a wire discontinuity in the current transformer circuit.
The function can be switched off via the control panel.
Reverse Power
The real power is monitored in the generator protection device/measurement transducer. If the reverse power limit value is exceeded, the generator switch is disconnected once a delay time has elapsed. The limit value and the delay time can be varied via the control panel. The function is password-protected.
The following signals are emitted:
Disconnection of generator switches
Machine set stop command
Block machine set
Switch to local semiautomatic mode
Request standby machine set
The following messages are displayed on the control panel:
“REVERSE POWER”
(SM)
“BLOCKED”
(BM)
The limit value and the delay time can be varied via the control panel. The function is password-protected. The standard settings are shown in Table 7.8.
The off command for the generator switch comes directly from the generator protection device/measurement transducer, and still operates even in the event of failure of the PLC or of the 24V DC supply voltage. The other functions are carried out in the PLC.
External Generator Protection
Some of the generator protection functions described above are already integrated in the generator switch, or in the switch panel. In order to avoid duplicated tripping with virtually the same limit values from two different gradients, the relevant limit values in the PMA could in this case be set sufficiently high that tripping is carried out only by the generator protection in the switch panel. The other functions (standby start, fault signaling, etc.) which are carried out by the PMA are not used in this situation.
Generator Switch with Built-in Short-Circuit Release (Option)
If a generator switch is used which has its own short-circuit tripping, then an auxiliary contact of the generator switch is required in order to form the short-circuit counting chain (contact open when there is a short circuit). The short-circuit detection in the generator protection device/measurement transducer should then sensibly be rendered inoperative.
Undelayed Short-Circuit Tripping (Option)
Some classes require undelayed tripping of the generator switch in response to particularly large short-circuit currents. An appropriate tripping device must be provided in the generator switch for this purpose.
The tripping point is greater than the short-circuit current of a single machine set. Tripping can take place only when the short-circuit is located between the generator and the generator switch or in the generator itself, and two or more generators which are operated in parallel with the faulty machine set can feed the short-circuit point.
In the PMA, one digital input is provided for connection of a signaling contact for the undelayed short-circuit release (tripping=contact closed). When tripping takes place, the following signals are emitted from the PMA:
Disconnection of generator switches
Machine set stop command
Block machine set
Switching to manual
Connection command to the next machine set
The following messages are displayed on the control panel:
“UNDELAYED SHORT-CIRCUIT TRIPPING”
(SM)
“BLOCKED”
(BM)
“SEMI”
(BM)
Differential Protection (Option)
Beyond a certain generator power level, some classes require differential protection. An external differential protection monitoring device must be provided for this purpose.
One digital input of the PMA is provided for connection of a signaling contact of the external differential protection monitoring device (tripping=contact closed). When tripping takes place, the PMA emits the following signals:
Disconnection of generator switches
Machine set stop command
Block machine set
Switching to local semiautomatic mode
Connection command to the next machine set
The following messages are displayed on the control panel:
“DIFFERENTIAL PROTECTION TRIPPED”
(SM)
“BLOCKED”
(BM)
“SEMI”
(BM)
7.9 Table of the generator protection functions (Table 7.8)
DISCON-
DISCON-
DISCON-
DISCON-
STANDBY
NECTION
NECTION
NECTION
NECTION
BLOCK
TIME
MACHINE
OF
OF
OF
OF
MA-
SWITCHING
LIMIT
VALUE
SET
UNWANTED
UNWANTED
UNWANTED
GENERATOR
CHINE
MOTOR
Auto →
VALUE
IN %
s
REQUEST
LOAD 1
LOAD 2
LOAD 3
SWITCHES
SET
STOP
Semi
GENERATOR CURRENT
1
95
30
X
2
100
5
X
3
100
5
X(1)
4
100
10
X(1)
5
100
15
X(1)
6
120
1
X
X(1)
X(1)
X(1)
7
110
30
X(1)
X
X
X
GENERATOR POWER
1
95
30
X
2
100
5
X
3
100
5
X
4
100
10
X
5
100
15
X
6
110
1
X
X
X
X
7
−10
6
X(1)
X
X
X
BUSBAR FREQUENCY
1
97.5
60
X
2
95
8
X(3)(4)
3
95
6
X
4
95
10
X
5
95
15
X
6
90
1
X(3)
X
X
X
7
90
15
X
X
X
X
8
105
2
GENERATOR VOLTAGE
1
90
5
X(3) (4)
2
60
1
X
X
X
X
3
105
5
X(3)(4)
4
110
5
X(2)
(1)Function provided in the GENOP 71 (independently of the S7-300 PLC)
(2)In addition, the generator is switched off
(3)Switching takes place via blackout, once the newly started machine set is ready to be connected.
Power Management
The power management has the following tasks:
Starting a standby machine set in the event of overcurrent, overload, underfrequency Definition of the starting sequence of the standby machine set Selection of a minimum number of generators (option) Time-delayed disconnection of generators which are not required (underload) Definition of disconnection sequence for the unrequired generators Control of the busbar frequency (constant frequency or with voltage droop) Real load distribution between the generators (proportional to the ratings or nonuniform load distribution) Reactive load distribution (option)
Connection Chain
The connection chain is used to preselect which machine set will be the next to be started in the event of a request from the PMA 71 (overload, overcurrent etc.). This function may be carried out from any control panel.
The “START/STOP SEQUENCE” submenu is displayed by pressing “ENTER” twice and ↓ once on the control panel, as follows:
START/STOP
SEQUENCE INPUT
1. GEN.:
1/3 : 1 ————
Transfer number with “ENTER”
2. GEN.:
2/4 : 2
3. GEN.:
4/2 : 4
4. GEN.:
3/1 : 3
.
.
.
13. GEN.:
0/0 : 0
Cnfrm:
1 ———————
Transfer new Start/Stop
sequence using “ENTER”
The new start sequence is entered in the “INPUT” column. Each input must be confirmed using “ENTER”. The ↓↑ keys are used to jump from line to line.
The new sequence is accepted by entering a “1” in the “Cnfrm” line, and then by pressing “ENTER”. The new start/stop sequence is now shown in the “Start/Stop” column. Double inputs and incorrect inputs are rejected by the error message:
“NOT POSSIBLE TO CHANGE THE START/STOP SEQUENCE”
Stop as a Result of Underloading
Preconditions:
Automatic mode
Function is enabled
Machine set is not running in the “UBL mode”
General
A machine set is stopped in the event of underloading. This is done by comparing the generator real power with a limit value. There are three different limit values for parallel operation of 2, 3 and 4 or more machine sets. The limit values must be set such that the remaining load does not lead to a repeated request for a standby machine set.
Disconnection Sequence
The disconnection sequence is the opposite of the connection sequence. The connection sequence is preselected on the control panel (see connection chain). If a machine set is not ready to be disconnected on the basis of the disconnection sequence, for example because it is not ready or is not in the automatic mode, then the next in the sequence is disconnected.
If the start sequence is 1>2>3, then the stopping sequence is 3>2>1. The machine set that is the next to be stopped in the event of underloading is indicated as the “NEXT STOP” in the control panel.
Disconnection Process
In the event of underloading, the following message is output on the control panel after an adjustable delay time (standard time 30 seconds).
UNDERLOADING
A “Stop with load reduction” is carried out after an adjustable delay time of 10 minutes (standard) and the machine set is stopped. The following message appears on the control panel:
UNDERLOADING, MACHINE SET BEING STOPPED”
Once the stopping time has elapsed, the machine set is available once again.
Block Disconnection Chain
The stop as the result of underloading function can be blocked from the control panel. The following text is displayed in the second submenu:
The “ENABLE STOP SEQUENCE” submenu is displayed as follows by pressing “ENTER” twice on the control panel:
ENABLE DISCONNECTION CHAIN
DISCONNECTION CHAIN
Active
ACTIVE/DEACTIVE
1
The disconnection chain is enabled or inhibited by entering “1” or “0” as well as “ENTER”. If the disconnection chain is inhibited, then all the machine sets which are connected to the power supply system remain connected to it, even if underloading occurs in the on-board power supply system.
Standby Start as a Result of Overcurrent
The actual value of the three generator currents I L1 /I L2 /I L3 is passed from the generator protection device/measurement transducer to the PLC where the currents are monitored to determine whether they exceed three different limit values. If at least one of the currents exceeds a limit value, a standby machine set is requested once a delay time has elapsed. The limit values and times are staggered such that the limit value being exceeded to a minor extent results in a slow reaction, while the limit value being exceeded to a major extent results in a fast reaction.
The following message is displayed on the control panel:
“STANDBY-START”
(SM) or
The limit values and delay times can be changed via the control panel. The function is password-protected. The association between the individual functions and the limit values as well as the standard settings are shown in Table 7.8.
Standby Start as a Result of Overload
The actual value of the generator real power is passed from the generator protection device/measurement transducer to the PLC where the real power is monitored to determine whether it exceeds three different limit values. If a limit value is exceeded, a standby machine set is requested after a delay time has elapsed. The limit values and times are staggered such that the limit value being exceeded to a minor extent results in a slow reaction, while the limit value being exceeded to a major extent results in a fast reaction.
The following message is displayed on the control panel:
“STANDBY-START” (SM) or
The limit values and delay times can be changed via the control panel. The function is password-protected. The association between the individual functions and the limit values as well as the standard settings are shown in Table 7.8.
Standby Start as a Result of Underfrequency
The actual value of the power supply system frequency is passed from the generator protection device/measurement transducer to the PLC where the power supply system frequency is monitored to determine whether it exceeds three different limit values. If a limit value is exceeded, a standby machine set is requested after a delay time has elapsed. The limit values and times are staggered such that the limit value being exceeded to a minor extent results in a slow reaction, while the limit value being exceeded to a major extent results in a fast reaction.
However, the standby machine set is synchronized only for the first limit value (very minor discrepancy). In the other two cases, a standby machine set which has been run up is switched via “blackout”. (This function is explained in Section “Underfrequency/overfrequency”).
The following message is displayed on the control panel:
“STANDBY-START” (SM) or
The limit values and delay times can be changed via the control panel. The function is password-protected. The association between the individual functions and the limit values as well as the standard settings are shown in Table 7.8.
Real Load and Frequency Regulation
The signals from the frequency regulator and from the real power regulator are both passed to assessment stages. The outputs of the assessment stages are passed to a stepping regulator, which produces “higher” or “lower” pulses for the machine set speed regulator.
The load regulator factor is higher than the frequency regulator factor, so that the influence of the real power regulator is greater than that of the frequency regulator. Thus, load distribution is first of all carried out between the machine sets, and the frequency is regulated at the appropriate nominal value only after this has been done.
Real Load Regulation
Two different operating modes are possible:
Paritetic load distribution
Unbalanced load
Paretetic Load Distribution
In this operating mode, each generator produces power on the basis of its rated values.
Power
UBL mode
In this operating mode, a generator accepts as much load as possible (UBL max.) but not more than a selected maximum value. The other machine set accepts as little load as possible, but not less than a selected minimum value (UBL min.). The minimum value has a higher priority than the maximum value.
Frequency Regulation
Two different operating modes are possible:
Constant frequency regulation
Frequency regulation with frequency droop
Constant Frequency Regulation
In this operating mode, the power supply system frequency is regulated such that it is constant at the rated frequency.
Frequency Regulation with Droop
In this operating mode, the power supply system frequency is regulated in accordance with a curve. The curve is based on the generator power. The nominal values are in general selected such that the rated frequency (60 or 50 Hz) is achieved at 70 . . . 80% power. The no-load frequency is about 2 Hz higher.
The profile of the power supply system frequency in response to load changes in the power supply system (frequency regulation with droop) is shown in FIG. 3 .
Generator Switch Monitoring
Generator Switch “ON” Monitoring
The “On” acknowledgement from the generator switch is monitored. If the acknowledgement does not appear within a variable time after the “ON” command, then the SM
“GENERATOR SWITCH ON ACKNOWLEDGEMENT FAULTY”
is output.
Generator switch “OFF” monitoring
The “Off” acknowledgement from the generator switch is monitored. If the acknowledgement does not appear within a variable time after the “Off” command, then the SM
“GENERATOR SWITCH OFF ACKNOWLEDGEMENT FAULTY”
is output.
Generator Switch “ON/OFF” Monitoring
The “On” acknowledgements and the “Off” acknowledgements from the generator switch are monitored for plausibility. If neither acknowledgement appears or both are present, then, after a variable time, the SM
“GENERATOR SWITCH ON/OFF ACKNOWLEDGEMENT FAULTY”
is output.
Second Connection Command
In certain on-board power supply system conditions, it may be worthwhile connecting two new machine sets in the event of a fault. This can be selected in the event of:
Blackout
Shutdown of one machine set
In this situation, the faulty machine set outputs two connection commands.
If one of the machine sets that is to be connected has a start fault, a further connection command is output to a third machine set, if there is one.
Generator Protection and Synchronization Device GENOP 71
The generator protection and synchronization device GENOP 71 provides the generator protection, with the following functions:
Short-circuit detection Monitoring for overcurrent in each phase Monitoring for reverse power Disconnection of unimportant loads Automatic synchronization of the generator to the busbar Detection, processing and transfer of different measurement values via the Profibus
FIG. 4 shows the GENOP 71 connections. Genop integrated in the PMA 71 system. FIG. 5 shows the Genop 71 integrated in the PMA 71 system. The Genop and the Simatic-S7 communicate via the Profibus DP. The parameters for synchronization and generator protection can be changed via the control panel OP7.
See Section 13 for more information about control.
Genop 71 as an Individual Device
The Genop 71 may also be used as an individual device, as is shown in FIG. 6 . The parameters for synchronization and generator protection can be changed via a serial interface (RS 232).
Test of the Device
The device should be tested once a year for correct operation. If the generator controller is designed in accordance with the standard circuit diagrams, then there will be a test set for testing the generator protection.
The cable from the test set is plugged into the test plug. A lamp for each phase now illuminates on the test set. There is a fuse behind each of the lamps, providing protection for the test set.
A current of 1 A or 5 A can be preselected on the secondary side in each phase, and can be set on the rotary knob. The instrument is also switched in this process. The current can be read on the appropriate scale. The direction of the current is set on a second switch. In the “Normal” position, the current direction is simulated from the generator to the power supply system, and in the “Reverse” position, the current direction is simulated from the power supply system to the generator. The ammeter in the switchgear assembly also operates in this case when the changeover switch ammeter is switched to the correct position.
The tripping point for shedding the unimportant loads and for disconnection of the switch as a result of overcurrent can now be approached for each phase by increasing the current in each phase. When checking the power settings, care must be taken to ensure that the currents are increased uniformly in the individual phases, in order to avoid spurious tripping as a result of one current possibly having been set too high.
Configuration Via a PC
If the Genop is in the form of a single device, then the settings can be made by way of a PC. The connecting cable to the PC is plugged to the serial interface. The configuration program is started by clicking the mouse on the “Genop 71” icon. The standard menu is displayed.
Load
The stored setup of a Genop can be loaded in the configuration program. The loading process does not automatically result in the parameters being transferred to the Genop 71.
Save
Stores the currently edited data from the configuration program. If the data has not yet previously been stored, then a file name is asked for first of all. The extension is always “Gen”.
Save as
This allows a path and file name to be entered before storing a parameter record.
Transmit Data
Transmits all the parameter values set in the configuration program to the Genop 71.
Receive Data
Loads all the parameters that are currently in the Genop 71 into the configuration program.
Print
All the values contained in the configuration program are printed.
Exit
Ends after checking the configuration program.
Edit
Limit values + Delay times
Parameter
Meaning
Current 1
Generator current limit value: if the
limit value is exceeded, the
unimportant loads are disconnected
with a time delay in stages,
stages 1–3
Current 2
Generator current limit value:
(Not used)
Current 3
Generator current limit value: if the
limit value is exceeded, the
unimportant loads are disconnected
with a short time delay (1 s),
stages 1–3
Current 4
Generator current limit value: if the
limit value is exceeded, the
generator switch is disconnected with
a time delay (15 seconds, as
standard)
Reverse Power
Reverse power limit value: if the
limit value is exceeded, the
generator switch is disconnected with
a time delay (6 seconds as standard)
Short circuit
Short circuit: if exceeded, the
generator switch is disconnected with
a short time delay (0.2–0.6 seconds)
Delay Time 1
The delay time starts after the limit
(Current 1)
value “Current 1” has been exceeded,
and disconnects the unimportant
loads, stage 1, when the time has
elapsed
Delay Time 2
The delay time starts after the limit
(Current 1)
value “Current 1” has been exceeded,
and disconnects the unimportant
loads, stage 2, when the time has
elapsed
Delay Time 3
The delay time starts after the limit
(Current 1)
value “Current 1” has been exceeded,
and disconnects the unimportant
loads, stage 3, when the time has
elapsed
Delay Time 3.1
The delay time starts after the limit
(Current 3)
value “Current 3” has been exceeded,
and disconnects the unimportant
loads, stages 1–3, when the time has
elapsed
Delay Time 4
The delay time starts after the limit
(Current 4)
value “Delay Time 4” has been
exceeded, and switches off the
generator switch after the time has
elapsed
Delay Time 5
The delay time starts after the limit
(Reverse Power)
value “Delay Time 5” has been
exceeded, and switches off the
generator switch after the time has
elapsed
Delay Time 6
The delay time starts after the limit
(Short Circuit)
value “Delay Time 6” has been
exceeded, and switches off the
generator switch after the time has
elapsed
Internal Parameters
Parameter
Limits
Meaning
Sync.Short-Pulse
Short pulse length synchronization
Length
Short-Pulse Pulse
Factor for setting the ratio
Ratio
between the pulse-pause time of the
short pulses for synchronization.
If the setting is 100%, the
pulse/pause time is equal. If the
setting is 50%, the pause time is
50% of the pulse time
Sync.Long-Pulse
Long pulse length synchronization
Length
Long-Pulse Pulse
Factor for setting the ratio
Ratio
between the pulse/pause time of the
short pulses for synchronization.
If the setting is 100%, the
pulse/pause time is equal. If the
setting is 50%, the pause time is
50% of the pulse time
Frequ. Limit
Limit value switching from
Switching from
continuous to long pulse
Permanent to Long
Pulse Length
Frequ. Limit
Limit value switching from long
Switching from Long
pulse to short pulse
to Short Pulse
Length
Sync.Enable Limits
Parameter
Limits
Meaning
Sync.Diff.Frequency
Difference between generator and
Limit
power supply system frequency. If
the limit value is exceeded, then
the adjusting pulses are inhibited.
Sync.Diff.Voltage
Voltage difference between
Limit
generator voltage and power supply
system voltage. If the limit value
is exceeded, then the connection of
the generator switch and the output
of adjusted pulses are inhibited.
Sync.Connecting
Difference between generator and
Limit
power supply system frequency where
synchronization is in fact still
possible. If the limit value is
exceeded, then switching on the
generator switch is inhibited.
However, adjusting pulses are still
output for frequency adjustment
Pre-Switching Time
Calculated time between outputting
the generator switching-on command
and the zero crossing of the beat
voltage
Switch ON Pulse
Length of the generator switching-
Length
on pulse
U + I Transformation
Parameter
Meaning
Primary Voltage
Rated voltage of the power
Transformer
supply system
Primary Current
Rated voltage of the
Transformer
generator
Extras
Trigger Controlling
A Genop 71 must be connected for activation of this function. This menu allows the limit-value tripping operations for Current 1–4, reverse power and short circuit to be suppressed.
Generator Frequency
The generator frequency can be adjusted here by clicking the mouse.
Precondition:
The voltage difference (power supply system/generator) is less than the value set in the “Sync.Diff.Voltage Limit” The frequency difference (power supply system/generator) is less than the value set in the “Sync.Diff.Frequency Limit”.
PC Interface
The number of the serial interface (COM Ports 1–3) can be selected.
About GENOP 71
This menu item shows the version data of the parameter program and the firmware for the Genop 71 that is connected. The menus “Show Data”, “Control-Signals” and “Adjustments” are provided only for work at the manufacturer's premises.
Generator Protection
Overcurrent Time Protection
The three generator currents IL 1 , IL 2 , IL 3 are detected by measurement transducers. The extreme values of the three currents are monitored for limit values.
The following table shows the generator protection function:
Generator current
Relay
Limit
Delay
generator
value
I in
time
Relay
Relay
Relay
switch
(GW)
%
sec.
GW1
GW2
GW3
off
GW1
100
5
s
x
10
s
x
15
s
x
GW3
120
1
s
x
x
x
GW4
110
30
s
x
Reverse power
Relay
Delay
generator
Limit
P in
time
Relay
Relay
Relay
switch
value
%
sec.
GW1
GW2
GW3
off
GW5
0–100
6
s
x
Short circuit
Relay
Delay
generator
Limit
time
Relay
Relay
Relay
switch
value
I in %
sec.
GW1
GW2
GW3
off
GW6
>300
0.1–1.5
s
x
FIG. 7 shows the functional relationship for generator protection.
FIG. 8 shows the functional relationship for disturbance evaluation.
The disturbance message signals which occur for generator protection are maintained until they are acknowledged by the high-level control system, or are canceled by a RESET. The failure of the 24V battery voltage or a defect in the computer results in unavoidable signaling by tripping of the “System Defect” relay.
Synchronization
Frequency Adjustment
Once the machine set has been started, the power supply system frequency is approached first of all with continuous adjustment commands, followed by long and short pulses. The comparison as to whether the power supply system frequency is greater than or less than the generator frequency is carried out in the GENOP 71 generator protection and synchronization device.
If f generator is <f power supply system, the signal “1” appears at the “HIGHER” output. If f generator is >f power supply system, the signal “1” appears at the “LOWER” output. The length of the HIGHER/LOWER adjusting pulses can be changed on the control panel.
Beat Voltage Detection and Evaluation
The beat voltage which is obtained from the synchronization device is evaluated for synchronization of the generator switch. The beat voltage is produced by comparing the power supply system voltage and the generator voltage. The gradient of the beat voltage changes in a corresponding manner to the difference between the generator frequency and the power supply system frequency. The gradient of the beat voltage curve as obtained from the measured values is evaluated, and the switch-on command is produced with the appropriate lead.
Lead
The lead time (time between the switch-on command and the closing of the generator switch) can be set on the control panel, on the basis of the generator switch data.
The following table shows the permissible lead times in the ratio of the generator frequency to the busbar frequency.
Generator/busbar
Lead time max.
n difference frequency [HZ]
[ms]
0.2
456
0.3
276
0.4
192
0.5
204
0.6
146
0.7
128
0.8
88
0.9
60
1.0
58
Difference Frequency
The difference frequency between the power supply system frequency and the generator frequency is likewise derived from the beat voltage. If the difference frequency is >0.5 Hz, synchronization is inhibited. If the difference frequency is >10 Hz, the HIGHER/LOWER adjusting pulses are inhibited entirely, since this indicates that a machine set fault must be present.
Frequency Tuning
If the generator frequency is made very close to the power supply system frequency by way of a tuning command, so that continuous beating occurs (power supply system frequency and generator frequency are the same), then this results in an adjusting pulse and a greater Delta-f is produced in order to allow rapid synchronization. This is done by evaluating the beat frequency zero crossings. If no zero crossing occurs in the beat frequency within a specific time, another adjusting pulse is produced.
Automatic synchronization/synchronization in the local semiautomatic mode and synchronization in the manual mode are described in Section 4.
Adjustable Values for Synchronization
Some values for synchronization can be adjusted via the OP7. If the generator protection device/measurement transducer GENOP 71 is used on its own, these values can be set via a PC program.
The following values can be set.
Limit value for the difference frequency for enabling the adjusting pulses (for example 10 Hz) Limit value for the difference frequency for switching from continuous pulse to long pulse (for example 1.5 Hz) Limit value for the difference frequency for switching from long pulse to short pulse (for example 0.6 Hz) Limit value for the difference frequency for switching the generator switch at a zero crossing (for example 0.5 Hz) Pulse length of the short pulses Pulse length of the long pulses Lead time to reach the zero crossing of the beat voltage (switch-on time for the generator switch) Pulse length of the switch-on command for the generator switch Trip delay time for initiating frequency tuning Pulse length of the “Higher/Lower” pulses for frequency tuning Limit value for the difference between the generator voltage and the power supply system voltage for inhibiting the adjustment process and connection of the generator switch
Voltage Difference Monitoring
The connection of the generator switch is blocked if the voltage difference is too great. If the voltage difference is greater than the limit value which can be selected, then the connection of the generator switch and the outputting of the adjusting pulses are inhibited. The fact that the limit value has been exceeded is signaled by an LED on the front face of the device.
Optionally, a voltage regulator can be provided in the Simatic-S7, which outputs higher/lower adjusting pulses to the voltage regulator for the generator.
FIG. 9 shows the functional procedures for synchronization
Meaning of the parameters:
BR_ON
Switch ON signal
SYN_EN
Enable synchronization
AUT_EN
Automatic mode
F_HIGHER
Frequency adjusting pulse, higher
F_LOWER
Frequency adjusting pulse, lower
FIG. 10 shows the principle of synchronization.
24V DC/24V DC Isolating Transformer
Object
The 24V DC/24V DC isolating transformer has the following functions:
1.) The connected components can be operated over a wider frequency range than is possible on the basis of the technical data for the individual components. 2.) The connected components are DC-decoupled from the marine vessel battery. The 24V DC supply voltage can be grounded downstream from the isolating transformer, and this has major advantages for disturbance protection.
The following components are fed from the power supply:
The SIMATIC S7 associated with the machine set All the signal sensors which are associated with the machine set and the control system The digital outputs from the SIMATIC S7 (operation of lamps or coupling relays) The generator protection device/measurement transducer The OP7 control panel
The power supply for the generator protection device/measurement transducer is designed in a redundant manner, that is to say in addition to the feed from the isolating transformer (and thus from the higher-level battery power supply), this device has a feed from a power supply unit, which is fed from the respective generator.
The voltage supply for the undervoltage coil for the generator switch as well as the delay time is not included in the PMA 71 but must be installed in the switch panel.
Mechanical design:
The 24V DC/24V DC isolating transformer is mounted on the mounting plate by way of a number of screws. It may be mounted horizontally or vertically. Input and output voltage are connected via Faston pins.
FIG. 11 shows the standard OP7 control panel (BT).
The invention being thus described, it will be obvious that the same may be varied in many ways. Such variations are not to be regarded as a departure from the spirit and scope of the invention, and all such modifications as would be obvious to one skilled in the art are intended to be included within the scope of the following claims.
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The invention relates to an electrical system for a ship, comprising generators, electrical consumers, such as electric motors, and an on-board power supply system with switchgears etc. as the components of the system. The electrical system is further characterized in that supplies sufficient electrical energy in all operating states of the ship and that the system components are automatically controlled by digitized standard modules.
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BACKGROUND OF THE INVENTION
1. Technical Field
The present invention relates to a method of manufacturing a GRIN lens using a sol-gel process, and a GRIN lens that can be manufactured by the manufacturing method.
2. Background Art
Optical fiber collimators, each including a GRIN lens (Graded Index Lens) fusion-spliced with an end of an optical fiber, can connect semiconductor lasers to optical fibers with high efficiency and can be used as connectors with low coupling loss, or the like, thus being useful as various optical communication parts.
As a method for manufacturing such a GRIN lens, an ion-exchange process, a vapor phase CVD process, or the like is known. A sol-gel process based on low-temperature synthesis is considered to be excellent. For example, Patent Documents 1 to 3 described below each disclose a method for manufacturing a GRIN lens using a sol-gel process. In the method, an acid or base as a solvent is added to an alcohol solution containing a silicon alkoxide (Si(OR) 4 (R: alkyl group)) as a main component, hydrolysis is performed to form a sol, and the sol is further subjected to polycondensation, followed by aging, to generate a crosslinking reaction, thereby forming a wet gel. In the production of a GRIN lens, it is necessary to form a concentration distribution in a dopant (i.e., metal component that provides a refractive index distribution). In a portion having a higher concentration of the dopant, the refractive index is higher. Consequently, the GRIN lens is produced such that the central portion has a high concentration of the dopant, and the concentration decreases toward the outer surface. In one method, a metal alkoxide or a metal salt is used as a material for the dopant. Furthermore, a molecular stuffing technique may be used. In particular, use of an alkoxide of Ti, Ta, Sb, or Zr is significantly useful. In order to form a concentration distribution, leaching is generally performed. In the leaching, a wet gel is immersed in an acid solution, and the dopant in the peripheral portion is dissolved away, thus providing a concentration distribution. The resulting wet gel is dried, the solvent in the gel is removed, and then firing is performed to produce a cylindrical, dense glass preform provided with a refractive index distribution. The resulting glass preform is subjected to wire-drawing to reduce its diameter, and thereby, a GRIN lens is produced.
Furthermore, Patent Document 3 described below discloses a technique in which, in the formation of a wet gel, a mixture of a titanium alkoxide and an aluminum alkoxide is added to an alcohol solution containing a silicon alkoxide as a main component to form a wet gel containing aluminum.
Patent Document 1: Japanese Unexamined Patent Application Publication No. 2005-115097
Patent Document 2: Japanese Unexamined Patent Application Publication No. 2005-145751
Patent Document 3: Japanese Unexamined Patent Application Publication No. 6-122530
In a conventional general sol-gel process, a preform is formed using two components, i.e., silicon and a dopant (for example, when the dopant is Ti, SiO 2 —TiO 2 ).
In the production of a preform and a lens obtained by wire-drawing the preform, in the case where the dopant concentration is about 10 mole percent, the preform is easily broken during sintering, and the yield in the sintering process is significantly low, which is a problem. Furthermore, in the case where the dopant concentration is 10 mole percent or more, the viscosity at the temperature at which wire-drawing is performed is low, and it becomes difficult to operate, thus decreasing the yield, which is also a problem.
Furthermore, in a GRIN lens having a high numerical aperture with a dopant concentration of 18 mole percent or more, a marked phase separation occurs in the preform during sintering, and it is difficult to obtain a transparent GRIN lens.
One of the means for overcoming such problems is a method in which the composition of the preform is changed from two components to three or more components. In Patent Document 3 described above, aluminum, boron, or germanium is added as a third component. However, many components suitable as the third component are susceptible to acids. Even when an alkoxide is added to a wet gel, most of the alkoxide added is dissolved away by an acid for leaching, and it is difficult to allow an effective amount of the alkoxide to remain in the glass preform.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method for manufacturing a GRIN lens using a sol-gel process, in which breaking and phase separation of a preform are prevented during sintering of a dry gel, and the viscosity of a glass during wire-drawing is increased so that the wire-drawing operation is facilitated and the yield is improved.
A method for manufacturing a GRIN lens according to the present invention is characterized by including a step of forming a wet gel from an alcohol solution containing, as main components, a silicon alkoxide, a dopant alkoxide, and an aluminum alkoxide, a step of dissolving by leaching the dopant and aluminum away from the outer peripheral surface of the wet gel to provide a refractive index distribution, a step of forming a dry gel by drying the wet gel, a step of forming a glass preform by firing the dry gel, and a step of wire-drawing the preform. In the step of forming the wet gel, the alcohol solution is prepared by first forming an alcohol solution containing the silicon alkoxide and the aluminum alkoxide as main components, and then mixing the dopant alkoxide thereto.
In the process of forming the wet gel, preferably, the alkoxides as starting materials are added in the order of the silicon alkoxide, the aluminum alkoxide, and the dopant alkoxide. When the aluminum alkoxide and the dopant alkoxide are added to the silicon alkoxide, if the aluminum alkoxide and the dopant alkoxide are simultaneously added, or if the aluminum alkoxide is added after the dopant alkoxide is added, the dopant alkoxide having a higher reaction rate is preferentially bonded to the silicon alkoxide, and the aluminum alkoxide hardly contributes to the crosslinking structure of the gel or can only be weakly bonded in the crosslinking structure. When leaching is performed, aluminum is easily dissolved away from such a wet gel by an acid. As a result, it is not possible to allow aluminum with a significant concentration to remain in the glass. Consequently, this point is important in particular in the case where aluminum is added for the purpose of suppressing phase separation.
In the step of forming the wet gel, the amount of the aluminum alkoxide added is preferably set so that the concentration of elemental aluminum is 2 to 20 mole percent on the basis of (elemental silicon+elemental dopant+elemental aluminum).
If the amount is less than 2 mole percent, the amount of aluminum remaining in the glass perform decreases, and the effect of preventing breaking and the effect of suppressing phase separation during sintering are decreased.
If the amount exceeds 20 mole percent, gelation may occur during preparation of the sol (in the stage where alkoxides or alcohols are being mixed), and there may be a possibility that a wet gel cannot be formed.
In the present invention, the dopant may be one or two or more selected from the group consisting of Ti, Ta, Sb, and Zr. These metals are highly capable of increasing the refractive index, have a coefficient of thermal expansion close to that of silica glass, and alkoxides thereof easily dissolve in an alcohol, thus being excellent as a dopant of the present invention. Furthermore, Sb tends to evaporate in the sintering process of the gel, and Zr precipitates in the process of forming the wet gel, although in a small amount, in an alcohol which is a solvent, thus being unstable in terms of the process. Consequently, Ti and Ta are most desirable as the dopant.
A GRIN lens according to the present invention is characterized by including a silicon oxide, a dopant oxide, and an aluminum oxide, wherein the concentration of elemental aluminum (aluminum content) is 0.04 mole percent or more on the basis of (elemental silicon+elemental dopant+elemental aluminum).
In the method for manufacturing a GRIN lens according to the present invention, aluminum is suppressed from being dissolved away in the leaching step, and it is possible to obtain a glass preform containing a significant amount of aluminum. Since breaking and phase separation of glass during sintering can be suppressed by aluminum, a transparent glass preform can be obtained with high yield. Furthermore, since the viscosity of glass during wire-drawing is controlled so that operation is facilitated, the yield is greatly improved in the production of the GRIN lens. In order to suppress the breaking of the preform and in order to sufficiently suppress the phase separation, preferably aluminum remains in an amount of 0.04 mole percent or more in terms of elemental aluminum.
In the GRIN lens of the present invention, because of the aluminum remaining in the interior thereof, the effects described below are achieved.
(1) Facilitation of Wire-Drawing Operation Due to Increase in Viscosity.
The viscosity of glass is increased by the aluminum slightly remaining in the glass preform. Therefore, it is possible to reach the proper state (a state in which wire-drawing can be performed stably to achieve a desired thickness) easily and in a short period of time from the start of the wire-drawing operation, the amount of yield increases, and the yield in the wire-drawing process is improved.
(2) Suppression of Breaking During Sintering.
The amount of breaking of the preform during sintering is decreased to almost zero by the aluminum slightly remaining in the glass preform, and the yield is greatly improved in the sintering process. Although the reason for this is not entirely clear at the present time, it is assumed that, by the action of the aluminum, differences in the shrinkage ratio and thermal expansion ratio between the outer portion and the central portion of the preform are reduced.
(3) Suppression of Phase Separation During Sintering
When a GRIN lens having a high numerical aperture with a dopant concentration in the wet gel exceeding 18 mole percent is produced, the glass preform becomes cloudy due to phase separation. As a result, it is not possible to obtain a transparent GRIN lens. By incorporating aluminum, phase separation is suppressed, and it is possible to obtain a colorless and transparent GRIN lens having a high numerical aperture with high yield.
In the GRIN lens of the present invention, because of the incorporation of aluminum, the steps of sintering and wire-drawing can be carried out with high yield. Furthermore, since the phase separation is suppressed, it is possible to have a product which has a high numerical aperture, which is colorless, and which has high light transmission. Consequently, it is possible to produce a GRIN lens having a very high numerical aperture with a dopant concentration in the wet gel exceeding 18 mole percent, which was conventionally impossible to achieve.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a graph illustrating the tendency of viscosity with respect to preforms prepared in different orders of addition of aluminum alkoxide.
DETAILED DESCRIPTION OF THE INVENTION
Example 1
Case of Slightly High Numerical Aperture (Titanium Concentration 10% and Aluminum 5% in the Preparation of Wet Gel)
To a mixed solution of 43.13 g of tetramethoxysilane (TMOS), 26.11 g of ethanol, and 6.09 g of dimethylformamide (DMF), 5.21 g of a 0.54 mol/l hydrochloric acid was added, followed by mixing. Then, 5.04 g of an aluminum chelate (aluminum disecondary butoxide acetoacetic ester chelate), 7.68 g of ethanol, and 6.09 g of DMF were added to the mixture, and further 11.35 g of titanium tetra-n-butoxide, 15.36 g of ethanol, and 12.18 g of DMF were added thereto. Furthermore, stirring was performed while gradually adding 18.62 g of ethanol and 18.04 g of pure water. Thereby, a wet gel including 85 mole percent of silicon, 10 mole percent of titanium, and 5 mole percent of aluminum was obtained. The resulting wet gel was aged at 60° C. for 6 days.
Subsequently, the wet gel was immersed in a 1.5 mol/l hydrochloric acid for 16 hours, and leaching was performed in which titanium and aluminum were dissolved away from the peripheral portion to impart a titanium concentration distribution to the gel.
Subsequently, the wet gel was dried at 70° C. for 4 days and at 120° C. for 3 days. Thereby, a dry gel with a diameter of about 7 mm was obtained.
The resulting dry gel was heated from room temperature to 550° C. in an oxygen atmosphere at 9° C./hr, and then to 1,250° C. in a helium atmosphere at 7° C./hr to perform firing. Thereby, a transparent glass preform was obtained. In the firing step, no breaking or foaming occurred in the glass preform, and the yield was 100%.
The cylindrical glass preform was wire-drawn to a GRIN lens with a diameter of 125 μm. In the wire-drawing step, no foaming was observed, and it was possible to obtain a transparent GRIN lens with a yield of 100%.
Additionally, in the case where a conventional production method is used in which aluminum is not incorporated, the yield in the firing process is about 30% due to breaking.
Example 2
Case of High Numerical Aperture (Titanium Concentration 20% and Aluminum 5% in the Preparation of Wet Gel
To a mixed solution of 38.06 g of tetramethoxysilane (TMOS), 17.28 g of ethanol, and 6.09 g of dimethylformamide (DMF), 4.513 g of a 0.06 mol/l hydrochloric acid was added, followed by stirring. Then, a mixed solution of 5.04 g of aluminum chelate, 9.21 g of ethanol, and 6.09 g of DMF was added thereto, and a mixed solution of 22.69 g of titanium tetra-n-butoxide, 23.03 g of ethanol, and 12.18 g of DMF was added thereto. Furthermore, stirring was performed while gradually adding 19.58 g of ethanol and 19.22 g of pure water. Thereby, a wet gel including 75 mole percent of silicon, 20 mole percent of titanium, and 5 mole percent of aluminum was obtained. The resulting wet gel was aged at 60° C. for 20 days.
Subsequently, the wet gel was immersed in a 3 mol/l hydrochloric acid for 4.5 hours, and leaching was performed in which titanium and aluminum were dissolved away from the peripheral portion to impart a titanium concentration distribution to the gel.
Subsequently, the wet gel was dried at 70° C. for 4 days and at 120° C. for 3 days. Thereby, a dry gel with a diameter of about 7 mm was obtained.
The resulting dry gel was heated from room temperature to 550° C. in an oxygen atmosphere at 9° C./hr, and then to 1,250° C. in a helium atmosphere at 7° C./hr to perform firing. Thereby, a transparent glass preform was obtained. In the firing step, no breaking or foaming occurred in the glass preform, and the yield was 100%. The glass preform had a square distribution, in which the concentration of titanium was 18 mole percent in the central portion and 3 mole percent in the peripheral portion, and the concentration of aluminum was 0.1 mole percent in the central portion and 0.05 mole percent on an average.
The cylindrical glass preform was wire-drawn to a GRIN lens with a diameter of 125 μm. As a result, a transparent GRIN lens was obtained, and its numerical aperture NA was 0.55.
Furthermore, the time required in which the preform was softened in a wire-drawing furnace and fell a certain distance under its own weight was about 60 seconds, which indicated a viscosity suitable for operation.
Comparative Example
When a glass preform was produced by a conventional production method in which alkoxides were added in an arbitrary order, the amount of the aluminum oxide remaining in the glass preform was less than 0.01 mole percent on an average. In the glass preform, a significant phase separation occurred, and, in addition, the time required in which the preform was softened in a wire-drawing furnace and fell was less than 5 seconds. That is, the viscosity was low, thus being inoperable. Therefore, it is not possible to manufacture a product that can be used as a GRIN lens.
FIG. 1 shows a change in viscosity with respect to the order of addition of aluminum alkoxide in preforms obtained from a dry gel with a titanium concentration of 20 mole percent and an aluminum concentration of 5 mole percent shown in Example 2. In the graph, the checkered bar shows the case described in Comparative Example where aluminum was not added, the white bar shows the case where the aluminum alkoxide and the titanium alkoxide were added simultaneously, the gray bar shows the case where the aluminum alkoxide was added slightly before the addition of the titanium alkoxide, and the black bar shows the case where the aluminum alkoxide was added well before the addition of the titanium alkoxide. The viscosity was evaluated by measuring the fall time in which, under a common downward load, a sample was softened at the wire-drawing temperature and fell a certain distance. As is evident from the graph, the viscosity varies depending on the procedure used for addition of aluminum.
In the method for manufacturing a GRIN lens according to the present invention, in the step of forming the wet gel, other additives may be added. For example, it may be possible to add acetylacetone as a stabilizer for titanium so that the titanium alkoxide is suppressed from being crystallized during preparation of the sol. Furthermore, a phosphorus alkoxide, a boron alkoxide, or the like may be added. By adding additives, such as boron and phosphorus, the thermal expansion ratio of the glass, the shrinkage ratio during sintering, the phase separation region in the glass, the softening point, etc. can be controlled to a certain extent.
The GRIN lens of the present invention may include, in addition to the silicon oxide, the dopant oxide, and the aluminum oxide, small amounts of other oxides. For example, if a phosphorus alkoxide, a boron alkoxide, or the like is added in the step of forming the wet gel, although boron, phosphorus, or the like is dissolved away in the leaching step, it is possible to obtain a GRIN lens containing a small amount of boron, phosphorus, or the like.
In the present invention, the silicon alkoxide, the dopant alkoxide, and the aluminum alkoxide are not limited to those described in Examples, and other alkoxides may be used.
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The manufacture of a GRIN lens using a sol-gel process includes forming a wet gel from an alcohol solution containing a silicon alkoxide, a dopant alkoxide, and an aluminum alkoxide, first, an alcohol solution containing the silicon alkoxide and the aluminum alkoxide as is prepared, and then the dopant alkoxide is mixed thereto.
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This is a continuation of application Ser. No. 254,477, filed Sept. 21, 1988, now abandoned.
BACKGROUND OF THE INVENTION
The invention relates to an apparatus for treating skins or hides with liquids in so-called wet processes, e.g. liming, drenching, tanning, dyeing or the like, comprising a liquid-impermeable substrate inflexibly receiving the hide and a treatment device substantially tightly applicable to the top of the hIde by means of which the treatment liquid penetrates the skin under high pressure.
In leather processing the term wet processes is used for the treatment stages in which the skin or hide is treated with dissolved chemicals and where there is a high liquid requirement This includes the soaking of the skin, liming in a strong alkaline solution, deliming (neutralizing) in an acid solution, drenching, e.g. by means of proteolytic enzymes, pickling by means of acids and salts, tanning, e.g. by means of chromium-lII-salts, retanning and dubbing the hide, as well as dyeing. Most of these wet processes in conventional tanneries take place in vat-like containers, accompanied by multiple circulation and for varyingly long action times, large liquid quantities being required and are constantly circulated.
These tannery wet processes are technically unsatisfactory for several reasons. The hide must pass through a plurality of process stages, which in part take place batchwise with a hide weight of up to 20 tons, but in part in individual form. This requires several times the dividing up of the batches, individualizing and orientation of the hides, e g. alignment or orientation on the basis of the head and butt, which is correspondingly time and labour-consuming. Large hides or skins can have a surface area up to 6 m 2 and can weigh up to 100 kg, as a function of the water content. As transportation must take place manually over considerable distances within the tannery, a correspondingly large labour requirement exists. As a result of the corrosive chemicals and the organic substance emanating from the hide, it is scarcely possible to bringabout hygienic working conditions for personnel. There is in particular the problem of getting rid of large waste water quantities, particularly as the treatment liquids can only be reused to a very limited extent.
Dyeing processes have been improved somewhat (German patent 822 060), in that the hides are placed on a belt and led part a dye spraying device, which makes it possible to at least reduce the difficulties during the handling of the hide. However, here again, the need for dyeing liquid is considerable, because it is sprayed at a distance onto the hide, so that a large amount of dyeing liquid does not reach the hide and consequently a considerable action time is required to ensure that the dyeing liquid penetrates the hide. In this way, thorough dyeing is either impossible, or requires a considerable amount of time. In the other aforementioned wet processes, the treatment liquid must intensely and completely penetrate the hide, so that it must be in constant contact with the treatment liquid for a long time. In order that in said wet processes it is possible to have a planned working with minimum liquid requirement, it has been proposed (EP-OS 0 009 081), to introduce the treatment liquid into the skin under high pressure in the manner of an injection process.
In this injection process it is possible to work with highly concentrated treatment liquids, so that the water requirement is much lower than in conventional tannery processes. Only a comparatively small treatment liquid excess has to be used, which must merely ensure that the entire thickness of the hide is penetrated by the treatment liquid. This process is carried out by means of injection nozzles similar to injection guns, which can be placed on the hide and by means of which the treatment liquid can be forced under a high pressure of more than 50 bar into the hide. Within the actual hide, the treatment liquid is spread out in roughly circular manner over a somewhat larger area. In order to treat a hide in this way, a large number of such injection nozzles is required. Tests over many years with this process have not led to satisfactory results. There are many reasons for this. Thus, difficulties are encountered in injecting the treatment liquid in uniform manner over the entire skin surface and cross-section. Thus, besides thoroughly tanned areas, there are inadequately tanned areas. The different thickness of the hide also leads to problems. The treatment liquid pressure level must be designed for the greatest hide thicknesses, i.e. for example in the neck and back regions, so that in the thin skin regions the treatment liquid is shot through the skin and cannot therefore have its desired action. Finally, skin damage can occur as a result of the high pressures, particularly in the vicinity of the injection nozzle attachment. Thus, this process only permits a waste-free operation from the flesh side of the hide. However, even here the hide must be left for a certain time to enable the treatment liquid forced in in jet-like manner to completely penetrate. This lateral penetration then varies very considerably as a function of the hide thickness.
It is finally impossible with acceptable equipment and general costs to treat a complete hide in a single operation. Thus, in the aforementioned apparatus (EP-OS 0 009 081), the hide is moved in synchronized manner passed two successively arranged and reciprocally displaced nozzle rows, so that it is only zonally treated. The injection pressure is absorbed by the inflexible support, which presses -he hide against the injection nozzles.
The problem of the present invention is to so improve the aforementioned apparatus that, with reduced operating pressure, a uniform penetration of the treatment liquids into the skin or hide is ensured.
According to the invention this problem is solved in that the treatment device has several liquid supply ducts arranged approximately perpendicular to the substrate and which on the underside of the device facing the hide are widened in large-area manner and are arranged in surface-filling manner thereon and that between the underside of the device and the hide is provided a net-like support and the gap between the substrate, hide, support and treatment device is substantially tightly sealable with respect to the outside. In the inventive apparatus, in the vicinity of their opening, the supply ducts have a comparatively large-area extended or widened portion of e.g. several cm 2 , said widened portions having a geometrical contour and an arrangement such that they are closely linked with one another and cover a large-surface area. In order that the treatment liquid entering the widened portions through the supply ducts is injected into the skin in uniform manner over the widened portion cross-section, the net-like support is provided on the hide, which on the one hand levels the hide somewhat in said area and on the other ensures a punctiform penetration of the treatment liquid over a large cross-section. In order to avoid a pressure drop to the outside the gap provided between the substrate, the hide, the support and the treatment device is tightly sealable to the outside. This is generally made possible in that the parts are moved correspondingly tight together, without separate edge-side seals being required.
Practical tests with the aforementioned apparatus have revealed a number of advantages. Thus, it is possible to work with much lower pressures than proposed by the prior art. An adequate, large-area penetration is ensured at a pressure of about 10 bar. As a result and through the large-area action, skin or hide damage is completely prevented. As a function of the nature of the wet process, the treatment liquids can be injected from the flesh or grain side. The treatment device can also have a large area, so that a complete hide can be treated in a single operation, so that the action time and overall treatment period can be considerably reduced. Due to the large-area action of the treatment liquid and the lower operating pressure, it is ensured that the treatment liquid effectively penetrates independently of the hide thickness and is distributed throughout the hide. "Shooting through" cannot occur, particularly in thin hide areas. This is also aided by the fact that, unlike in high pressure injection nozzles, the low pressure of approximately 10 bar can be maintained for a longer period in the widened portions and therefore on the hide
The large-area widened portions of the supply ducts on the underside of the treatment device can have a polygonal or circular contour, in whose centre issues at least one supply duct in each case. The widened portions can e.g. have a contour in the form of equilateral triangles, squares, polygons or circles.
As is known per se, also in the case of the inventive apparatus it is possible to provide a net-like intermediate layer between the hide and the substrate, to permit the draining off of the treatment liquids penetrating the hide. However, as such an intermediate layer would be too flexible in order to receive and withstand the treatment pressure at the other side, it is also necessary to provide an inflexible substrate, which then has several juxtaposed drains for the treatment liquid penetrating the skin. The excess treatment liquid penetrating the skin or hide consequently passes through the fine-mesh intermediate layer to the inflexible substrate, where it is led away through the drains.
In a preferred embodiment of the invention the net-like support and intermediate layer are formed by a fine-mesh plastic or metal net, which on the one hand has the necessary flexibility for adapting to unevenesses of the hide and on the other hand has the necessary strength to resist the operating pressure, without the mesh width changing under the action of the operating pressure. It is admittedly known (German patent 822 060) to use metal nets as a substrate for hides, in order to permit a draining of the treatment liquid (dyeing liquid), whilst it is also known to use such metal nets during the pressing of water out of the hides. However, in the present invention the metal net fulfils another function, namely in that it forms a support for the hide, which uniformly distributes the treatment liquid supplied from the outside and allows it to penetrate the hide in punctiform manner.
According to another embodiment the underside of the treatment device or the widened or extended portions arranged there in surface-filling manner can, in one extension direction, have an extension corresponding to the hide width or length. In this case the treatment liquids are injected stripwise into the skin, which is in turn moved intermittently through the apparatus.
However, according to a preferred embodiment, the underside of the treatment device or the extended portions of the supply ducts arranged there in surface-filling manner cover a surface roughly corresponding to the surface of a hide. This embodiment makes it possible to treat a complete hide in one operation, so that a high throughput can be achieved.
According to another embodiment the support and intermediate layer receiving the hide between them are constructed as conveyor belts. Thus, the hide can be placed between the two conveyor belts and conveyed between them into the apparatus, so that the necessary manual activities for the complete treatment are restricted to placing the hide on the entry to the conveyor belts and removing the hide at the exit therefrom. Optionally the hide can be ejected at the exit from the conveyor belts.
According to another development of the invention the substrate is constructed as a table and can be raised against the treatment device. In this case the skin is introduced by means of the metal nets constructed as conveyor belts between the substrate and the treatment device, the table is then raised against the latter, accompanied by the simultaneous pressing of intermediate layer, hide and support against the treatment device and accompanied by tight sealing against the outside, after which the treatment liquid can be supplied by means of the supply ducts.
Another embodiment is inventively characterized in that the substrate is constructed as a revolving link belt, between whose links the treatment liquid can drain off. In this case the link belt forms an adequately inflexible support for the hide, which is here again conveyed between the fine-mesh intermediate layer and a support.
In this embodiment, the link belt can be guided in trough-like manner in the vicinity of the treatment device and the underside of the latter can be curved so as to fill the trough. In this embodiment the hide is conveyed between the support and the intermediate layer into the trough between the treatment device and the link belt and can be treated intermittently, or advantageously continuously.
In the case of a continuous treatment, it is appropriate if the treatment device is constructed as a revolving cylinder, on whose circumference are arranged the widened portions of the supply ducts, which are controllable in their opening position only in the vicinity of the trough. In this embodiment with a treatment device concomitantly rotating with the link belt, there is no relative movement between the hide and the treatment device, i.e. despite the continuous operation, it is ensured that the widened portions on the underside of the treatment device always remain in the same relative position with respect to the hide, so that the action time of the treatment liquid is exclusively controllable by the conveying speed through the trough gap. In this way, movement through the treatment device can take place with juxtaposed hides.
According to another development of the invention with the fine-mesh support and intermediate layer is associated outside the treatment device at least one cleaning device, e.g. a spraying device, by means of which it is possible to eliminate any contaminants or dirt which has deposited between the meshes and which come from the skin. The spraying device can be operated with compressed water or air. This ensures that in particular the fine-mesh support has free mesh cross-sections prior to each entry into the apparatus, so as to permit a completely satisfactory distribution of the treatment liquids.
The inventive apparatus is also characterized by a collecting container penetrating the hide and receiving excess treatment liquid and from which the latter can be recirculated. As the inventive apparatus gives the possibility to work with highly concentrated treatment liquids and during the actual treatment said liquids undergo no or only minimum changes to their composition, the excess treatment liquid can be reused. Optionally a purely mechanical treatment, e.g. the filtering of the treatment liquid is sufficient, to enable it to be resupplied to the treatment device. It is only necessary to quantitatively compensate the losses resulting from the penetration of the hide, Large waste water quantities are not produced, because it is only necessary to eliminate that treatment liquid, which can no longer be reused for chemical and/or physical reasons. This is constituted by extremely small quantities with known constituents, which can easily be dealt with by the waste disposal system.
According to another advantageous development with the treatment device is associated a large-volume pressure vessel for the treatment liquids, which on the one hand is provided with the collecting container and on the other with a feedline for the fresh treatment liquid. By means of the pressure vessel, e.g. an air chamber, an identical pressure can be maintained in easy manner for all the supply ducts. The pressure vessel is on the one hand supplied from the collecting container with the recirculated treatment liquid and on the other hand, for compensating the liquid remaining in the skin and any other liquid which may be lost, with fresh treatment liquid. Instead the treatment device can be directly supplied by pumps.
It is finally appropriate if chemical-physical sensors are arranged in the collecting container or pressure vessel enabling the feedline to be controlled for fresh treatment liquid in order to maintain given concentrations in the pressure vessel. This makes it possible to achieve a completely automated sequence of wet processes in the tannery.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is described in greater detail hereinafter relative to embodiments and the attached drawings, show:
FIG. 1 is a diagrammatic view of a first embodiment of the apparatus.
FIG. 2 is a broken away, larger-scale partial view of the treatment device and substrate,;
FIGS. 3a-3d are views of the different embodiments of the widened portions of the supply ducts and their reciprocal arrangement,;
FIG. 4 a diagrammatic view of a second embodiment of the apparatus,;
FIG. 5 is a diagrammatic flow chart of a supply device for the treatment device.
DETAILED DESCRIPTION
The apparatus according to FIG. 1 has as its essential components a substrate generally designated by the reference numeral 1 and a treatment device generally designated by the reference numeral 2 located above it, whereby the substrate 1 is constructed as a type of table 3 in a rigid, inflexible form. The top of the table 3 has several drains 4 for the treatment liquid.
The treatment device 2 comprises a pressure tight casing 5 with a central supply duct 6 and several supply ducts 7 connected thereto, which are approximately at right angles to the surface of table 3 and are successively arranged in juxtaposed manner in parallel rows. The supplied ducts are connected by a distribution line 8 to the central supply line 6 equipped with a valve 9 for closing or blocking off the entire treatment device 2. In addition, each individual supply duct 7 has a shutoff valve 10 and the supply ducts 7 issue into widened or extended portions 11, which have a large area compared with the duct cross-section and which are positioned open on the underside 12 of treatment device 2.
As can in particular be gathered from FIG. 2, the valves 10 in supply ducts 7 can be differently constructed, e.g. they can be mechanically operated piston-type valves 13, as shown in the central construction, or can be electromagnetic valves 13a. In place of the valves 10, each supply duct 7 need only have a single diaphragm 13 s and then only the central shutoff valve 9 in the central supply line 6 ensures the connecting in and out.
In the central construction the piston-type valve 13 has on an extension a ram 13", which serves to cover part of the subsequently described support 27, if e.g. there is no hide below it, so that an excessively fast pressure drop at this point is avoided and liquid consumption is kept as low as possible.
As can also be gathered from FIG. 2, drains 4 on the top surface of the table-like substrate 3 can be connected to a central drain passage 14.
In the embodiment of FIGS. 1 and 2, an endless upper belt 15 and an endless lower belt 16 pass between the table-like substrate 1 and the treatment device 2 between which is placed the hide an being loaded between the belts 15, 16 at a position designated by the arrow 17. The upper and lower belts 15,16 are guided by several guide pulleys and, in each case at least one driving pulley. At least the upper belt 15 comprises a fine-mesh metal net and serves as a hide support in the vicinity of treatment device 2. The lower belt 16 can also be a fine-mesh metal net, but can also be a different permeable belt.
The skin or hide loaded at the 17, position is introduced between upper belt 15 and lower belt 16 between the table-like substrate 1 and the treatment device 2 and is brought into position by stopping the belts 15, 16. The construction is such that the upper belt 15 is located directly below the underside 12 of the treatment device 2 and also bounds towards the bottom the widened portions 11 of supply ducts 7. The gap between substrate 1 and treatment device 2 is then closed and sealed to the outside, in that, in this embodiment, the substrate 1 can be moved in the direction of arrow 18, e.g. by pressure cylinders, and thereby acts against the lower belt 16 serving as an intermediate layer in the vicinity of the treatment device 2, the hide placed thereon and the support-forming upper belt 15 in such a way that they are tightly pressed against the treatment device 2. Subsequently the treatment liquid is supplied via the central supply duct 6 or valves 10 are opened. Following an adequate action time during which the excess treatment liquid penetrating the skin or hide 26 is removed by the drains 4 and passage 14 (FIG. 2), the table-like substrate 1 is lowered, belts 15,16 are moved on by at least one hide length and simultaneously the next hide is introduced into the apparatus.
Behind the treatment device 2 a squeezing gap is formed by two rollers 19,20, where the excess treatment liquid leading to the soaking of the skin or 26 hide is squeezed out. Finally, the upper belt 15 and the lower belt 16 pass in each case one spraying device 21 enabling any contaminants to be removed from the meshes of the belts 15,16.
The excess treatment liquid falling onto the table-like substrate 1 and is led away by a passage 14, as well as the treatment liquid squeezed out between squeezing rollers 19,20 pass into a collecting container 22, which in the embodiment according to FIG. 1 is constructed in the form of a tub. The tub can be equipped with chemical-physical sensors 23, e.g. pH-meters, so that it is possible to obtain chemical-physical information on the excess treatment liquid and the extent of its reusability. The tub-like collecting container 22 can also be equipped with a mechanism 24, in order to ensure a certain treatment liquid temperature. The excess treatment liquid can be recirculated by a drain 25.
FIG. 2 makes it clear that the hide or skin 26 located between support 27 (upper belt 15) and intermediate layer 28 (lower belt 16), which can both be constructed as fine-mesh metal nets, after moving the table 3 against the treatment device 2 is secured between them. The sealing to the outside can take place by external warp and/or weft wires of the metal net. The reciprocal sealing of the individual widened portions 11 takes place in such a way that small-area webs 29 are formed between the widened 11 portions and which, in the operating position according to FIG. 2 also press against support 27 and, consequently, at least substantially prevent a passage of treatment liquid from one widened portion 11 into an adjacent portion.
The widened portions 11 are arranged in surface-filling manner on the underside 12 of treatment device 2 (FIG. 1). Various embodiments and arrangements for the widened portion are shown in FIGS. 3a-3d. In the embodiment according to FIG. 3a, the widened portions generally designated by the reference numeral 11a have a contour in the form of equilateral triangles, into whose center issue the supply ducts 7. FIG. 3b shows widened portions generally designated by the ref. 11b with a square contour and centrally issuing supply ducts 7, while FIG. 3c shows widened portions generally designated by the reference numeral 11c with a circular contour and supply ducts 7 terminating at the centre thereof. Finally, the widened portions generally designated by the reference numeral 11d in the embodiment according to FIG. 3d are constructed as polygons, namely in the form of regular hexagons. Instead of a single supply duct 7, naturally several ducts can issue at each widened portion 11, 11a, 11b, 11c, 11d and a symmetrical arrangement with respect to the outline of the widened portion is favourable.
A different construction of the apparatus is shown in FIG. 4, where the table-like substrate 1' comprises a link belt 30, which is guided by guide pulleys in such a way that upper strand 31 can be deformed in trough-like manner. Between the individual links of the link belt 30 are formed drainage gaps, through which the excess treatment liquid can drain away.
Above link belt 30 is arranged the treatment device 2' in the form of a circular cylinder 32, which is provided over its entire circumference with widened portions 11e of not shown supply ducts. The treatment liquid can be supplied by means of a central feed into cylinder 32 and can be supplied to the widened portions 11e by means of corresponding radial supply ducts. Each of the supply ducts has a shutoff valve, which is opened and closed by means of an actuator 33. For this purpose a control cam 34' is provided, which is only located on the path of the rotary cylinder 32 covered by link belt 30. In this path portion in which the upper strand 31 of link belt 30 is deflected downwards in trough-like manner, the hide is treated.
Here again there is a support formed by an upper belt 336, as well as a lower belt 34. Between upper belt 33 and lower belt 34 the hide is loaded at 35 and conveyed in the gap between the treatment device 2 and the link belt 30. Through synchronous revolution of the treatment device 2 and the link belt 30, it is possible to ensure that the widened portions 11, where the treatment liquid is under pressure, always face the same point of the skin.
FIG. 5 shows part of the supply mechanism for the treatment device in the form of a flow chart. It has an air chamber 36 as a supply vessel for the treatment liquid, which is equipped with a pressure transducer 37 and a safety valve 38. The treatment liquid level in the air chamber 36 is controlled between a maximum level 39 and a minimum level 40. Air chamber 36 is connected by means of a supply line 41 to the treatment device 2 and also, via a supply line 42, to the collecting container 22, as well as, via a further feedline 43, to a storage vessel 44, which contains fresh treatment liquid. Pumps 45 and 46 are placed in feedlines 42,43. Treatment liquid losses are compensated by feedline 43, as are any concentration fluctuations, while feedline 42 carries the recirculatable treatment liquid from collecting container 22.
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An apparatus for treating hides or skins with liquids in so-called wet processes, e.g. tanning, drenching, dyeing, etc., includes a liquid-impermeable substrate receiving the hide in inflexible manner and a treatment device tightly applicable to the top of the hide by which the treatment liquid penetrates the hide under pressure. For limiting the operating pressure in the range of approximately 10 bar, and for the effective penetration of the treatment liquids, the treatment device has several juxtaposed liquid supply ducts arranged roughly at right angles to the substrate, which are widened in large-area manner on the underside of the device facing the hide and are arranged thereon in surface-filling manner. Between the underside of the treatment device and the hide is arranged a fine-mesh support and the gap between the substrate, hide, support and treatment device can be substantially tightly sealed to the outside.
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CROSS-REFERENCE TO RELATED APPLICATION
This application is based on a provisional application Ser. No. 60/402,066 filed on Aug. 9, 2002.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for brewing coffee, and in particular, a method for brewing coffee by an automatic drip method, fully portable, and utilizing common combustible fuels in container form as the power source.
2. Description of the Related Art
Modern automatic drip coffee makers are well known, but all depend on external sources, which severely limits their portability. An exception is the battery powered variety, but these are so slow in operation as to be almost unacceptable in the marketplace. Furthermore, of all the truly portable coffee makers available, all are either coffee presses or percolators; none are of the automatic drip variety. As personal tastes for properly brewed coffee expand and refine, obviously the preferred brewing method is automatic drip, where the full flavor is extracted from the coffee bean without exposing the grounds to excessive temperatures, which would impair the true flavor of the coffee.
Accordingly, it is desirable to provide a truly portable automatic drip coffee maker, not reliant on external power sources, and operating within normal, expected preparation times. The present invention answers this need. It uses commonly available combustible fuels, uses the automatic drip method to make coffee (as does a home appliance type coffee maker), and is self-contained, hand-transportable, and not reliant on external power sources.
Portable coffee makers usable in remote locations, such as at camping sites, in recreational vehicles, or on boats are well known. Combustible fuels such as propane, butane, and mixtures as well as liquid fuels such as white gasoline and kerosene, are commonly available through retail outlets, and are used in portable stoves and other devices, such as sold by The Coleman Company.
However, there is a need for a fully portable, automatic drip coffee maker which does not require an electric power source. This invention fulfills this purpose, using one of the commonly available fuel sources, and further provides not only drip coffee, but hot water as well.
Moreover, the inventive coffee maker is designed and constructed to fulfill a further need to permit the easy and convenient removal and replacement of a water heating coil that can typically become fouled and clogged after prolonged use.
U.S. Pat. No. 61,454, issued to Plumb on Jan. 22, 1867, describes a portable oil-burning lamp stove useable for making coffee or water.
U.S. Pat. No. 368,340, issued to Kaplan on Aug. 16, 1887, describes a cooking stove using gas heat or an oil burner to heat water for making tea, coffee and hot water.
U.S. Pat. No. 1,041,822, issued to De Lima on Oct. 22, 1912, describes a portable coffee maker using an alcohol lamp for heating.
U.S. Pat. No. 3,133,536, issued to Knapp on May 19, 1964, describes a propane-heated lantern stove usable for making coffee.
U.S. Pat. No. 3,978,844, issued to Wilkens on Sep. 7, 1976, describes a portable propane heated cooking vessel.
U.S. Pat. No. 4,354,427, issued to Filipowicz et al. on Oct. 19, 1982, describes a coffee or tea-making apparatus using electrical heaters.
U.S. Pat. No. 4,757,754, issued to Welker on Jul. 19, 1988, describes a gas-heated coffee maker, but is not a portable device.
U.S. Pat. No. 5,123,335, issued to Aselu on Jun. 23, 1992, U.S. Pat. No. 5,233,914, issued to English on Aug. 10, 1993, and U.S. Pat. No. 5,274,736, issued to Rohr, Jr. on Dec. 28, 1993, describe coffee makers that are portable using a vehicle cigarette lighter to operate electrical heater elements.
U.S. Pat. No. 5,690,094, issued to Sheinfeld et al. on Nov. 25, 1997, describes a portable combustible gas-heated kettle.
U.S. Pat. No. 5,943,945, issued to Ishihara on Aug. 31, 1999, describes an electrically heated coffee maker.
U.S. Pat. No. 6,123,010, issued to Blackstone on Sep. 26, 2000, teaches a portable electrically heated coffee maker.
U.S. Pat. No. 6,257,227, issued to Harbin on Jul. 10, 2001, describes a coffee maker that uses heat provided by a barbeque grill.
U.S. Pat. No. 6,298,770, issued to Blankenship et al. on Oct. 9, 2001, describes a coffee maker using an elongated valve that is used to switch the water flow between a re-circulation setting, in which the water re-circulates through the heater and the reservoir, and a drip coffee setting, in which the water passes through the coffee grounds into the carafe.
None of the above devices teaches a completely portable, automatic drip coffee maker using combustible fuels.
None of the above inventions and patents, taken either singularly or in combination, is seen to describe the instant invention as claimed. Thus, a portable combustible gas fueled automatic drip coffee maker solving the aforementioned problems is desired.
SUMMARY OF THE INVENTION
The portable combustible fuel automatic drip coffee maker has two separate fluid streams, i.e., a combustible liquid fuel stream and a water stream. The fuel stream begins at a contained fuel supply, such as a refillable reservoir or replaceable container of either propane, butane, regular grade gasoline, white gasoline, kerosene, diesel fuel, naphtha, or even peanut oil, and ends as depleted combustion gases leaving a burner. The water stream includes two pathways: (1) a re-circulating pathway between a water reservoir and a water heater coil, and (2) a one-way drip coffee pathway from the hot water heater coil through a basket and filter containing coffee grounds into a carafe. The water heater coil is positioned directly above the burner in order that the heat from the combustion of the fuel is transferred to the water in the coil.
Accordingly, it is a principal object of the invention to provide a portable automatic drip coffee maker device that uses combustible fuel and additionally provides hot water.
It is another object of the invention to provide a portable automatic drip coffee maker device that uses a water heater coil easily removable and replaceable when fouled.
It is a further object of the invention to provide a portable automatic drip coffee maker device in which the water heater coil and burner are attached together as an assembly using a unique 3-arm support brace for strength and sturdiness.
It is yet a further object of the invention to provide a method of installing the burner and heater assembly into the housing using a unique clip structure.
It is still another object of the invention to provide liquid fuel sources contained in either refillable reservoirs or replaceable cylinders of either propane, butane, regular grade gasoline, white gasoline, kerosene, diesel fuel, naphtha or peanut oil.
It is an object of the invention to provide improved elements and arrangements thereof for the purposes described which is inexpensive, dependable and fully effective in accomplishing its intended purposes.
These and other objects of the present invention will become readily apparent upon further review of the following specification and drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an environmental, perspective left side view of a portable combustible gas fueled automatic drip coffee maker according to the present invention.
FIG. 2 is a front elevational view of the portable automatic drip coffee maker.
FIG. 3 is a right side elevational view of the portable automatic drip coffee maker.
FIG. 4 is a top plan view of the portable automatic drip coffee maker.
FIG. 5 is a cross-sectional view of the coffee maker as viewed from the right side.
FIG. 6 is a cross-sectional view of the coffee maker as viewed from the front.
FIGS. 7A and 7B show a top plan view and a side view, respectively, of the combined water heater coil and burner assembly.
Similar reference characters denote corresponding features consistently throughout the attached drawings.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Perspective front, side and top plan views of the inventive portable automatic drip coffee maker 10 are shown in FIGS. 1-4 . The outer housing is made up of three main interlocking parts, the top 26 , the sides 34 and bottom 28 . Preferably these parts are made of a sturdy molded plastic material. Water reservoir 27 has a lid 74 hinged to the top of the housing that can be opened by grasping either of the grip tabs 46 and lifting the lid 74 . Side door 82 can be opened to access a hot water tap (hidden) to draw hot water from a reservoir.
The coffee maker 10 has two separate fluid streams, i.e., a fuel stream used to provide heat and a water stream to provide hot water or drip coffee.
As shown in the cross-sectional views of FIGS. 5 and 6 , the fuel stream begins at a fuel cylinder 76 , e.g., a replaceable cylinder of either propane, butane, white gasoline, low octane gasoline, kerosene, diesel fuel, naphtha, or even peanut oil, and ends as combustion products emitted through apertures 32 , seen in FIG. 7A , in the top of the burner 108 (FIG. 7 B).
At the top of the fuel cylinder 76 is a fuel valve 12 , e.g., a needle valve, which is adjusted using valve handle 14 . Fuel passes from the cylinder 76 through valve 12 into conduit 16 . Fuel conduit 16 is connected directly to the burner inlet conduit 18 where the fuel mixes with air in the aerating portion of the burner inlet.
The air enters the burner inlet conduit 18 through apertures 22 ( FIGS. 5 , 7 A and 7 B) and the fuel-air mixture enters the burner assembly 20 near its center, and is distributed radially outwardly to the burner apertures 32 (FIG. 7 A). The air is drawn into the burner inlet line 18 by a partial vacuum created by the expansion of the fuel as it flows through a narrow conduit into a wider diameter conduit immediately upstream of the air inlet apertures 22 . The fuel-air mixture exiting the burner apertures undergoes combustion, giving off heat that is absorbed by the water flowing in the water heating coil 40 . A portion of the heat generated by the combustion is also absorbed by the carafe 90 .
In order to ignite the fuel during routine use of the coffee maker 10 , after partially opening fuel valve 12 to initiate fuel flow, a spark is produced by spark plug 88 ( FIG. 7A ) by depressing the igniter button switch 62 .
The water stream can flow through two possible pathways depending upon the position of the water switching valve 44 (FIGS. 1 and 5 ): (1) a recirculating pathway when the water switching valve 44 is pushed downward into the closed position (not shown); and (2) a drip coffee pathway when the water switching valve 44 is pulled upward in the open position as shown in FIG. 5 . Thus, the water switching valve handle 42 can be pulled up or pushed down depending upon whether the user wants to make drip coffee (i.e., the “drip coffee” mode) or to circulate hot water in the reservoir 27 (i.e., the “hot water recirculation” mode). A detailed cross-sectional view of the water switching valve 44 is shown in FIG. 5 , in which the movable concave portion 94 of the valve 44 matches the contour of the stationary convex portion 96 , thereby forming a seal when the valve 44 is closed.
Hot water coming from the water heater coil 40 passes through the vertical inlet conduit 116 to the water switching valve 44 . In the “drip coffee” mode, the hot water passes through the slit-like opening in valve 44 into the space 86 in the top of the housing and into the basket 54 which contains a conventional filter, e.g., paper filter or metal mesh basket filter, holding coffee grounds. The filtered drip coffee then passes through the opening 56 into the carafe 90 , wherein the drip coffee is collected. Carafe handle 92 permits the user to hold the carafe 90 . Also, filter basket handle 52 is used to hold the filter basket 54 , and to remove and replace the spent coffee grounds.
Alternatively, when the water switching valve 44 is in the “hot water recirculating” mode, the hot water passes out of the valve 44 into reservoir 72 . After recirculation has taken place over a period of time, the water contained in the reservoir becomes sufficiently hot to use, e.g., for making tea. A reservoir tap 114 , shown in FIG. 5 , is provided to permit the user to draw hot water from the reservoir. The hot water tap is accessed by opening the housing door 82 , shown in FIGS. 1 and 5 .
In either mode, the water that leaves the bottom of the reservoir 27 passes through the reservoir outlet port 112 through a check valve 110 , e.g., an in-line ball check valve, to ensure flow only in one direction, and into the water heater coil 40 .
Features of the unique water heater coil and burner assembly 20 are shown in detail in FIGS. 7A and 7B . A 3-arm support brace 50 serves to provide support for the carafe 90 as well as to securely hold the water heater coil 40 in a fixed spaced relationship with the burner 30 . The support brace 50 is made up of three pieces of stamped, bent metal strips that are riveted together. As a result, each of the three arms of the assembled, riveted support brace 50 are formed by two parallel portions of the stamped, bent metal strips, thus forming spaced dual strip arms.
The arms of the brace 50 radiate outwardly from a central opening 60 to the distal ends 70 . At the end of each arm is a permanent headed rivet 84 and two removable rivet pins held by retaining rings 100 and 102 . Single strip connectors 78 are held in place at their ends by the removable rivets. At the locations where the ends of the arms contact the sides of the burner 30 , tabs bent 90 degrees with respect to the direction of the arms are permanently fastened to the sides of the burner 30 , e.g., by soldering or welding.
Over a prolonged period of use of the coffee maker, when the internal surfaces of the water heating coil 40 become fouled and/or clogged because of accumulated deposits caused by using mineral-laden water or other water containing debris, the water heater can be removed as follows: The water reservoir 72 is drained; the water heater coil lines are disconnected from the reservoir 72 ; retaining rings 100 are removed from each arm of the support brace 50 ; and connectors 78 are lifted and rotated on the pivot provided by the inmost rivets to thereby allow the water heater coil 40 to be lifted up and away from the burner 30 . A new water heater coil can then be inserted in its place, the connectors 78 , and retaining rings 100 reconnected and attached, and the water heater inlet and outlet lines reconnected to the appropriate lines at the bottom of the reservoir 72 .
Referring to FIGS. 5 , 6 and 7 A, during initial assembly of the coffee maker 10 , the water heater and burner assembly 20 are installed into mounting clips 80 in the opening in the bottom portion of the housing 28 defined by the lip 24 . Three mounting clips 80 are distributed in and permanently held in the opening and are arranged to correspond to the positions of the distal portions of each of the arms 50 . The mounting clips 86 are made of stamped, bent metal strips. The portion of the mounting clips 80 that are permanently attached to the inside surface of the bottom opening of the housing 28 have an intermediate rounded portion.
At one end of each of the mounting clips 80 is a flat portion 48 that has two notches. The lower notch 58 accommodates the lower seamed edge 104 of the burner 30 . The upper notch accommodates the shaft of the rivet pin 84 of the respective arm of the support brace. Thus, the width of the flat portion 48 of the mounting clip 80 is approximately equal to the width of the space between the two parallel strips of the arm (see item 84 in FIG. 7 A). At the opposite end of each of the mounting clips 80 are two tabs 66 and 68 . Once the water heater and burner assembly 20 has been installed into the mounting clips, tab 68 is bent from a vertical position 90 degrees to a horizontal position into a small notch in the back 64 of the flat portion 48 of the clip to permanently lock the mounting clips 80 onto the burner 30 and brace 50 assembly. Tab 66 remains in a vertical position attached to the inside surface of the bottom of the housing.
It is to be understood that the present invention is not limited to the embodiments described above, but encompasses any and all embodiments within the scope of the following claims.
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Portable combustible fuel automatic drip coffee making apparatuses use combustible fuels such as propane, butane, white gasoline, and kerosene to heat water which can be alternatively used to make drip coffee, or for other requirements calling for heated water, depending on the selected position of a switching valve. The portability of these devices is self contained and hand transportable. The inventive units are designed to be user maintained with easily cleanable or replaceable parts, as well as designed for manufacturing. These units are configured based on the specific fuel being used, and some units are designed to be able to use a variety of fuels in the same unit.
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BACKGROUND OF THE INVENTION
(Field of the Invention)
The present invention relates to an on-demand type ink jet print head that prints data by jetting ink in a pressure chamber onto a recording medium from nozzle openings in the form of ink droplets upon input of a print signal and thereby forming dots on the recording medium by such ink droplets.
(Prior Art)
A so-called "on-demand type ink jet print head" that forms ink droplets by input of a print signal roughly comes in three types. The first is a bubble jet type in which a heater is arranged on the front end of a nozzle to instantaneously gasify ink, whereby ink droplets are produced and jetted by expansive pressure at the time the ink is gasified. The second is a type in which a part of a container forming ink reservoir is formed of a piezoelectric element that deforms by a print signal, whereby ink is jetted in the form of droplets by pressure produced within the container by deformation of the piezoelectric element. The third is a type in which a piezoelectric element is arranged in a pressure chamber having a nozzle opening, whereby ink is jetted in the form of droplets from the nozzle by varying the ink pressure in the pressure chamber by expansion and contraction of the piezoelectric element.
As disclosed in Japanese Patent Examined Publication Nos. 45985/1990 and 52625/1990, the above three types of on-demand type ink jet print heads are so designed that one end of a piezoelectric element whose other end is fixed to a base is brought into resilient contact with a vibrating film forming a pressure chamber, so that ink in the pressure chamber can jet in the form of droplets from a nozzle opening while causing the vibrating film to be deformed by expansion and contraction of the piezoelectric element.
Since these print heads receive ink from an ink tank through a pipe, ink supply piping is necessary, and this makes a head assembly large in structure. In addition, ink supply pressure must be maintained constant, and in the case of supplying the ink while utilizing a difference in water head, the ink pressure to be applied to the print head varies depending on the remaining amount of ink, thereby causing inconsistency in print quality. Further, removal of bubbles that have entered into the print head entails a waste of ink due to the bubbles being sucked together with the ink by applying negative pressure to the nozzle openings.
SUMMARY OF THE INVENTION
A first object of the invention is to provide an on-demand type ink jet print head featured as minimizing a difference in water head between nozzle openings as much as possible and requiring no sucking out of the ink to remove bubbles.
A second object of the invention is to provide an on-demand type ink jet print head featured as having minimal crosstalk.
A third object of the invention is to propose techniques for operating an on-demand type ink jet print head, such as a technique for replenishing ink to the tanks, a technique for removing bubbles having entered into the head assembly, and the like.
Other objects of the invention will become more apparent from the following description of preferred embodiments.
To achieve the above objects, the invention is characterized as forming a plurality of independent tanks at a part that is on a lower side when mounted on a carriage. One of the tanks has a pressure varying means and the other tank communicates with an air release port. A head assembly is arranged on top of the tanks so as to communicate with the respective tanks by means of flow paths disposed on both sides of the head assembly.
If the pressure of one of the tanks is varied by a pump with a nozzle opening surface of the head assembly sealed by a cap or the like, then ink in this tank moves to the other tank via the head assembly. It is during this process that bubbles having entered into the head assembly are discharged into the other tank. These bubbles are then released into the atmosphere from the air release port.
When the pressure in the two tanks is released to the atmosphere upon end of the discharging of the bubbles, the ink moves from one tank to the other via the head assembly so that the ink levels in the tanks come to be equal to each other. As a result, the ink that has passed through the head assembly at the time the bubbles have been discharged is replenished for printing again, thus producing no waste of ink. Further, since the head assembly is connected to the tanks by siphonage, the ink is supplied at a certain water head independently of the ink level in the tanks, thus allowing stable printing to be achieved.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram showing an embodiment of the invention with ink flow paths;
FIG. 2 is a perspective view showing an appearance of a print head of the invention;
FIG. 3 is an exploded perspective view showing an embodiment of a base forming the print head;
FIGS. 4 (a) and 4(b) are diagrams showing an embodiment of a head assembly, of which FIG. 4 (a) is a front view of the head assembly and FIG. 4 (b) is a diagram showing a cross-section taken along a line A--A shown in FIG. 4 (a);
FIG. 5 is a perspective view showing an exemplary head assembly of the invention;
FIG. 6 is a sectional view showing an exemplary vibrating element unit;
FIG. 7 is a sectional view showing a structure for connecting a vibrating element and a vibrating plate;
FIG. 8 is a diagram showing another exemplary vibrating element;
FIG. 9 is an exploded perspective view showing another exemplary head assembly of the invention;
FIG. 10 is a diagram showing a structure of a pressure chamber forming plate in enlarged form;
FIG. 11 is a diagram showing an exemplary pressure transmitting member in enlarged form;
FIG. 12 is a perspective view showing the vibrating element unit in enlarged form;
FIG. 13 is a perspective view showing another exemplary vibrating element unit;
FIG. 14 is an exploded perspective view showing an exemplary head assembly using the vibrating element unit shown in FIG. 13;
FIG. 15 is a diagrams showing another embodiment of the invention with ink flow paths;
FIG. 16 is a diagram showing still another exemplary vibrating element unit;
FIG. 17 is a diagram showing another embodiment with a nozzle plate; and
FIGS. 18 (a) and 18(b) are diagrams illustrative of an operation of the nozzle plate shown in FIG. 17.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiments of the invention will now be described with reference to the accompanying drawings.
FIG. 2 shows an appearance of a print head of the invention. In FIG. 2, reference numeral 1 designates a base serving also as a carriage mounting member. In this base a main tank 3 and a sub tank 4, which are independent of each other as shown in FIG. 3, are disposed at a position lower than a head 2 when mounted on the carriage. In the respective tanks are partitions 3a, and 4a.
Returning to FIG. 2, the base 1 includes a portion 7 that forms a tank body and a cover member 8 that seals a front end of the tank body portion 7. The tank body portion 7 has an ink replenishing port 10 on top of the main tank 3, an air release port 11 on top of the sub tank 4, and a heater mounting hole 12 between these tanks 3, 4 as the provision for using hot melt ink. The air release port 11 permits passage of gas, and at the same time, is sealed by a member that blocks passage of liquid, such as a filter 17 made of porous fluorine-containing resin or porous silicon.
The cover member 8 includes a front plate 14 and a back plate 15 as shown in FIG. 3. In front of the front plate 14 are arms 13, 13 that support the print head 2 and grooves 14a, 14b, each forming a flow path that allows the respective tanks 3, 4 to communicate with a head assembly 2 (described later) in cooperation with the back plate 15. On the upper ends of the respective grooves 14a and 14b are throughholes 14c and 14d that communicate with ink supply ports 138, 138 of the head assembly 2 (FIG. 9). On the back plate 15 are throughholes 15a and 15b that communicate with the lower ends of the respective grooves 14a and 14b formed on the front plate 14, so that the respective grooves 14a and 14b can communicate with the main tank 3 and the sub tank 4, respectively, at lower positions of the tanks. In FIG. 3, reference numeral 16 designates an ink receiving member to be used when ink is replenished.
FIG. 1 roughly shows the print head of the invention by way of a flow path structure. The head assembly 2 communicates with the bottom portions of the respective tanks 3, 4 on the side thereof by means of vertically extending flow paths 20 and 21 that are formed of the grooves 14a and 14b of the cover member 8 so that the head assembly 2 can be connected to the main tank 3 and the sub tank 4 by siphonage. The head assembly 2 has, as will be described later, nozzle openings 31 so that the head assembly 2 can communicate with the air. The size of each nozzle opening 31 is as small as 60 μm in diameter so that the siphoning action is maintained by the meniscus.
In such a construction, when the main tank 3 is pressured or evacuated by supplying air from, e.g., a pump or by a sucking means 23 with the entire surface over the nozzle openings 31 hermetically sealed with a cap, a difference in pressure is produced between the main tank 3 and the sub tank 4. As a result, the ink in a tank whose pressure is higher, e.g., the main tank 3, flows into the sub tank 4 whose pressure is lower via the head assembly 2. At this point, the air in the sub tank 4 that is compressed by the flowing of the ink is released into the atmosphere from the filter 17, thereby maintaining the sub tank 4 at atmospheric pressure. Even if the pressure of the main tank 3 is increased so much as to cause the ink level to reach the filter 17, the filter 17, having the function of blocking fluid, the ink will in no way outflow.
In the ink moving process the bubbles in the head assembly 2, riding on the ink flow, are bound to be discharged into, e.g., the sub tank 4. When the main tank 3 is caused to communicate with the atmosphere upon movement of the ink by a predetermined amount, the ink moves via the head assembly 2 until the difference in water head between the main tank 3 and the sub tank 3 is eliminated, while the bubbles that have flown into the sub tank 4 are released into the atmosphere from the air release port 11.
Since the bubbles in the head assembly 2 have been removed by moving the ink from one tank 3 to the other tank 4 in this way, no such operation as sucking the ink from the nozzle openings is required as in a conventional head assembly in which bubbles are removed by applying a negative pressure to the nozzle openings. Thus, even in the case where large amounts of bubbles are produced at the time of melting, particularly, such as in hot melt ink that involves melting of solid ink for use, there is no waste of ink by sucking out, thereby contributing to a reduction in operating cost.
Further, the head assembly 2 is disposed at a position higher than the ink tanks 3 and 4 and is supplied with ink from the bottom of each of the tanks 3 and 4 by siphonage. As a result, the ink is supplied to all the nozzle openings 31 at a certain pressure irrespective of the levels of ink in the tanks 3, 4, thereby allowing stable ink droplets to be formed.
FIGS. 4 (a) and 4(b) and FIG. 5 show an embodiment of the head assembly. In FIGS. 4 (a) and 4(b) and FIG. 5, reference numeral 30 designates a nozzle plate, which has a plurality of nozzle openings 31 extending in a sheet forward direction in the form of an array (in a vertical direction as viewed in the figures). A plurality of such arrays of nozzle openings are arranged in an auxiliary scanning direction (in a horizontal direction as viewed in the figures). These nozzle openings 31 are isolated from one another in the vertical direction by walls 32 so that the ink can be supplied from ink flow paths 33 which interpose the nozzle openings therebetween.
Reference numeral 34 designates a vibrating plate, which is arranged at a predetermined distance from the nozzle plate 30 so as to form a pressure chamber 35 with respect to the nozzle plate 30. An end of the vibrating plate 34 is fixed on a front end of a support member 37 that is carried on a base 36. On a side of the support member 37 confronting the nozzle plate project wall surfaces 38 so as to form a groove 33 for supplying the ink to the pressure chambers 35. The vibrating plate 34 is firmly secured to a front end of the wall surface 38 so that the vibrating plate 34 can be supported. By the way, at the time the ink is jetted, i.e., when a vibrating element 40 is expanded and contracted, stress acts also on the wall surface 38 through the vibrating plate 34, thereby causing the support member 37 to be distorted. As a result, the gap between the nozzle plate 30 and the vibrating plate 34 having an array of nozzle openings to which the expanded and contracted vibrating plate belongs changes. The phenomenon of jetting the ink from nozzles by such change of gap, the so-called "crosstalk," is likely to occur. In order to prevent such trouble from happening, it is desirable to employ a means for increasing the strength of the support member 37 to a possible degree. For example, a material such as titanium that is lightweight and highly synthetic may be used, or a reinforcing plate may be mounted at a lower region of the support member. The inventors have found that a practically adequate print quality can be ensured by suppressing a distortional displacement of the support member 37 to such a degree as from 1/9 to 1/11 times a displacement of the vibrating plate 34 due to expansion and contraction of the vibrating element 40. As a result of the above structure, the ink can flow into the pressure chamber 35 in a stream shown by arrow B in FIG. 4(b) from the groove 33 whose fluid resistance is relatively small. Further, since the vibrating element 40 (described later) can be isolated from the ink, shortcircuiting of the vibrating element between the electrodes can be obviated even in the case of using electrically conductive ink.
Reference numeral 40 designates the above-mentioned vibrating element. The vibrating element 40 is divided into two regions in an axial direction. On both sides of an inactive region (lower as viewed in FIG. 4(b)), i.e., the side that exhibits no piezoelectric effect, substrates 41, 42 are bonded. This inactive region is fixed on the base 36 through these substrates 41 and 42. Each of the substrate 41 and 42 is made of a material whose acoustic impedance is larger than the vibrating element 40, e.g., alumina or metallic silicon. On the other hand, on the end of an active region of the vibrating element 40, i.e., the region expanding and contracting upon application of a signal, a pressure transmitting member 43 is fixed. This active region is connected to the vibrating plate 34 through the pressure transmitting member 43. By providing the inactive region and fixing such region in this way, repetitive expansion and contraction of the vibrating element 40 do not produce distortion on the bonded surfaces between the substrates 41 and 42 and the vibrating element 40. This contributes to minimizing the fatigue and thereby increasing the life of the vibrating element 40, the substrates 41 and 42, and the bonded surfaces. In addition, since the acoustic impedance of the substrates 41 and 42 is larger than that of the vibrating element 40, abnormal vibrations can be prevented by positively reflecting elastic undulations produced within the vibrating element 40 on the surfaces of the substrates 41 and 42, thereby ensuring that vibrating components effective in jetting the ink will be transmitted to the vibrating plate 34.
Further, since the vibrating element 40 is connected to the vibrating plate 34 through the pressure transmitting member 43, in the case of using a small vibrating element, if the pressure transmitting member is fabricated in a size larger than the end surface area of the vibrating element 40 and smaller than the area of the vibrating plate 34, the expansion and contraction of the vibrating plate 34 can be transmitted effectively to the vibrating plate 34. As a result, ink jetting performance can be improved.
FIG. 6 is a diagram showing an embodiment of the above-mentioned vibrating element. This vibrating element includes a first layer forming a first electrode 50, a second layer forming a piezoelectric layer 52, and a third layer forming a second electrode 51. The first electrode 50 is a thin coating made of a silver-palladium (Ag--Pd) or platinum (Pt) containing electrically conductive coating material prepared as a paste. The second layer is a thin coating made of a piezoelectric element material, e.g., a lead titanate or lead zirconate containing composite perovskite ceramic material prepared as a paste. The third layer is a thin coating made of the silver-palladium (Ag--Pd) or platinum (Pt) containing electrically conductive material prepared as a paste. These three layers are laminated on a surface plate so that each electrode layer is interposed between the piezoelectric layers. At this point, electrodes, which are the electrodes 51 in this embodiment, are cut off almost at middle portions 54 thereof to stop conductivity. An electrode forming material is coated on each of the first electrodes 50 so as to expose from an end surface (the right end surface as viewed in FIG. 6) and on each of the second electrodes 51 are formed so as to expose from the other end surface (the left end surface as viewed in FIG. 6). The vibrating element thus prepared in laminated form with a predetermined number of layers is dried, and then baked at temperatures from 1000° to 1200° C. for about one hour while applying pressure.
A vibrating element plate in the form of a single board has a structure such that each of the first electrodes 50 forming one of a pair of electrodes, exposes one end thereof to an end surface of the vibrating element, with the other end thereof being covered with the piezoelectric layer, while one end of each of the second electrodes 51 is exposed to the other end surface of the vibrating element with the other end thereof being covered with the piezoelectric layer.
The vibrating element is formed by cutting this vibrating element plate in strip-like form or slitting the plate in comb-like form while leaving one end thereof not slitted into a predetermined size using a dicer or a diamond cutter.
Electrically conductive layers 55 and 56 on both end surfaces of the vibrating element are formed, so that the electrodes 50 whose polarities are the same, can be connected in parallel with one another by the electrically conductive layer 55 and the electrodes 51 by the electrically conductive layer 56. If these electrically conductive layers 55 and 56 are fixed with an electrically conductive adhesive to electrically conductive layers 57 and 58 formed on the substrates 41 and 42, respectively, then the layers 55 and 56 can be connected to external sources electrically. The vibrating element can provide an adequate ink jetting output even with a minimal voltage because the piezoelectric layers 52 are very thin and because the respective electrodes 50 and 51, producing a drive electric field, are connected in parallel with each other.
Further, the electrodes 51 are electrically disconnected by the piezoelectric material at the middle portions thereof 54 and 54. Therefore, it is only a free end side (the left side as viewed in FIG. 6) that expands and contracts upon application of an exciting voltage, while leaving no voltage applied to the regions secured to the substrates 41 and 42. As a result, there will be in no way a case where undesired force acts on the vibrating element, thereby ensuring a long life. In addition, since the vibrating element has a general structure in which a layer made of a piezoelectric material and a layer made of an electrode material are as uniformas possible; in other words, since the whole structure of the vibrating element is such that the electrodes extend as far as to the inactive region, warpage or bending of the vibrating element due to temperature change or secular deterioration over time can be prevented.
FIG. 7 shows a structure by which the vibrating plate is connected to the front end of the thus constructed vibrating element. The front end of the vibrating element 40, which is the free end side thereof, is covered with a cup-like pressure transmitting member 60. The pressure transmitting member 60 has on the back surface thereof a recessed portion whose size is slightly larger than the size of the front end of the vibrating element 40, and the recessed portion side of the pressure transmitting member 60 confronts the vibrating element 40. The pressure transmitting member 60 is secured by loading a heat-resistant adhesive 61 into the free space in the recessed portion to ensure that the pressure transmitting member 60 will be in contact with a vibrating plate 62. Accordingly, the effect of not only preventing the outflow of the adhesive, but also positioning the pressure transmitting member at the very small front end surely can be provided.
While the case of preparing a plurality of layers integrally has been described in the above-mentioned embodiment, it is apparent that the same effect can be obtained by fixing a plurality of piezoelectric vibrating plates 65, each vibrating plate having at one end thereof electrodes 63, 64 bonded integrally on both sides with an adhesive as shown in FIG. 8.
FIG. 9 shows a print head structure in the form of an exploded lamination structure. In FIG. 9, reference numeral 70 designates a nozzle plate. The nozzle plate has a plurality of nozzle openings 71 formed by electroforming when made of nickel as a material, by etching when made of metallic silicon, or by press working when made of stainless steel, nickel, or brass. These nozzle openings 71 are arranged so as to form a vertical array when mounted on a carriage. There are a plurality of such arrays. In FIG. 9, reference numeral 72 designates positioning holes for assembling.
Reference numeral 81 designates a pressure chamber forming plate, which is arranged as a second layer member for forming pressure chambers with the nozzle plate 70. The pressure chamber forming plate interposes a plurality of vibrating plates 73 between frames 77 and 78, a number of such vibrating plates being equal to a number of nozzle opening arrays. As shown in FIG. 10, each vibrating plate 73 has film-like vibrating portions 74 and horizontally extending walls 75. The vibrating portions 74 are formed by molding a high polymer material having heat resistance and resilience, e.g., polyimide®. Each wall 75 isolates the vertically arrayed nozzle openings 71 from one another and controls the gap between the vibrating portion 74 and the nozzle plate 70 with an end thereof abutting against the back surface of the nozzle plate 70. On both sides of each vibrating plate 73 are gaps provided to allow slits 80 to be formed, the slits being provided to supply ink to the nozzle plate 70. On the frames 77 and 78 are throughholes 82 and 82 provided to supply the ink between the vibrating plates 73 and the nozzle plate 70. These throughholes 82 are designed to widen toward a print region but are disposed outside the print region. In FIG. 10, reference numeral 84 designates positioning holes for assembling.
Reference numeral 86 designates pressure transmitting members, which are arranged as third layer members to connect vibrating elements 122 (described later) to the vibrating portions 74 of the corresponding vibrating plate 73. In the case of using hot melt ink, a heat-resistant high polymer such as PPS is subjected to injection molding, or a metallic material is etched or pressed so that the pressure transmitting member can be formed into, e.g., a C-shaped member such as shown in FIG. 11 so as to be fitted with a front end of the vibrating element 122. The surface area of the front end 86a of the pressure transmitting member is selected so as to be larger than the surface area of the front end of the vibrating element 122 and smaller than the surface area of a single vibrating portion 74 defined by the walls 75. The mass of the pressure transmitting member is set so as to be smaller than the mass of the active region of the vibrating element, i.e., the mass of the vibrating region. More preferably, the mass of the pressure transmitting member is set to about 1/10 the mass of the vibrating region.
Reference numeral 88 designates a pressure transmitting member support plate for positioning the pressure transmitting members 86, which is arranged as a fourth layer member. This pressure transmitting member support plate 88 is formed by providing ladder-like frames 90 so as to be positioned in alignment with the pressure transmitting members 86. The pressure transmitting member support plate 88 is also designed to allow the pressure transmitting members 86 to be held by throughholes 92 provided by the frames 90 in such a manner that the pressure transmitting members 86 can move in the axial direction. Outside the print region are throughholes 94. These throughholes 94 widen toward the print region to supply the ink between the vibrating plates 73 and the back surface of the nozzle plate 70. In FIG. 11, reference numeral 96 designates positioning holes for assembling.
Reference numeral 98 designates a flow path forming plate, which is arranged as a fifth layer member. The flow path forming plate has long holes 100 (described later) that allow the vibrating elements 122 to pass therethrough. Each long hole 100 is disposed at a position confronting an array of nozzle openings, and a moat-like recessed portion that encloses each of these long holes 100 is formed to provide ink supply paths 102. These ink supply paths 102 are formed at such positions as to allow communication with long holes 93 of the pressure transmitting member support plate 88 and the slits 80 of the pressure chamber forming plate 73. These ink supply paths 102 also communicate with throughholes 104 that widen toward the print region but are disposed outside the print region. In FIG. 11, reference numeral 106 designates positioning projections.
Reference numeral 110 designates a vibrating element unit holder, which is arranged as a sixth layer member. This vibrating element unit holder 110 has a window 112 for allowing vibrating element units 120 to pass therethrough and indentations 114 that come in engagement with both ends of the vibrating element units 120. Throughholes 116, 116 for supplying the ink to the first to the fifth layer members are also provided in regions outside the print region. In FIG. 11, reference numeral 118 designates positioning throughholes.
Reference numeral 120 designates the above-mentioned vibrating element unit, in which a plurality of vibrating elements 122 are arranged so as to be aligned with the nozzle openings 71 as shown in FIG. 12, so that the vibrating element unit 120 is interposed between two substrates 124 and 126. Each of the substrates 124 and 126 is made of a material such as the above-mentioned material whose acoustic impedance is large. Each vibrating element 122 is designed to have the active region and the inactive region as described above. The inactive region is fixed to the substrates 124 and 126 and the length of the active region is selected so that the inactive region extends almost from the fifth-layer flow path forming plate 98 to the pressure transmitting members 86. The substrates 124 and 126 have steps 128 and 130 respectively so that these substrates do not come in contact with the active region of each vibrating element 122.
Reference numeral 134 designates a base having a throughhole 136 and throughholes 138 and 138 outside the throughhole 136. The throughhole 136 can accommodate a necessary number of vibrating element units 120. The throughholes 138 communicate with the openings of the ink flow paths of the base 1 that forms the ink tanks. In FIG. 12, reference numeral 140 designates positioning throughholes.
As a result of the above-mentioned lamination structure, when a plurality of vibrating element units 120 are assembled into the throughhole 136 of the base 134 and then let the window 112 of the vibrating element unit holder 110 allow such assembly to pass therethrough, the substrates 124 and 128 forming each vibrating element unit 120 come in engagement with the indentations 114 of the holder 110, thereby causing each vibrating element unit 120 to be set to a predetermined position. As the projections 106 of the flow path forming plate 98 are inserted into the positioning holes 140 and 118 of the base 134 and the holder 110, respectively, under this condition, the vibrating elements 122 of the respective vibrating element unit 120 project from the long holes 100 of the flow path forming plate 98.
The pressure transmitting member support plate 88 is carried on the thus assembled body so that the front ends of the vibrating elements 122 can pass through the throughholes 92 of the support plate 88. The pressure transmitting members 86 are then inserted into the respective throughholes 92. Accordingly, the pressure transmitting members 86 are set on the front ends of the vibrating elements 122.
Then, when the vibrating plate 73 and the nozzle plate 70 are placed on the thus assembled body while positioned with the projections 106 as a reference, the respective pressure transmitting members 86 abut against the vibrating portions 74 of the vibrating plates 73, so that the pressure chamber 35 (FIG. 4) is formed by a vibrating portion 74 and the walls 75 defining such vibrating portion 74. The thus formed pressure chambers 35 communicate with the nozzle openings 71, respectively.
Upon completion of laminating the respective layer members, these layer members are fixed integrally to complete a head assembly. As this head assembly has been mounted on the base 1 so that the arrays of nozzle openings extend vertically, throughholes 14c, 14d formed on the cover member 8 of the base 1 are connected to the throughholes 138 of the base 134, thus completing the ink flow paths between the ink tanks 3 and 4 and the head assembly 2.
When pressure is applied to one of the tanks, e.g., the ink tank 3 under this condition as described above, the ink from the ink tank 3 flows the throughholes 138 of the base stand 134 and the throughholes 116 of the holder 110 to reach the throughholes 94 of the flow path forming plate 88. The ink that has reached the flow path forming plate 88 is scattered around while passing through the ink supply paths 102, flowing into the slits 80 of the pressure chamber forming plate 81 from the long holes 93 of the pressure transmitting member support plate 88, then and from the slits 80 to the pressure chambers formed between the vibrating plates 73 and the nozzle plate 70. Since the respective throughholes 92 of the pressure transmitting member support plate 88 are sealed by the vibrating plates 73, the vibrating element units 120 will never be immersed in the ink.
While it is designed to fix a plurality of vibrating elements 122 between the long substrates 124 and 126 in this embodiment, as shown in FIG. 13, a single vibrating element 150 may be fixed between substrates 152, each of which substrates has the same width as the vibrating element 150 to achieve a single-vibrating element single-unit construction. In this case, as shown in FIG. 14, throughholes 156 are formed so as to be aligned with vibrating element units 158 and the vibrating element units 158 are set to these throughholes 156 by sliding. By similarly setting the flow path forming plate 98, the pressure transmitting support plate 88, the pressure transmitting members 86, the pressure chamber forming plate 81, and the nozzle plate 70 under this condition, the head assembly can be completed.
This embodiment allows correspondence between a single vibrating element unit and a single nozzle opening. This allows replacement of a defective vibrating element on a single element basis, thereby contributing to reducing maintenance and manufacturing cost.
While pressure is applied to one of the tanks to move the ink to the other tank through the head assembly in the above embodiment, it is apparent that the same effect can be achieved by evacuating one of the tanks.
FIG. 15 shows another embodiment of ink supply paths to the respective pressure chambers in the print head of the invention. In this embodiment seal members 161 to 165 are arranged on either an upper or a lower end or ends of the vertically extending arrays of nozzle openings in order to regulate the direction of the ink flowing into the ink supply paths 33. According to this embodiment, the ink flows from a single ink supply path 33 to the other ink supply path 33 via the pressure chambers 35 as shown by arrows in FIG. 15, when the ink passes through the head assembly 2 upon pressuring or evacuating the main tank 3. As a result, the ink can be loaded into the pressure chambers 35 surely by driving out bubbles remaining at the pressure chambers 35 into the supply path 33.
While the inactive region of the vibrating element is interposed by the substrates on both sides in the above embodiment, the inactive region may also be fixed only on a single side of the vibrating element as shown in FIG. 16.
That is, the inactive region of a vibrating element 170 is fixed on a substrate 171 on a single side thereof by an adhesive, and then such an adhesive as to become rigid after cured, e.g., an adhesive prepared by mixing ceramic powder with a binder, is applied as far as to a support member 172 in such a manner that the bottom and the exposed other side of the substrate 171 can be covered up.
This technique allows reaction produced at the time of driving the vibrating element to be received by the adhesive layer 173, thus preventing variations in the gap between the nozzle opening and the vibrating element surface accompanied by the deformation of the substrate 171, which further obviates crosstalk.
FIG. 17 shows another embodiment of the nozzle plate. In FIG. 17, reference numeral 181 designates buffer flow paths arranged at positions as close to nozzle openings 180 as possible and remote from the vibrating plates 34. Each buffer flow path is formed into a throughhole whose diameter is smaller than the nozzle opening 180. The diameter of each buffer flow path 181 is selected to about 45 to 50 μm if the diameter of the nozzle opening is set to 60 μm. It has been verified that-the diameter of the buffer flow path which is 0.6 to 0.95 times that of the nozzle opening can prevent drying of the ink from the buffer flow path as well as crosstalk while maintaining the siphonage.
In this embodiment, if no printing is performed, the meniscus 182 of each buffer flow path 181 retreats toward the ink flow path side as shown in FIG. 18(a). When a vibrating element 40 is excited to form a dot under this condition, the ink in the pressure chamber 35 is compressed as the vibrating plate 34 confronting the vibrating element 40 projects toward the pressure chamber 35. As a result, an ink droplet jets out from the nozzle opening 180 confronting the vibrating element 40 that has been excited. The change in ink pressure in the pressure chamber 35 is propagated around to apply pressure to the ink in pressure chambers belonging to other nozzle openings that are adjacent to this nozzle opening 180. However, the meniscus 182 of the buffer flow path advances toward the front surface (FIG. 18 (b)) by the propagation of pressure undulations, which propagation is absorbed by a change in volume of the meniscus 182, thereby causing the pressure undulations to be damped. As a result, the crosstalk caused by the driving of adjacent vibrating elements can be prevented.
As the pressure undulations are damped in this way, the meniscus of the buffer flow path 181 retreats toward the ink flow path 33 side. Accordingly, dots are sequentially formed by repeating the above-mentioned process while preventing crosstalk to a possible extent.
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An on-demand type ink jet print head, comprising: a plurality of ink tanks disposed at a lower position of a carriage to be independent of each other, pressure varying means provided on one of the tanks; an air release port communicating with the other one of the tanks; a head assembly provided on top of the tanks to communicate with the tanks through flow paths at both sides of the head assembly. The object of the invention is to achieve stable printing independent of the amount of ink in an ink tank and discharge bubbles in a nozzle head together with the ink.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a U.S. National Stage Application under 35 U.S.C. 371 of PCT International Application No. PCT/DE2003/00539, filed Feb. 21, 2003, which claims priority to German Patent Application No. DE 102 10 707.6, filed Mar. 12, 2002.
The present invention relates to a method for outputting status data of a measuring system in a telecommunications network, the status data including the status of components in the measuring system, connections in the measuring system, and/or measurement results of the measuring system.
BACKGROUND
A contract between a network operator and customers may offer the customer guaranteed characteristics in the telecommunications network, such as an upper limit for the packet delay and IP delay variations, which is particularly important for IP telephony and video conferencing.
Consequently, quality characteristics are guaranteed in the telecommunications network, which are made up of the unidirectional packet delay and the parameters derivable therefrom. Thus, the intention is to guarantee the customer maximum values for one or more of these parameters in the telecommunications network, for example, packet delays, IP delay variations and packet losses and/or minimum values for the throughput.
Moreover, compliance with these values must be verifiable the network operator and the customer.
Therefore, unidirectional measurement connections are established between measuring computers. On these measurement connections, measurement packets are sent from a measuring computer serving as a sender to a measuring computer serving as a receiver with a configurable distribution in time. The measurement packets contain, inter alia, time stamps and sequence numbers. To be able to measure the one-way delay, the time stamps at the measuring computer serving as a sender and the measuring computer serving as a receiver must be time-synchronized with sufficient accuracy. A technical implementation is, for example, the generation of time stamps via the GPS (Global Positioning System) receivers. This allows the time stamps to be generated with an error of ±½ μs.
The measurement results are retrieved from the measuring computers by a control computer controlling the measuring computers and stored in a database, where they are made available for visualization. The customer and the service provider need to get a prompt overview of the status of the measurement connections and of the measuring system. In this context, “prompt” means that a change in the status of the measurement connections or of the measuring system is indicated as quickly as possible. In particular, when using a plurality of measuring computers, which may also be assigned to different control computers, a large amount of information—status data—is generated. The problem here is that, due to the large amount of information, one loses track of important messages that would possibly require measures to ensure transmission quality.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a method for outputting status data including at least at least one of a status of a component of a measuring system, a status of a connection of the measuring system, and a measurement result of the measuring system, in such a manner that an overview of the overall situation is made available in a simple manner, even for a large amount of status data, while avoiding the above-mentioned disadvantages.
The present invention provides a method for automatically indicating status information via an output device, the status information including at least one of a status of a component of a measuring system, a status of a connection of the measuring system, and a measurement result of the measuring system. The method includes:
assigning first status information to a first status range of a plurality of fixed status ranges according to at least one first predetermined condition, the first status range being limited by at least one first threshold value;
outputting the assigned first status range; and
automatically updating the first status information at a predetermined time interval.
The present invention includes the discovery that the number of pieces of information can be reduced and weighted in a simple manner by assigning status data to certain ranges according to predetermined conditions. The user is only informed of the status range, and thus of the quality level, the status data was assigned to. This then allows the user to draw conclusions, for example, for the measures to be taken to ensure the transmission quality in a telecommunications network.
Therefore, according to the present invention, the status data is at least partially assigned to fixed status ranges according to predetermined conditions, and the respective assigned status ranges are individually output, thus allowing easy identification of the status range the status data was assigned to. Preferably, the status ranges may be limited by at least one threshold value so that when this threshold value is exceeded, the status data is assigned to a different status range.
To prepare the status data for the user in as simple a manner as possible, the output device displays the status data in a graphic along with the assigned status range. This graphic can take the form of a matrix.
According to one embodiment of the present invention, the graphic is implemented in the form of a graphical user interface, for example, using a windows technique; at least individual status ranges of the graphical user interface having further, underlying representation levels which are made visible by activation in the status range lying thereabove.
These graphical user interfaces (GUI) are now widely used as a man-machine interface in computer applications. The graphical user interfaces simplify working with a computer system because they eliminate the need to enter complex textual commands to execute programs. Instead, intuitive graphical symbols (Icons), which correspond to the commands mentioned, are provided on a display screen, i.e., the output device, of the computer system.
Also part of this graphical user interface is a pointing element, which is used in the graphical user interface with the aid of a mouse, trackball, or keyboard. In a graphical user interface, the pointing element, which is generally represented as a pointer, is positioned on an object on the desktop to initiate an action. An object may be, for example, the icon of a program, or an element of the above-mentioned window. The positioning of the pointer above the object may already be an event that causes the computer system to perform a specific action, such as popping up a menu, or displaying information intended to help a user.
This method of displaying information is also referred to as “tooltip”. Tooltips are, in particular, small help windows explaining the buttons of the graphical user interface, or providing further information about the status data and/or status ranges.
In the further representation levels of the graphical user interface, which may take the form of underlying windows or tooltips, the status data and/or the status ranges assigned to the status data are displayed in an increasingly detailed manner.
To simplify the identification of the important information, the individual status ranges are individualized by giving them different colors.
In addition, preferably, the ranges reflecting, in particular, the magnitude of a measurement result, several measurement results and/or the values describing a status of a component of the measuring system, together form a hierarchy.
According to one embodiment of the present invention, the measuring system has at least two measuring computers and a control computer controlling the measuring computers. Here, the status data is based on the status of the measuring computers, the quality of the measurement connection between the measuring computers, the reachability of the measuring computers by the control computer, the time synchronization of the measuring computers and/or the currentness of the status data.
In this connection, when the representation is in the form of a matrix, the first column of the matrix displays status data relating to the status of the individual measuring computers; each field of the first column of the matrix being assigned to a measuring computer.
In particular, each measuring computer is represented in its field in the first column by its identifier—name, IP address, or similar.
The status data that belongs to a field of the first column of the matrix and is based on the status of the respective measuring computer is made up of the status of the time synchronization of the measuring computer, the reachability of the measuring computer by the control computer, and error messages of the measuring system regarding this measuring computer.
In this connection, the individual assignments of a measuring computer to a control computer are each shown in the first row of the matrix; each field of the first row of the matrix showing an assignment to a measuring computer.
The matrix fields arranged in row two and the following as well as in column two and the following each indicate the status of the measurement connections between the individual measuring computers, for the purpose of which the measuring computers are arranged in the first column from top to bottom in a predetermined order, and, in the first row, the assignment of the measuring computers is arranged in the same order from left to right in terms of their assignment to a control computer.
Preferably, one of these fields of the matrix in each case indicates a measurement connection or several measurement connections of a measuring computer to another measuring computer in one direction, and the corresponding field symmetrical to the diagonal of the matrix indicates the reverse direction of the measurement connection or connections.
The status of the respective measurement connection is made up of the assignment of the measurement results regarding the quality of the measurement connection to status ranges, of the time synchronization of the measuring computers and/or the currentness of the measurement results.
The matrix fields arranged in row two and the following as well as in column two and the following each have a second representation level in which the status of the measurement connection is shown in more detail.
In particular, the further representation level indicates the type of the measurement connection as well as the status of the individual measurement parameters determining the quality of the measurement connection between the respective measuring computers. Here, the status of the measurement parameters can be made up of the transmission characteristics in the measurement connection, such as the packet delay, IP delay variations, packet losses, or the like.
Moreover, the second representation level may have a subordinate third representation level in which the measurement results are shown in detail over a predetermined period of time. The fields of the first row and column of the matrix may be provided with a subordinate second representation level in which the system messages are displayed.
The measurement results are retrieved from the measuring computers by the control computer and stored in a database, where they are made available for visualization. Offline display of the measuring results and other status data is via a browser. In this context, “offline” means that the display of the measurement results and other status data must be initiated manually while in the case of online visualization, this is done automatically at certain time intervals.
BRIEF DESCRIPTION OF THE DRAWINGS
Further advantages, features and possible uses of the present invention for outputting status data will become apparent from the following description in conjunction with the exemplary embodiments shown in the drawings.
FIG. 1 is a schematic representation of a telecommunications network including a three measuring computers for carrying out the method according to the present invention;
FIG. 2 schematically shows the graphical user interface in a first representation level in the form of a status matrix;
FIG. 3 shows a further representation level of the status matrix of FIG. 2 ; and
FIG. 4 schematically shows a graphic of measurement results over a measurement connection.
DETAILED DESCRIPTION
FIG. 1 schematically shows a telecommunications network 10 including a plurality of switching devices 12 through 24 interconnected via trunk lines 26 . Switching device 12 is assigned to a first measuring computer 28 , switching device 16 is assigned to a second measuring computer 30 , and switching device 18 is assigned to a third measuring computer 32 . A measurement program for measuring the unidirectional transmission characteristics is installed in each measuring computer 28 , 30 , 32 .
Each measuring computer 28 , 30 , 32 is connected to a GPS antenna (Global Positioning System) and provided with a GPS map for processing the data received via the GPS antenna. The GPS antenna and the GPS map together form GPS unit 34 , which interacts with a plurality of satellites 34 a.
The connection between first measuring computer 28 , switching device 12 , switching device 14 , switching device 16 , and second measuring computer 30 forms first measurement path 36 shown in dashed lines. The connection between second measuring computer 30 , switching device 16 , switching device 18 , and third measuring computer 32 forms second measurement path 38 , which is also shown in dashed lines.
Switching device 24 is assigned a control computer 40 . Control computer 40 interacts with a database 42 , to which is connected an output device in the form of an output computer 44 having a display screen.
Telecommunications network 10 is, for example, the Internet or an intranet.
The goal of the measurement system is, for example, to determine the packet delay from first measuring computer 28 via measurement path 36 to second measuring computer 30 . Thus, the measurement connection is a unidirectional measurement connection, where separate measurement packets are sent from first measuring computer 28 to second measuring computer 30 .
On measurement path 36 , measurement packets are sent from first measuring computer 28 to second measuring computer 30 with an adjustable distribution in time (for example, a constant or exponential distribution). In the process, the measurement packets are dispatched using the User Datagram Protocol (UDP). This is a connectionless Internet transport protocol based on IP. The measurement packets contain, inter alia, time stamps and sequence numbers.
To allow the unidirectional delay to be measured with sufficient accuracy, the time stamps are generated, for example, by GPS unit 34 . This allows the time stamps to be generated with an error of ±½ μs. Here, first measuring computer 28 sets the time stamp shortly (as shortly as possible) before the first bit of the measurement packet is sent.
The measurement packet is sent to second measuring computer 30 via measurement path 36 , i.e. via trunk line 26 , switching exchange 12 , switching exchange 14 , and switching exchange 16 . When the last bit of the measurement packet is received at second measuring computer 30 , the second time stamp is recorded. The second time stamp is generated by second measuring computer 30 , for example, also by a GPS unit 34 .
Then, the packet delay is calculated from the time stamps taking into account a computer-related time slice; and this value is transmitted to control computer 40 as a measurement result and stored in database 42 . The results are continuously displayed online via output computer 44 . The measurement packets sent via measurement path 36 can also be used to determine the IP delay variations as well as packet losses, and the like. This data is then stored in database 42 accordingly.
Based on these values, the quality of measurement path 36 , i.e., the connection between first measuring computer 28 and second measuring computer 30 , can be determined and monitored. The same method can also be used on measurement path 38 , and also for further measurement paths not shown here. In this manner, a large amount of data is generated and stored in database 42 .
The above-mentioned measurement results—status data—are retrieved from measuring computers 28 , 30 and 32 by control computer 40 and stored in database 40 , where they are made available for visualization.
Output computer 44 has a graphical configuration interface as well as a graphical user interface for online and offline operation; the interfaces being used to visualize the status data stored in database 42 .
The graphical user interface is used, in particular, for output and processing of the status data.
FIG. 2 shows a graphical user interface 46 for displaying the status data stored in database 42 via output computer 44 .
In its first representation level, graphical user interface 46 has a status matrix 48 shown in FIG. 2 . Located in a further representation level under status matrix 48 are, first of all, a detailed status display and, secondly, a system message display.
The status data is assigned to fixed status ranges according to predetermined conditions. These respective assigned status ranges are individually shown marked in color, thus allowing easy identification of the status ranges the status data was assigned to, and of the quality requirements that are met.
For example, the status of the components of the measuring system shown in FIG. 1 and of the measurement connections is visualized for the user by the colors gray, green, yellow, and red. The colors used have the meaning shown in Table 1.
TABLE 1
Color
Meaning
Possible cause
Gray
Nothing to observe
Green
Everything OK
Yellow
Alert situation
For example, a level 1
threshold value for a
measurement connection was
exceeded
Red
Alarm situation
For example, a level 2
threshold value for a
measurement connection was
exceeded, or a system
component is no longer
available.
The colors may also be associated with an audible output, if desired.
The uppermost level of graphical user interface 46 is made up of status matrix 48 shown in FIG. 2 . Here, the status of the components of the measuring system shown in FIG. 1 and of the measurement connections over measurement paths 36 and 38 is displayed. The display is updated at intervals of about one minute. Status matrix 48 is divided into several subregions. In first column 50 , the fields arranged below each other are numbered serially from top to bottom, and measuring computers 28 , 30 , 32 are listed. In the following, it is assumed that there are nine measuring computers. The IP addresses or the names of the measuring computers are displayed next to the continuous numbers so that the user can easily associate the field in column 50 with the corresponding measuring computer 28 , 30 , 32 . The current status of measuring computers 28 , 30 , 32 is visualized by the color in the fields of first column 50 . In this context, the status of measuring computers 28 , 30 , 32 is influenced by three things:
a) the display of the status of the time synchronization of measuring computer 28 , 30 , 32 ;
b) the display of the reachability of measuring computer 28 , 30 , 32 by control computer 40 ;
c) the display of whether there exist system messages of the status “error” or “alerts” generated by measuring computers 28 , 30 , 32 .
In first column 50 , in each case the color representing the worst status is displayed.
In this connection, the following cases are distinguished:
TABLE 2
Color
Display text
Meaning
Green
Synchronized (GPS, highly
The measuring computer is synchronized
accurate)
using a GPS unit (synchronization error <1 μs).
Synchronized (NTP, accurate)
The measuring computer has no GPS unit.
Synchronization is via NTP (synchronization
error <1 ms).
Yellow
Synchronized (NTP, accurate)
The measuring computer does have a GPS
unit, but obviously, GPS synchronization is
currently not possible. Possible causes:
Antenna/antenna feeder defective, antenna has
no visual contact with at least 4 satellites of
the GPS. Synchronization is via NTP
(synchronization error <1 ms). Switchover to
NTP synchronization occurs automatically.
Synchronized (NTP, inaccurate)
Synchronization is via NTP (synchronization
error <2 ms). No information whether a GPS
unit is present.
Red
Not synchronized
The measuring computer is not synchronized.
The measuring computer has no GPS unit, and
synchronization via NTP is not configured.
Not synchronized (GPS)
The measuring computer is not synchronized.
The measuring computer has a GPS unit.
Obviously, GPS synchronization is currently
not possible. Synchronization via NTP is not
configured.
Not synchronized (NTP)
The measuring computer is not synchronized.
The measuring computer has no GPS unit.
Synchronization via NTP is configured, but
obviously currently not possible or not
accurate enough (NTP synchronization may
take several hours until the synchronization
error is <2 ms).
Not synchronized (GPS, NTP)
The measuring computer is not synchronized.
The measuring computer has a GPS unit.
Obviously, GPS synchronization is currently
not possible. Synchronization via NTP is
configured, but obviously currently not
possible or not accurate enough (NTP
synchronization may take several hours until
the synchronization error is <2 ms).
The display text shown in column 2 in Table 2 is stored as a tooltip in the respective field of first column 50 of status matrix 48 , and is therefore displayed when the pointing element is positioned and left on a field in column 50 of status matrix 48 .
Thus, the color selection corresponds to status ranges with regard to the time synchronization of measuring computers 28 , 30 and 32 .
As mentioned above, time synchronization may be done using GPS unit 34 . Alternatively, it is also possible to perform time synchronization via NTP (Network Time Protocol). In the process, local clock 34 b is synchronized.
Time synchronization via GPS unit 34 is more accurate than via NTP. Consequently, the type of time synchronization is included as status data for the assignment of the measuring computer to a status range.
The reachability of measuring computer 28 , 30 , 32 by control computer 40 enters into the evaluation as further status data for the assignment of a measuring computer to a status range.
TABLE 3
Color
Display text
Meaning
Green
(No specific text)
The last contact between the
measuring computer and the
control computer was less
than 5 minutes ago.
Red
Not reachable
There has been no contact
with the measuring computer
for at least 5 minutes.
Possible causes: The
connection to the measuring
computer was interrupted, or
the measuring computer did
not start up, or is no longer
running.
The text in column 2 in Table 3 is also stored as a tooltip, and a corresponding display text is displayed when the pointing element is positioned and left in first column 50 of status matrix 48 .
Furthermore, the status data included for the assignment of the status of measuring computers 28 , 30 , 32 to predetermined status ranges correspondingly marked in color also includes system messages of measuring computers 28 , 30 , 32 .
TABLE 4
Color
Display text
Meaning
Green
(No specific text)
No unacknowledged errors or
alerts present.
Yellow
(No specific text)
There is at least one
unacknowledged alert (but no
error).
Red
(No specific text)
There is at least one
unacknowledged error.
In first row 52 of status matrix 48 , the fields are assigned to measuring computers 28 , 30 , 32 ; the left-to-right order corresponding to the top-to-bottom order in first column 50 with regard to measuring computers 28 , 30 , 32 . The fields of first row 52 display the assignment of the respective measuring computer 28 , 30 , 32 to control computer 40 , of which also a plurality of control computers 40 may be present in telecommunications network 10 .
This assignment, too, is assigned to a status range marked in color. This status range is influenced by the following status data:
a) the assignment of the respective measuring computer 28 , 30 , 32 to an operational control computer 40 ;
b) the display of the reachability of measuring computers 28 , 30 , 32 by control computer 40 ;
c) the display of whether there exist system messages of the status “error” or “alerts” generated by control computer 40 .
In first row 52 , in each case the color representing the worst status is displayed.
In the context of the assignment of measuring computers 28 , 30 , 32 to a control computer 40 , the following status data is taken as a basis for the respective status ranges marked in color.
TABLE 5
Color
Display text
Meaning
Red
Invalid or not defined
This measuring computer was
not assigned to a control
computer.
Green
(No specific text)
This measuring computer is
assigned to a control
computer.
The text in column 2 of Table 5 is stored as a tooltip, and a corresponding display text is displayed when the pointing element is positioned and left in the field of first row 52 of status matrix 48 .
In the context of the reachability of measuring computers 28 , 30 and 32 by control computer 40 , the following status data is taken as a basis for the respective status ranges marked in color.
TABLE 6
Color
Display text
Meaning
Red
Not reachable
The last status update was at
least 5 minutes ago.
Green
Reachable
The control computer updated
the status less than 5 minutes
ago.
The text in the second column of Table 6 is stored as a tooltip, and a corresponding display text is displayed when the pointing element is positioned and left in the field of first row 52 of status matrix 48 .
In the context of the system messages of measuring computers 28 , 30 , 32 and control computer 40 , the following status data is taken as a basis for the respective status ranges marked in color:
TABLE 7
Color
Display text
Meaning
Green
(No specific text)
No unacknowledged errors or
alerts present.
Yellow
(No specific text)
There is at least one
unacknowledged alert (but no
error).
Red
(No specific text)
There is at least one
unacknowledged error.
The remaining region of status matrix 48 , i.e., rows 2 through 10 and columns 2 through 10 , form the third region 54 of status matrix 48 . In this region 54 , the status of the measurement connections between measuring computers 28 , 30 , 32 is displayed. The status of the measurement connections is influenced by the following status data:
a) whether so-called “threshold values” are defined;
b) whether these threshold values are currently met;
c) whether measurement packets were received in the last time interval taken as a basis for threshold value monitoring;
d) whether the two measuring computers 28 , 30 , 32 communicating with each other are sufficiently time-synchronized;
e) whether the two measuring computers 28 , 30 , 32 communicating with each other are reachable by control computer 40 .
Each field of this third region identifies the respective measurement connection(s) from one measuring computer 28 , 30 , 32 to the other measuring computer 28 , 30 , 32 in one direction, i.e., unidirectionally. The opposite direction is shown in the respective field of third region 54 symmetrical to the diagonal (represented in black).
In third region 54 , in each case the color representing the worst status is displayed. In the context of the definition of threshold values, the following status data is taken as a basis for the respective status ranges marked in color. In this connection, in principle, different levels are conceivable for the threshold values. In the following, only two levels are entered, namely a pre-alert value—level 1—and an alarm value—level 2—. The threshold values may be defined independently of each other for each traffic class and each measurement parameter, such as propagation delay, IP delay variations, and packet loss.
TABLE 8
Color
Meaning
Gray
No threshold value was defined for either of
the measurement connections between these
measuring computers.
Same as Tables 9 and 10
For at least one of the measurement
connections, at least one threshold value was
defined at least for one measurement
parameter.
In the context of threshold value monitoring, the following status data is taken as a basis for the respective status ranges marked in color:
TABLE 9
Color
Meaning
Green
No threshold value was exceeded for either of
the measurement connections between these
measuring computers.
Yellow
For at least one of the measurement
connections between these measuring
computers, at least one level 1 threshold value
was exceeded, but no level 2 threshold value.
Red
At least one level 2 threshold value was
exceeded for at least one of the measurement
connections between these measuring
computers.
In the context of the reception of measurement packets in the time interval, the following status data is taken as a basis for the respective status ranges marked in color:
TABLE 10
Color
Meaning
Green
In the last time interval, at least one
measurement packet was received for all
measurement connections between the two
measuring computers.
Red
For at least one of the measurement
connections between the two measuring
computers, no measurement packet was
received in the last time interval.
In the context of the time synchronization of the measuring computers, the following status data is taken as a basis for the respective status ranges marked in color:
TABLE 11
Color
Meaning
Green
Both measuring computers were synchronized
with sufficient accuracy.
Red
At least one of the two measuring computers
was not sufficiently time-synchronized so that
the timing values are invalid. Only the packet
loss is measured correctly because it is not
affected by the time synchronization.
Each field of third region 54 has an underlying further representation level providing a detailed status display. The status display indicates the status of the individual measurement connections between two measuring computers 28 , 30 ; a distinction being made according to the direction of transmission. The detailed status display can be activated by
1. positioning and leaving the pointing element on a field in third region 54 of status matrix 58 —the detailed status matrix is thus stored using the tooltip technique—, or
2. positioning the pointing element on a field of third region 54 of status matrix 48 , and clicking on the field with the left key of a mouse.
In the first case, the display remains visible for a few seconds, and in the second case, it remains permanently visible until the display is actively closed by clicking the top right box containing the “X”.
Detailed status display 56 is shown in FIG. 3 and includes four columns. In first column 58 of detailed status display 56 , the type of the measurement connection is visualized:
“Standard connection”: dark gray “Expert connection”: light gray
Expert connections are special connections, which are used only to a limited extent, for example, to locate errors in the network. They can be set up in a special input mode during the configuration of the measuring system, and allow a larger range of values for some configuration parameters as, for example, shorter packet spacings.
Second, third and fourth columns 60 , 62 and 64 of detailed status display 56 show the status for the individual measurement parameters of each measurement connection between two measuring computers. There are three entries for each measurement connection:
a) one-way delay in ms: OWD—second column 60 ;
b) IP delay variation in absolute values in ms: IPDV—third column 62 ;
c) packet loss in %: PL—fourth column 64 .
The status of the individual measurement parameters is influenced by three things:
a) the definition of threshold values and threshold value monitoring;
b) the reception of measurement packets in a predetermined time interval;
c) the time synchronization of the two measuring computers 28 , 30 , 32 .
In each case the color representing the worst status is displayed.
In the context of the definition of threshold values and threshold value monitoring, the following status data is taken as a basis for the respective status ranges marked in color:
TABLE 12
Color
Meaning
Gray
For this measurement parameter, no threshold
values were entered in the database.
The connection is an “expert” connection,
where the measurement results for each
measurement packet are stored in the database
(so-called “raw data mode”). Due to the
potentially very large data volume, there is no
threshold value monitoring for this type of
measurement connections.
Green
No threshold value was exceeded for this
parameter.
Yellow
The level 1 threshold value was exceeded for
this parameter.
Red
The level 2 threshold value was exceeded for
this parameter.
In the context of the reception of measurement packets in a predetermined time interval, the following status data is taken as a basis for the respective status ranges marked in color.
TABLE 13
Color
Meaning
Green
In the last time interval, at least one
measurement packet was received for this
measurement connection.
Red
In the last time interval, no measurement
packet was received for this measurement
connection. In this case, the value 0 is
displayed for the individual measurement
parameters, respectively.
In the context of the time synchronization of the two measuring computers 28 , 30 , 32 , the following status data is taken as a basis for the respective status ranges marked in color:
TABLE 14
Color
Meaning
Green
Both measuring computers were synchronized
with sufficient accuracy.
Red
At least one of the two measuring computers
was not sufficiently time-synchronized so that
the timing values are invalid. In this case, “-”
is displayed for OWD and IPDV,
respectively, and the correct value is
displayed for PL (not affected by the time
synchronization).
Second, third and fourth columns 60 , 62 and 64 of detailed status display 56 have an underlying further representation level. When the pointing element is positioned in one of the fields of second, third and fourth columns 60 , 62 and 64 of detailed status display 56 and, in this field, a measured value is clicked with the left key of a mouse in this field, then the measurement results are graphically represented in a new window for the selected measurement connection. As soon as a new measurement result is stored for this measurement connection in the database, this graphic 66 is updated. An example of such a graphic 66 is shown in FIG. 4 .
The fields in first column 50 of status matrix 48 and the fields in first row 52 also have an underlying further representation level. This further representation level displays the system messages. The system message display is activated when the pointing element is positioned on the field of a measuring computer in first column 50 of status matrix 48 , or in a field of first row 52 of status matrix 48 , and the respective field is clicked with the left mouse button. The system messages are displayed in a list. Errors are displayed in red, while alerts are colored in yellow. As soon as there is an error message or an alert, the field in the status matrix is also colored accordingly. By clicking on a message in the system message display, the user acknowledges the perception of the message, as a result of which the message is colored in gray. Status matrix 48 is colored in green again only after all messages in the display have been acknowledged and, of course, only if the status of the measuring computer allows this (see Table 2).
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A method for automatically indicating status information of a measuring system via an output device includes assigning status information to respective status ranges according to at least one predetermined condition, the status ranges being limited by at least one threshold value. The status ranges are individually outputted. The status information is automatically updated at a predetermined time interval.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims priority to provisional application Ser. No. 61/015,915, filed on Dec. 21, 2007, the entire contents of which are hereby expressly incorporated by reference for all purposes.
BACKGROUND
[0002] The orthopedic and laboratory industries, among others, use various tools to perform different functions such as drilling, reaming, scraping, filing, etc. Quick tool interchangeability and very little play between mating tool parts are important considerations in such industries and wherever quick-change connectors are used. At present, different tools can be quickly interchanged by manually removing and replacing a desired interchangeable component of the main base tool, which can universally attach to a variety of interchangeable components by means of a universal clamp or chuck. An example tool utilizing a quick-change connector is a drill where numerous rotary attachments such as reaming or burring attachments can be interchanged by axial removal and insertion.
[0003] The present embodiments simplify the method of assembling such tools by providing a rapid means for installing and removing such components. Interchangeable components being incorporated are held in place by individual holders that provide secure axial locking means and quick radial removal means requiring no axial, space for the removal of such components from the main base tool. In a typical orthopedic application, for example, interchangeable component holders may be installed in a stationary drill press or a portable drill, depending on the application. The holder is permanently secured to the drilling machine and the interchangeable component can be axially or radially installed, axially locked upon installation but radially removable. In the assembled position, the holder provides circumferential concentricity and the component is axially locked.
[0004] The axial locking means may comprise, for example, an axially mounted canted-coil spring, in either the stationary or the rotary portion of the holder combination. In some embodiments, a sleeve restricts radial movement and a non-cylindrical tongue of the interchangeable component and corresponding slot in the holder may allow rotational movement to be transferred between the component and holder. A combination of factors contributes to axial locking motion. The combination may include one or more of:
The groove width is smaller than the coil height so that an interference occurs at assembly between the coil height and the groove width. The interference may range from no interference to approximately 25%, but is preferably between about 5-10% of the coil height so that the spring is firmly retained in the cavity, while at the same time allowing deflection of the spring along the minor axis during locking. Interference between the groove height and the coil width along the major axis to reduce or prevent radial movement of the components. Such variation may range from no interference to approximately 15%, but more preferably is under 10%, such as less than 5%. Deflection of the spring coils during assembly to achieve locking. The deflection may range from about 1% to the maximum safe deflection of the coil. The maximum safe deflection may be about 15-25% deflection along the minor axis, but not exceeding the safe deflection, that can cause permanent deformation of the spring's coils. Tapered locking angle at the bottom of the groove. The taper may range from zero up to about 30%, but is preferably from approximately 5% to approximately 15% to provide a gradual locking action without achieving permanent deformation of the coil.
[0009] Aspects of the present embodiments include a number of different “rotary locking mechanisms with quick radial disassembly means.” with each providing certain useful advantages. The embodiments are configured as providing locking between a housing and a piston. In actual application of the embodiments as a mechanism for interchangeable tools, the holder and the interchangeable component(s) can correspond to either the piston and housing or housing and piston respectively in reference to the figures of the designs. Those of ordinary skill in the art will appreciate that the embodiments may be practiced other than as specifically described, and should not be limited to the embodiments described herein.
SUMMARY
[0010] The various embodiments of the present locking mechanism with quick disassembly means have several features, no single one of which is solely responsible for their desirable attributes. Without limiting the scope of the present embodiments as expressed by the claims that follow, their more prominent features now will be discussed briefly.
[0011] One embodiment of the present locking mechanism for use in quick-release applications comprises a housing including a longitudinal axis. A first end portion of the housing includes first and second furcations defining a slot therebetween. An inner surface of the first furcation includes a first groove therein. The locking mechanism further comprises a piston including a body section. A first end of the body section defines first and second shoulders. A tongue extends away from the shoulders along the longitudinal axis. A surface of the tongue includes a second groove therein. The locking mechanism further comprises a sleeve slidably engaging an outer surface of the piston body section. The locking mechanism further comprises a canted-coil spring. The locking mechanism further comprises a first configuration in which the tongue is disposed within the slot such that the furcations abut the shoulders and the first and second grooves are aligned, the canted-coil spring is disposed within the first and second grooves and is compressed by the first and second grooves, and the sleeve is positioned over at least a portion of a junction between the housing and the piston such that the sleeve engages the outer surface of the piston body section and outer surfaces of the furcations, thereby resisting relative motion of the housing and the piston in a direction perpendicular to the longitudinal axis.
[0012] Another embodiment of the present locking mechanism for use in quick-release applications comprises a housing including a longitudinal axis. A first end portion of the housing includes first and second furcations defining a slot therebetween. An inner surface of the first furcation includes a first groove therein. An inner surface of the second furcation includes a second groove therein. The locking mechanism further comprises a piston including a body section. A first end of the body section defines first and second shoulders. A tongue extends away from the shoulders along the longitudinal axis. A surface of the tongue includes a continuous perimeter groove therein. The locking mechanism further comprises a sleeve slidably engaging an outer surface of the piston body section. The locking mechanism further comprises a canted-coil spring disposed within the continuous perimeter groove. The locking mechanism further comprises a first configuration in which the tongue is disposed within the slot such that the furcations abut the shoulders and the continuous perimeter groove is aligned with the first and second grooves, the canted-coil spring is disposed within the first and second grooves and is compressed by the first and second grooves, and the sleeve is positioned over at least a portion of a junction between the housing and the piston such that the sleeve engages the outer surface of the piston body section and outer surfaces of the furcations, thereby preventing relative motion of the housing and the piston in a direction perpendicular to the longitudinal axis.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The various embodiments of the present locking mechanism now will be discussed in detail with an emphasis on highlighting the advantageous features. These embodiments depict the novel and non-obvious locking mechanism shown in the accompanying drawings, which are for illustrative purposes only. These drawings include the following figures, in which like numerals indicate like parts:
[0014] FIG. 1A is a cross-sectional front elevation view of one embodiment of a housing portion of the present locking mechanism;
[0015] FIG. 1B is a cross-sectional front elevation view of one embodiment of a piston portion of the present locking mechanism;
[0016] FIG. 1C is a cross-sectional front elevation view of the housing portion and the piston portion of FIGS. 1A and 1B in an assembled configuration;
[0017] FIG. 1D is a top plan view of the housing portion and the piston portion of FIGS. 1A and 1B in a partially disassembled configuration;
[0018] FIG. 1E is a cross-sectional left side elevation view of the housing portion and the piston portion of FIGS. 1A and 1B taken through the line E-E in FIG. 1C ;
[0019] FIG. 1F is a cross-sectional left side elevation view of the housing portion and the piston portion of FIGS. 1A and 1B taken through the line F-F in FIG. 1D :
[0020] FIG. 1G is a detail view of the portion of FIG. 1C indicated by the circle G;
[0021] FIG. 1H is a cross-sectional top plan view of the housing portion and the piston portion of FIGS. 1A and 1B taken through the line H-H in FIGS. 1A and 1B :
[0022] FIG. 1J is a cross-sectional front elevation view of the housing portion and the piston portion of FIGS. 1A and 1B in an assembled configuration and including an alternative embodiment of the sleeve portion;
[0023] FIG. 1K is a cross-sectional front elevation view of the housing portion and the piston portion of FIGS. 1A and 1B in an assembled configuration and including an alternative embodiment of the sleeve portion;
[0024] FIG. 1L is a detail view of the portion of FIG. 1J indicated by the circle L:
[0025] FIG. 1M is a front elevation view of the axially-canted-coil spring FIG. 1A :
[0026] FIG. 1N is a front elevation view of the radially-canted-coil spring FIG. 1A :
[0027] FIG. 2A is a cross-sectional front elevation view of another embodiment of the present locking mechanism in an assembled configuration:
[0028] FIG. 2B is a cross-sectional left side elevation view of the housing portion and the piston portion of FIG. 2A taken through the line B-B in FIG. 2A ;
[0029] FIG. 2C is a cross-sectional front elevation view of the locking mechanism of FIG. 2A in an improperly assembled configuration:
[0030] FIG. 3A is a cross-sectional front elevation view of another embodiment of the present locking mechanism in an assembled configuration:
[0031] FIG. 3B is a cross-sectional left side elevation view of the housing portion and the piston portion of FIG. 3A taken through the line B-B in FIG. 3A :
[0032] FIG. 3C is a detail view of the portion of FIG. 3A indicated by the circle C;
[0033] FIG. 3D is a detail cross-sectional bottom plan view of an axial spring portion of FIG. 3A , taken through the line D-D in FIG. 3A ;
[0034] FIG. 3E is a detail cross-sectional bottom plan view of an axial spring portion of FIG. 3A , taken through the line E-E in FIG. 3A ;
[0035] FIG. 4 is a cross-sectional front elevation view of another embodiment of the present locking mechanism in an assembled configuration;
[0036] FIG. 5A is a cross-sectional front elevation view of another embodiment of the present locking mechanism in an assembled configuration:
[0037] FIG. 5B is a cross-sectional left side elevation view of the housing portion and the piston portion of FIG. 5A taken through the line B-B in FIG. 5A :
[0038] FIG. 5C is a detail view of the portion of FIG. 5A indicated by the circle C;
[0039] FIG. 5D is a detail view of the portion of FIG. 5A indicated by the circle D;
[0040] FIG. 6A is a cross-sectional front elevation view of another embodiment of the present locking mechanism in an assembled configuration:
[0041] FIG. 6B is a cross-sectional left side elevation view of the housing portion and the piston portion of FIG. 6A taken through the line B-B in FIG. 6A ;
[0042] FIG. 6C is a detail view of the portion of FIG. 6A indicated by the circle C:
[0043] FIG. 6D is a detail view of the portion of FIG. 6A indicated by the circle D:
[0044] FIG. 7A is a cross-sectional front elevation view of another embodiment of the present locking mechanism in an assembled configuration;
[0045] FIG. 7B is a cross-sectional left side elevation view of the housing portion and the piston portion of FIG. 7A taken through the line B-B in FIG. 7A ;
[0046] FIG. 7C is a front elevation view of the axially-canted-coil spring of FIG. 7A :
[0047] FIG. 8A is a cross-sectional front elevation view of another embodiment of the present locking mechanism in an assembled configuration:
[0048] FIG. 8B is a cross-sectional left side elevation view of the housing portion and the piston portion of FIG. 8A taken through the line B-B in FIG. 8A ;
[0049] FIG. 9A is a cross-sectional front elevation view of another embodiment of the present locking mechanism in an assembled configuration:
[0050] FIG. 9B is a cross-sectional left side elevation view of the housing portion and the piston portion of FIG. 9A taken through the line B-B in FIG. 9A ;
[0051] FIG. 10 is a front perspective view another embodiment of the present locking mechanism in an assembled configuration;
[0052] FIG. 10A is a cross-sectional front elevation view of die housing portion of the locking mechanism of FIG. 10 ;
[0053] FIG. 10B is a cross-sectional front elevation view of the piston portion of the locking mechanism of FIG. 10 ;
[0054] FIG. 10C is a cross-sectional front elevation view of the housing portion and the piston portion of FIGS. 10A and 10B in a partially assembled configuration;
[0055] FIG. 10D is a cross-sectional front elevation view of the housing portion and the piston portion of FIGS. 10A and 10B in a fully assembled, configuration;
[0056] FIG. 10E is a cross-sectional left side elevation view of the housing portion and the piston portion of FIG. 10D taken through the line E-E in FIG. 10D ;
[0057] FIG. 10F is a cross-sectional left side elevation view of the housing portion and the piston portion of FIG. 10C taken through the line F-F in FIG. 10C ;
[0058] FIG. 10G is a detail view of the portion of FIG. 10D indicated by the circle G;
[0059] FIG. 11 is a front perspective view another embodiment of the present locking mechanism in an assembled configuration;
[0060] FIG. 11A is a cross-sectional front elevation view of the housing portion of the locking mechanism of FIG. 11 ;
[0061] FIG. 11B is a cross-sectional front elevation view of the piston portion of the locking mechanism of FIG. 11 ;
[0062] FIG. 11C is a cross-sectional front elevation view of the housing portion and the piston portion of FIGS. 11A and 11B in a partially assembled configuration;
[0063] FIG. 11D is a cross-sectional front elevation view of the housing portion and the piston portion of FIGS. 11A and 11B in a fully assembled configuration;
[0064] FIG. 11E is a cross-sectional left side elevation view of the housing portion and the piston portion of FIG. 11D taken through the line E-E in FIG. 11D ;
[0065] FIG. 11F is a cross-sectional left side elevation view of the housing portion and the piston portion of FIG. 11C taken through the line F-F in FIG. 11C ; and
[0066] FIG. 11G is a detail view of the portion of FIG. 11D indicated by the circle G.
DETAILED DESCRIPTION
[0067] The detailed description set forth below in connection with the appended drawings is intended as a description of the presently preferred embodiments of a simple release locking mechanism and is not intended to represent the only forms in which the present embodiments may be constructed or used. The description sets forth the features and the steps for constructing and using the simple release locking mechanism of the present embodiments. It is to be understood, however, that the same or equivalent functions and structures may be accomplished by different embodiments that are also intended to be encompassed within the spirit and scope of the embodiments. As denoted elsewhere herein, like element numbers are intended to indicate like or similar elements or features.
[0068] Unless specifically noted, it is intended that the words and phrases in the specification and the claims be given their ordinary and accustomed meaning to those of ordinary skill in the applicable arts. If any other special meaning is intended for any word or phrase, the specification will clearly state and define the special meaning. In particular, most words have a generic meaning. If it is intended to limit or otherwise narrow the generic meaning, specific descriptive adjectives will be used to do so. Absent the use of special adjectives, it is intended that the terms in this specification and claims be given their broadest possible, generic meaning. For example, unless the context indicates otherwise, a canted-coil spring can be either an axial or a radial canted-coil spring. It can also be a hybrid, with characteristics of both axial and radial springs. It can also have different configurations, such as round, oval, square, etc.
[0069] The illustrated embodiments of the present locking mechanism discussed herein include canted coil springs. In certain embodiments the coil springs may be radially canted, while in certain other embodiments the coil springs may be axially canted. In still further embodiments the coil springs may be both radially canted and axially canted. Canted coil springs are described in detail in U.S. Pat. Nos. 4,655,462; 4,826,144; 4,876,781; 4,907,788; 4,915,366; 4,964,204; 5,139,243; 5,160,122; 5,503,375; 5,615,870; 5,709,371; 5,791,638; and 7,055,812. The contents of each of the foregoing patents are hereby incorporated by reference herein.
[0070] FIGS. 1A-1H and 1 J- 1 M illustrate one embodiment of the present locking mechanism 100 . With reference to FIGS. 1A and 1B , the locking mechanism 100 includes a generally cylindrical housing 101 having a longitudinal axis 103 . The housing 101 comprises a first furcation 102 and a second furcation 104 in a first end portion. The first and second furcations 102 , 104 define a slot 106 therebetween. The slot 106 is an open space that is shaped substantially as a rectangular parallelepiped, being bounded along three faces by the housing 101 and the furcations 102 , 104 , and being open along the remaining three faces. Those of ordinary skill in the art will appreciate that in alternative embodiments the slot 106 may have other configurations. With reference to FIGS. 1A and 1H , an inner surface 107 of the first furcation 102 includes a taper bottom groove 108 that retains a linear axially-canted-coil spring 110 . The spring length runs perpendicular to the longitudinal axis 103 . The linear canted-coil spring 110 is illustrated in further detail in FIG. 1M . In other embodiments, the tapered bottom groove may be located on the second furcation 104 .
[0071] The locking mechanism 100 further includes a generally cylindrical piston 112 configured to assemble in-line with the housing 101 . The piston 112 includes a body section 114 and a longitudinal axis 103 . A piston tongue 116 extends away from the body section 114 , defining first and second shoulders 118 to either side of the tongue 116 . In the illustrated embodiment, the tongue 116 is shaped substantially as a rectangular parallelepiped. However, with reference to FIG. 1E , two opposite faces of the tongue 116 are convex so that when the tongue 116 is disposed in the slot 106 an outer surface of the slot 106 /tongue 116 junction is substantially cylindrical. Those of ordinary skill in the art will appreciate that in alternative embodiments the tongue 116 may have other shapes.
[0072] With reference to FIGS. 1A and 1B , a first face 120 of the tongue 116 includes a flat bottomed groove 122 . The groove 122 receives the linear canted-coil spring 110 when the locking mechanism 100 is in the assembled configuration of FIG. 1C . The groove 122 contributes to the locking action in the locking mechanism 100 , as explained in further detail below.
[0073] With continued reference to FIGS. 1A and 1B , the outer surface 124 of the piston 112 includes a circumferential groove 126 . The circumferential groove 126 receives a circular or garter radially-canted-coil spring 128 . The circular radially-canted-coil spring 128 is illustrated in greater detail in FIG. 1N .
[0074] In one embodiment, the circular canted-coil spring 128 may be secured inside the circumferential groove 126 by controlling a spring squeeze between the groove 126 and the spring 128 . In alternative embodiments, or in the event the spring 128 does not have enough squeeze, the ends of the groove 126 could be pinned or staked such as to cap the channel of the groove to retain the spring 128 therein.
[0075] A generally cylindrical sleeve 130 is mounted over the outer surface 124 of the piston 112 . The sleeve 130 is slidable along the outer surface 124 between the retracted position, of FIG. 1B and the closed position of 1 C. In the retracted position the sleeve 130 is spaced apart from the circular canted-coil spring 128 on a side of the spring 128 opposite the tongue 116 . In the closed position the sleeve 130 covers the spring 128 to retain the housing 101 and the piston 112 in the assembled configuration, as described in further detail below.
[0076] To assemble the illustrated locking mechanism 100 , the tongue 116 is inserted into the slot 106 as illustrated in FIG. 1C . The tongue 116 may be inserted into the slot 106 by relative axial movement of the housing 101 and the piston 112 , as shown by the arrow 132 in FIGS. 1A , 1 B and 1 H. The tongue 116 is inserted into the slot 106 until the ends of the furcations 102 , 104 contact the shoulders 118 . In this configuration the groove 122 in the tongue 116 at least partially aligns with the groove 108 in the inner surface 107 of the first furcation 102 . The linear canted-coil spring 110 is thus compressed between the two grooves 108 , 122 as shown in the detail view of FIG. 1G . The compressed spring 110 provides locking action that prevents the axial separation of the housing 101 and the piston 112 , as described in further detail, below.
[0077] FIG. 1G shows the manner in which the axial locking occurs. First, the groove width (G.W.) is smaller than the coil height (C.H.). Second, a base 134 of the groove 108 is tapered such that a depth of the groove increases with increasing distance from a second end portion 136 ( FIG. 1C ) of the housing 101 . The taper bottom groove 108 facilitates the counter-clockwise rotation of the linear canted-coil spring 110 as the tongue 116 is inserted axially into the slot 106 . Further the relative dimensions of groove width and coil height in combination with the taper bottom groove also retards the reverse rotation of the coil spring 110 as the tongue 116 is withdrawn axially from the slot 106 , as occurs when a tensile force is applied to the locking mechanism 100 . Consequently, a greater force is required to remove the tongue 116 axially from the slot 106 than is required to insert the tongue 116 axially into the slot 106 . The magnitude of the difference between the insertion force and the removal, force can be adjusted by adjusting the relative dimensions of groove width and coil height and the angle 144 of the taper bottom groove 108 . In certain embodiments the angle 144 of the taper bottom groove 108 may be tapered to produce a spring in a convex initial position. In other embodiments, the angle produces a spring in a concave initial position. In still other embodiments the magnitude of the removal force may be so great that the tongue 116 cannot be removed axially from the slot 106 without destroying the spring 110 . These concepts are described in detail in U.S. Pat. Nos. 4,678,210; 5,082,390; 5,411,348; 5,545,842; 6,749,358; 6,835,084; 7,055,812, 7,070,455 and 7,195,523, all of which are incorporated herein by reference.
[0078] To complete the assembly of the locking mechanism, the sleeve 130 is slid along the piston 112 from the retracted position of FIG. 1B to the closed position of 1 C. In the closed position an end 138 of the sleeve 130 abuts a shoulder 140 on the housing 101 to prevent further movement of the sleeve 130 toward the housing 101 . In the closed position the sleeve 130 covers the spring 128 and compresses the spring 128 into the circumferential groove 126 , Friction between the spring 128 and the sleeve 130 thus resists sliding movement of the sleeve 130 away from the housing 101 . The inner surface of the sleeve 130 , however, is smooth. Thus, the sleeve 130 is not locked against sliding movement relative to the piston 112 . Rather, sliding movement relative to the piston 112 is merely retarded by the friction between the spring 128 and the sleeve 130 . In the closed position the sleeve 130 also covers the junction between the tongue 116 and the slot 106 . In inner surface of the sleeve 130 contacts the outer surfaces of the furcations 102 , 104 and the tongue 116 , as illustrated in the cross-sectional view of FIG. 1E . The sleeve 130 thus prevents relative movement of the housing 101 and the piston 112 in a direction perpendicular to the longitudinal axis 103 . In the assembled configuration, the housing 101 and the piston 112 are thus locked because they cannot be separated from one another in either the axial direction (parallel to the longitudinal axis 103 ) or the radial direction (perpendicular to the longitudinal axis 103 ).
[0079] With reference to FIGS. 1A , 1 B, 1 C and 1 G, it is possible to insert the tongue 116 into the slot 106 in a configuration in which the piston 112 is rotated 180° about its longitudinal axis from the configuration shown in FIG. 1C . In this reversed configuration, locking action may not occur between the housing 101 and the piston 112 because the groove 122 in the tongue 116 would not align with the groove 108 in the slot 106 . Therefore, in order to ensure locking action the piston 112 is preferably inserted into the housing 101 in the orientation shown in FIGS. 1A-1C in which the grooves 108 , 122 line up. In one example embodiment, a longitudinally aligned combination tongue-and-group is incorporated for alignment purposes, which would run parallel to but offset from the longitudinal axis of the piston, instead of the current orthogonal configuration to the longitudinal axis of the piston. In alternative embodiments, external markers may be provided as alignment indicia.
[0080] FIGS. 1D and 1F illustrate a method of disassembling the housing 101 and the piston. 112 from one another. The reader will note that the cross-sectional view of FIG. 1F is taken through the line F-F in FIG. 1D , but FIG. 1F has been rotated 90° counter-clockwise from the orientation shown in FIG. 1D . To disassemble the housing 101 and the piston 112 from, one another, first the sleeve 130 is slid along the piston 112 from the closed position ( FIG. 1C ) to the retracted position ( FIG. 1D ). Next, the housing 101 and the piston 112 are moved relative to one another in the radial direction (perpendicular to the longitudinal axis 103 , as indicated by the arrows 142 in FIGS. 1D and 1F ). The compressed linear spring 110 resists, but does not prevent, relative sliding movement of the housing 101 and the piston 112 . These components can thus be separated from one another by relative radial movement once the locking sleeve 130 is moved to the retracted position.
[0081] FIGS. 1J , 1 K, and 1 L illustrate alternate configurations for the present locking mechanism 146 , 148 . With reference to FIGS. 1J and 1L , in the illustrated embodiment 146 the sleeve 150 includes a circumferential groove 152 on its inner surface. When the sleeve 150 is slid to the locked position ( FIG. 1J ), the groove 152 at least partially aligns with a circumferential taper bottom groove 154 in the piston 156 . The groove 152 thus receives an axially canted-coil spring 158 and compresses the axially canted-coil spring 158 between the groove 152 and the groove 154 . The compressed spring 158 resists, but does not prevent the sleeve 150 from sliding away from the housing 101 and out of the locked position. In contrast to the taper bottom groove 108 illustrated in FIG. 1G , the taper bottom groove 154 tapers in the opposite direction. Thus, as the sleeve 150 slides to the right relative to the piston 156 in FIG. 1L , the sleeve 150 moves across the groove 154 from its deep end 160 toward its shallow end 162 . There is thus room for the spring 158 to rotate clockwise under the influence of friction from the groove 152 and the inner surface of the sleeve 150 .
[0082] FIG. 1K illustrates another embodiment 148 in which the piston 164 does not include a circumferential groove retaining a circular coil spring. Instead, the piston 164 includes an end portion 166 having an enlarged outer diameter. The sleeve 168 includes an annular shoulder 170 formed at a junction between a first inner diameter portion 172 and a second inner diameter portion 174 . A coil spring 176 (or similar resilient member) is held in compression between the enlarged end portion 166 and the annular shoulder 170 . The compressive force in the spring 176 holds the sleeve 168 in the closed position in which it covers the junction between the furcations 102 , 104 and the tongue 116 . An operator may squeeze the sleeve 168 with his hand (or with a tool) to slide the sleeve 168 along the piston 164 toward the enlarged end portion 166 until it no longer covers the junction between the furcations 102 , 104 and the tongue 116 . With the sleeve 168 no longer covering the junction, the housing 101 and piston 164 may be separated by relative movement in the radial direction (perpendicular to the longitudinal axis 103 ).
[0083] FIGS. 2A-2C illustrate another embodiment of the present locking mechanism 200 . The locking mechanism 200 includes many of the same features described above with respect to the locking mechanism 100 illustrated in FIGS. 1A-1H and 1 J- 1 M. Accordingly, the discussion below will focus on only the differences between the embodiments. With reference to FIG. 2A , in the locking mechanism 200 the tongue 202 of the piston 204 is offset from the longitudinal axis 103 . The slot 206 of the housing 208 is similarly offset from the longitudinal axis 103 . The offset of the tongue 202 and the slot 206 contribute to proper alignment of the housing 208 and the piston 204 . If the housing 208 and the piston 204 are misaligned, as shown in FIG. 1C , the misalignment will be obvious to the operator.
[0084] In the locking mechanism 200 the sleeve 210 includes an enlarged end portion 212 spaced from the housing 208 . The enlarged end portion 212 provides a bearing surface 214 for the operator's hand or a tool, facilitating the sliding movement of the sleeve 210 aware from the closed position of FIG. 2A .
[0085] FIGS. 3A-3E illustrate another embodiment of the present locking mechanism 300 . The locking mechanism 300 includes many of the same features described above with respect to the locking mechanisms 100 , 200 illustrated in FIGS. 1A-1H , 1 J- 1 M and 2 A- 2 C. Accordingly, the discussion below will focus on only the differences between the embodiments. With reference to FIGS. 3A-3D , in the locking mechanism 300 a first surface 301 the tongue 302 of the piston 304 includes a taper bottom groove 306 chat retains a linear axially-canted-coil spring 308 . A first surface 310 of the first furcation 312 of the housing 314 includes a flat bottomed groove 316 . Accordingly, with reference to FIGS. 1G and 3C the configuration of the grooves 306 , 316 in the locking mechanism 300 is the reverse of the configuration of the grooves 108 , 122 in the locking mechanism 100 . However, the function of the grooves 306 , 316 is identical to the function of the grooves 108 , 122 , which is described in detail above and will not be repeated here. With reference to FIGS. 3D and 3E , the taper bottom groove 306 may extend perpendicular to the longitudinal axis 103 ( FIG. 3D ), or it may lie at a non-perpendicular to the longitudinal axis 103 ( FIG. 3E ). The linear canted-coil spring 308 assumes the same angle to the longitudinal axis 103 as the groove 306 . Those of ordinary skill in the art will appreciate that the illustrated angles for the taper bottom groove 306 and linear canted-coil spring 308 are applicable to all of the present embodiments, regardless of whether they are specifically discussed with respect to any particular embodiment.
[0086] FIG. 4 illustrates another embodiment of the present locking mechanism 400 . The locking mechanism 400 includes many of the same features described above with respect to the locking mechanisms 100 , 200 , 300 illustrated in FIGS. 1A-1H , 1 J- 1 M, 2 A- 2 C and 3 A- 3 E. Accordingly, the discussion below will focus on only the differences between the embodiments. With reference to FIG. 4 , in the locking mechanism 400 the tongue 402 of the piston 404 includes a step defined by a first portion 406 having a relatively shorter length and a second portion 408 having a relatively longer length. The slot 410 in the housing 412 similarly includes a step defined by a first portion 414 having a relatively lesser depth and a second portion 416 having a relatively greater depth. The steps contribute to proper alignment of the housing 412 and the piston 404 . The tongue 402 may only be inserted completely within the slot 410 when the tongue first portion 406 is aligned with the slot first portion 414 and the tongue second portion 408 is aligned with the slot second portion 416 . If the housing 412 and the piston 404 are misaligned, the misalignment will be obvious to the operator.
[0087] FIGS. 5A-5D illustrate another embodiment of the present locking mechanism 500 . The locking mechanism 500 includes many of the same features described above with respect to the locking mechanisms 100 , 200 , 300 , 400 illustrated in FIGS. 1A-1H , 1 J- 1 M, 2 A- 2 C, 3 A- 3 E and 4 . Accordingly, the discussion below will focus on only the differences between the embodiments. With reference to FIGS. 5A , 5 B and 5 D, in the locking mechanism 500 a first surface 502 of the first furcation 504 of the housing 506 includes a taper bottom groove 508 that retains a linear axially-canted-coil spring 510 . A first surface 512 of the tongue 514 of the piston 516 includes a flat bottomed groove 518 . With reference to FIGS. 5A-5C , in the locking mechanism 500 a first surface 520 of the second furcation 522 of the housing 506 includes a taper bottom, groove 524 that retains a linear canted-coil spring 510 . A second surface 526 of the tongue 514 of the piston 516 includes a flat bottomed groove 528 . The function of the grooves 508 , 518 , 524 , 528 is identical to the function of the grooves 108 , 122 , which is described in detail above and will not be repeated here. However, because the locking mechanism 500 includes two linear canted-coil springs 510 and associated grooves, in certain embodiments it may provide greater axial holding power than the locking mechanisms including only one linear canted-coil spring and associated grooves.
[0088] FIGS. 6A-6D illustrate another embodiment of the present locking mechanism 600 . The locking mechanism 600 includes many of the same features described above with respect to the locking mechanisms 100 , 200 , 300 , 400 , 500 illustrated in FIGS. 1A-1H , 1 J- 1 M 2 A- 2 C, 3 A- 3 E, 4 and 5 A- 5 D. Accordingly, the discussion below will focus on only the differences between the embodiments. With reference to FIGS. 6A-6C , in the locking mechanism 600 a first surface 602 of the tongue 604 of the piston 606 includes a taper bottom groove 608 that retains a linear axially-canted-coil spring 610 . A first surface 612 of the first furcation 614 of the housing 616 includes a fiat bottomed groove 618 . With reference to FIGS. 6A , 6 B and 6 D, in the locking mechanism 600 a second surface 620 of the tongue 604 of the housing 606 includes a taper bottom groove 622 that retains a linear canted-coil spring 610 . A first surface 624 of the second furcation 626 of the piston 616 includes a flat bottomed groove 628 . The function of the grooves 608 , 618 , 622 , 628 is identical to the function of the grooves 306 , 316 , which is described in detail above and will not be repeated here. However, because the locking mechanism 600 includes two linear canted-coil springs 610 and associated grooves, in certain, embodiments it may provide greater axial holding power than the locking mechanisms including only one linear canted-coil spring and associated grooves.
[0089] FIGS. 7A-7C illustrate another embodiment of the present locking mechanism 700 . The locking mechanism 700 includes many of the same features described above with respect to the locking mechanisms 100 , 200 , 300 , 400 , 500 , 600 illustrated in FIGS. 1A-1H , 1 J- 1 M, 2 A- 2 C, 3 A- 3 E, 4 , 5 A- 5 D and 6 A- 6 D. Accordingly, the discussion below will focus on only the differences between the embodiments. With reference to FIGS. 7A and 7B , the locking mechanism 700 includes a piston 702 having a tongue 704 . With reference to FIG. 7B , the tongue 704 has a square cross-section. The locking mechanism 700 further includes a housing 706 having a first furcation 708 and a second furcation 710 . A slot 712 defined between the first and second furcations 708 , 710 is sized and configured to receive the square tongue 704 in locking engagement.
[0090] With continued reference to FIGS. 7A and 7B , the square tongue 704 includes a circumferential taper bottom groove 714 that extends around all four outer faces of the square tongue 704 . The circumferential taper bottom groove 714 receives and retains a circular, axially-canted-coil spring 716 . The circular, axially-canted-coil spring 716 is illustrated in greater detail in FIG. 7C .
[0091] With reference to FIG. 7A , inner surfaces 717 of the first and second furcations 708 , 710 each include a respective flat bottom groove 718 . Thus, when the square tongue 704 is inserted into the slot 712 as shown in FIG. 7A , the circular, axially-canted-coil spring 716 is compressed along two portions of its length. Those portions are the first portion 720 ( FIG. 7B ) that lies between a first one of the flat bottom grooves 718 and a first length of the circumferential, taper bottom groove 714 and the second portion 722 ( FIG. 7B ) that lies between a second one of the flat bottom grooves 718 and a second length of the circumferential taper bottom groove 714 . The interaction of the grooves 714 , 718 and the compressed spring portions 720 , 722 prevents the axial separation of the housing 706 and the piston 702 in the same manner as described above with respect to the previous embodiments. The housing 706 and the piston 702 may be separated by relative radial movement as also described above with respect to the previous embodiments.
[0092] FIGS. 8A-8B illustrate another embodiment of the present locking mechanism 800 . The locking mechanism 800 includes many of the same features described above with respect to the locking mechanisms 100 , 200 , 300 , 400 , 500 , 600 , 700 illustrated in FIGS. 1A-1H , 1 J- 1 M, 2 A- 2 C, 3 A- 3 E, 4 , 5 A- 5 D, 6 A- 6 D and 7 A- 7 C. Accordingly, the discussion below will focus on only the differences between the embodiments. With reference to FIGS. 8A and 8B , the locking mechanism 800 includes a piston 802 having a tongue 804 . With reference to FIG. 8B , the tongue 804 has an oval cross-section comprising opposite flat sections 803 and opposite arcuate sections 805 . The locking mechanism 800 further includes a housing 806 having a first furcation 808 and a second furcation 810 . A slot 812 defined between the first and second furcations 808 , 810 is sized and configured to receive the oval tongue 804 in locking engagement in which the opposite flat sections 803 engage inner surfaces 817 of the first and second furcations 808 , 810 .
[0093] With continued reference to FIGS. 8A and 8B , the oval tongue 804 includes a circumferential taper bottom groove 814 that extends around the opposite flat sections 803 and the opposite arcuate sections 805 . The circumferential taper bottom groove 814 receives and retains a circular, axially-canted-coil spring 816 .
[0094] With reference to FIG. 8A , the first and second furcations 808 , 810 each include a respective flat bottom groove 818 . Thus, when the oval tongue 804 is inserted into the slot 812 as shown in FIG. 8A , the circular, axially-canted-coil spring 816 is compressed along two portions of its length. Those portions are the first portion 820 ( FIG. 8B ) that lies between a first one of the fiat bottom grooves 818 and a first length of the circumferential taper bottom groove 814 and the second portion 822 ( FIG. 8B ) that lies between a second one of the flat bottom grooves 818 and a second length of the circumferential taper bottom groove 814 . The interaction of the grooves 814 , 818 and the compressed spring portions 820 , 822 prevents the axial separation of the housing 806 and the piston 802 in the same manner as described above with respect to the previous embodiments. The housing 806 and the piston 802 may be separated by relative radial movement as also described above with respect to the previous embodiments.
[0095] FIGS. 9A-9B illustrate another embodiment of the present locking mechanism 900 . The locking mechanism 900 includes many of the same features described above with respect to the locking mechanisms 100 , 200 , 300 , 400 , 500 , 600 , 700 , 800 illustrated in FIGS. 1A-1H , 1 J- 1 M, 2 A- 2 C, 3 A- 3 E, 4 , 5 A- 5 D, 6 A- 6 D, 7 A- 7 C and 8 A- 8 B. Accordingly, the discussion below will focus on only the differences between the embodiments. With reference to FIGS. 9A and 9B , the locking mechanism 900 includes a piston 902 having a tongue 904 . With reference to FIG. 9B , the tongue 904 has a round cross-section. The locking mechanism 900 further includes a housing 906 having a first furcation 908 and a second furcation 910 . A slot 912 defined between the first and second furcations 908 , 910 is sized and configured to receive the round tongue 904 in locking engagement.
[0096] With continued reference to FIGS. 9A and 9B , the round tongue 904 includes a circumferential taper bottom groove 914 . The circumferential taper bottom groove 914 receives and retains a circular, axially-canted-coil spring 916 .
[0097] With reference to FIG. 9A , the first and second furcations 908 , 910 each include a respective flat bottom groove 918 . Thus, when the round tongue 904 is inserted into the slot 912 as shown in FIG. 9A , the circular, axially-canted-coil spring 916 is compressed along two portions of its length. Those portions are the first portion 920 ( FIG. 9B ) that lies between a first one of the flat bottom grooves 918 and a first length of the circumferential taper bottom groove 914 and the second portion 922 ( FIG. 9B ) that lies between a second one of the flat bottom grooves 918 and a second length of the circumferential taper bottom groove 914 . The interaction of the grooves 914 , 918 and the compressed spring portions 920 , 922 prevents the axial separation of the housing 906 and the piston 902 in the same manner as described above with respect to the previous embodiments. The housing 906 and the piston 902 may be separated by relative radial movement as also described above with respect to the previous embodiments.
[0098] FIGS. 10-10G illustrate another embodiment of the present locking mechanism 1000 . The locking mechanism 1000 includes many of the same features described above with respect to the locking mechanisms 100 , 200 , 300 , 400 , 500 , 600 , 700 , 800 , 900 illustrated in FIGS. 1A-1H , 1 J- 1 M, 2 A- 2 C, 3 A- 3 E, 4 , 5 A- 5 D, 6 A- 6 D, 7 A- 7 C, 8 A- 8 B and 9 A- 9 B. Accordingly, the discussion below will focus on only the differences between the embodiments. With reference to FIGS. 10-10B , the locking mechanism 1000 includes a piston 1002 having a tongue 1004 . With reference to FIG. 10E , the tongue 1004 has a round cross-section. The locking mechanism 1000 further includes a housing 1006 having a first furcation 1008 and a second furcation 1010 ( FIGS. 10 and 10E ). A wall portion 1011 extends between the first and second furcations 1008 , 1010 to form a substantially U-shaped cross-section. A slot 1012 bounded by the furcations 1008 , 1010 and the wall portion 1011 is sized and configured to receive the round tongue 1004 in locking engagement.
[0099] With reference to FIGS. 10B and 10C , the round tongue 1004 includes a circumferential taper bottom groove 1014 . The circumferential taper bottom groove 1014 receives and retains a circular, axially-canted-coil spring 1016 .
[0100] With reference to FIG. 10A , the first and second furcations 1008 , 1010 and the wall portion 1011 include a flat bottom groove 1018 . Thus, when the round tongue 1004 is inserted, into the slot 1012 as shown in FIGS. 10C and 10D , the circular, axially-canted-coil spring 1016 is compressed along approximately half its length in the areas that abut the groove 1018 in the first and second furcations 1008 , 1010 and the wall portion 1011 ( FIG. 10E ). The interaction of the grooves 1014 , 1018 and the compressed spring 1016 prevents the axial separation of the housing 1006 and the piston 1002 in the same manner as described above with respect to the previous embodiments. The housing 1006 and the piston 1002 may be separated by relative radial movement as also described above with respect to the previous embodiments and as shown in FIG. 10F .
[0101] FIGS. 11-11G illustrate another embodiment of the present locking mechanism 1100 . The locking mechanism 1100 includes many of the same features described above with respect to the locking mechanisms 100 , 200 , 300 , 400 , 500 , 600 , 700 , 800 , 900 , 1000 illustrated in FIGS. 1A-1H , 1 J- 1 M, 2 A- 2 C, 3 A- 3 E, 4 , 5 A- 5 D, 6 A- 6 D, 7 A- 7 C, 8 A- 8 B, 9 A- 9 B and 10 - 10 G. Accordingly, the discussion below will focus on only the differences between the embodiments. With reference to FIGS. 11-11B , the locking mechanism 1100 includes a piston 1102 having a tongue 1104 . With reference to FIG. 11E , the tongue 1104 has a round cross-section. The locking mechanism 1100 further includes a housing 1106 having a first furcation 1108 and a second furcation 1110 ( FIGS. 11 and 11E ). A wall portion 1111 extends between the first and second furcations 1108 , 1110 to form a substantially U-shaped cross-section. A slot 1112 bounded by the furcations 1108 , 1110 and the wall portion 1111 is sized and configured to receive the round tongue 1104 in locking engagement.
[0102] With reference to FIGS. 11B and 11C , the round tongue 1104 includes a circumferential taper bottom groove 1114 . The circumferential taper bottom groove 1114 receives and retains a circular, axially-canted-coil spring 1116 .
[0103] With reference to FIG. 11A , the first and second furcations 1108 , 1110 and the wall portion 1111 include a fiat bottom groove 1118 . Thus, when the round tongue 1104 is inserted into the slot 1112 as shown in FIGS. 11C and 11D , the circular, axially-canted-coil spring 1116 is compressed along approximately half its length in the areas that abut the groove 1118 in the first and second furcations 1108 , 1110 and the wall portion 1111 ( FIG. 11E ). The interaction of the grooves 1114 , 1118 and the compressed spring 1116 prevents the axial separation of the housing 1106 and the piston 1102 in the same manner as described above with respect to the previous embodiments. The housing 1106 and the piston 1102 may be separated by relative radial movement as also described above with respect to the previous embodiments and as shown in FIG. 11F .
[0104] Unlike the previous embodiments, the locking mechanism 1100 does not include a circumferential groove in the body portion 1120 ( FIG. 10 ) of the piston 1102 . However, the locking mechanism 1100 includes a sleeve 1122 shaped substantially as a cylinder having a flat side wall 1124 . With reference to FIGS. 11D and 11E , when the sleeve 1122 is slid toward the housing 1106 into the locked position, the flat side wall 1124 compresses a portion of the spring 1116 into the circumferential groove 1118 . Friction between the spring 1116 and the inner surface of the flat side wall 1124 resists sliding movement of the sleeve 1122 away from the locked position.
[0105] In certain aspects of the present embodiments, the housing is part of a rotating or reciprocating shaft of equipment or an appliance, such as a drill or a food mixer, and the piston is part of a removable component, such as a chuck. In another embodiment, the piston is part of a rotating or reciprocating shaft of equipment or an appliance, and the housing is part of a removable component. In yet other aspects of the present embodiments, the removable component may be provided with a bore, a socket, a key, a groove, or other mechanical means known in the art for coupling to a tool such as a drill bit, a saw blade, or a food mixer blade, for example.
[0106] Although limited embodiments of simple release locking mechanisms and their components have been specifically described and illustrated herein, many modifications and variations will be apparent to diose skilled in the art. For example, different spring material, different spring size, and multiple rows of springs may be used without deviating from the spirit and scope of the present embodiments. Furthermore, it is understood and contemplated that features specifically discussed for one simple release locking mechanism may be adopted for inclusion with another simple release locking mechanism, provided the functions are compatible. Accordingly, it is to be understood that the simple release locking mechanisms and their components constructed according to principles of these embodiments may be embodied other than as specifically described herein. The embodiments are also defined in the following claims.
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A locking tool or device that permits rapid installation and removal of a removable component from a component that is fixed to a housing or equipment. The interchangeable, and hence removable, components may be held in place by individual holders that provide secure axial locking means and quick radial removal means requiring no axial space for the removal of such components from the main base tool.
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BACKGROUND OF THE INVENTION
The present invention relates to temporary protective coating compositions which are useful in passivating untreated metallic substrates. More specifically, the invention relates to aqueous temporary protective coating compositions comprising addition polymers and waxes which are useful as mill passivating compositions.
BRIEF DESCRIPTION OF THE PRIOR ART
Passivation of metals in mills is done in the main with mill oils or chemical treatments in order to prevent or reduce corrosion, particularly white rust. The shortcoming of mill oils is the difficulty in removing them effectively and the less than desired corrosion protection provided thereby. The shortcoming of chemical treatments, particularly those involving film-forming materials, is their incompatibility with materials and processes that are subsequently applied to the subject substrate.
Art-related protective coating compositions comprising alkali-soluble carboxyl group-containing polymers and/or waxes are known in the art. Most of these compositions are employed distinctly on painted or polished surfaces and are less effective on untreated metallic substrates.
In contrast, the protective coating compositions which are of interest here should be suited to the application to bare metallic substrates. Additionally, these protective coating compositions should be compatible with subsequently applied pretreatment compositions, they should be formable, weldable, and removable with an aqueous alkaline solution, and they should be able to prevent or reduce corrosion, particularly in the form of white rust. These types of temporary protective coating compositions are hereby provided.
SUMMARY OF THE INVENTION
In accordance with the foregoing, the present invention encompasses: a formable, weldable aqueous temporary protective compositions for a metallic substrate, said composition comprises in combination a neutralized acid- or base-functional polymer and a lubricating composition consisting essentially of a relatively high amount of wax, i.e., an amount sufficient to provide drawability and formability, of the metallic substrate to which it was applied.
In the present embodiment of the invention, there is employed herein a base-neutralized acid-functional polymer. The acid-functional polymer in combination with a wax is prepared by copolymerization of ethylenically unsaturated monomers, at least one of which is acid functional, in a solvent, in the presence of a wax such as hydrocarbon wax. The resultant composition is dispersed in water in the presence of a base such as ammonium hydroxide.
When applied as a passivating agent, the protective coating compositions, in the preferred embodiment, are found to produce coatings which are corrosion resistant, drawable, formable, weldable, and easily removable with an aqueous alkaline or acidic solution.
The term "formable" or "formability" is defined as the ability of a coated sheet of metal to be bent without creating substantial cracks or voids in the film. The term "drawable" or "drawability" is defined as the ability to stamp a coated sheet of metal into a curved three-dimensional shape without substantially breaking the sheet and without significant damage to the coated sheet of metal. The term "weldable" or "weldability" is defined as the ability to perform spot welds on a coated sheet of metal using conventional spot welding tips and pressures. As would be realized, the above properties can be affected by the nature of the selected sheet of metal. At any rate, the protective coating compositions of this invention show remarkable improvement in the aforestated properties.
DETAILED DESCRIPTION OF THE INVENTION
The aqueous temporary protective coating compositions of this invention, in the preferred embodiment, are characterized as being drawable, formable, weldable, and easily removable with an aqueous alkaline solution. These and other aspects of the claimed protective coating compositions are described more fully below.
The acid- or base-neutralized, functional polymers that are employed herein has a Tg of about -30° C. to 100° C. and preferably about -15° C. to 30° C., and a weight average molecular weight of about 3,000 to 90,000 and preferably about 5,000 to 30,000. Typically, the polymer is a solution polymerized free-radical addition polymer. The polymers can be acid or base functional. In accordance with this invention, the acid-functional polymer can be prepared by polymerizing in a solvent medium, ethylenically unsaturated monomers at least one of which is an acid-functional monomer. Examples of the acid-functional monomers can be acrylic acid, methacrylic acid, crotonic acid, itaconic acid, maleic acid, and the like. Amounts of about 5 to 100 percent by weight of the acid-functional monomer based on the total monomer content can be employed. Typically, amounts of about 10 to 40 and preferably about 10 to 30 percent by weight are employed. Copolymerizable ethylenically unsaturated monomers such as vinyl monomers, e.g., styrene, vinyl toluene and the like, esters of acrylic or methacrylic acid, such as methyl methacrylate, butyl acrylate, and 2-ethylhexylacrylate, can be employed.
The base-functional polymer can be prepared by polymerizing in a solvent medium ethylenically unsaturated monomers at least one of which is a base-functional monomer. Examples of the base-functional monomers can be amino alkyl(meth)acrylate, t-butyl aminoethyl(meth)acrylate, diisobutylaminoethyl(meth)acrylate, and dimethyl aminoethyl(meth)acrylate. Amounts of about 1 to 50 and preferably about 5 to 20 of the base-functional monomers are employed.
The lubricant composition useful herein consists essentially of wax. The wax is believed to impart the property of drawability to the protective coating compositions. Typically, the wax has a melting point of about 140° F. Suitable waxes include hydrocarbon and/or ester containing waxes of varying melting points and grades, e.g., polyethylene. petrolatum wax, bees wax, carnauba wax and a mixture thereof. Amounts of wax ranging from about 5 to 70 and preferably about 10 to 30 percent by weight, based on the total weight of the wax and polymer are employed herein. The lubricant composition may contain additives such as silicone fluids, molybdenum disulfide, graphite, hydrocarbon oils, vegetable oils, fatty acids, and resins. In the preferred embodiment wherein the addition polymer is prepared in the presence of the wax, it is believed, without being bound thereby, that a graft of the wax and the polymer are thereby formed. It should, however, be realized that a polymer can be made in the absence of wax and then employed in combination with a wax, preferably in the form of a powder or liquid.
In a particularly preferred embodiment of the invention, graphite or an equivalent thereof, is employed as an additive that enhances conductivity of the applied protective coating compositions during welding. These additives are usually employed in the form of particulates. They are employed in amounts sufficient to effect welding of films of a relatively higher thickness. In the context of this invention, it would be preferable to employ these additives in films of thickness of about 1.5 milligrams per square inch or higher.
The protective coating compositions can be prepared by thinning the wax-containing acid- or base-neutralized solution polymer in water to a conducive application viscosity. This can be done by at least partially neutralizing the functional polymer. Neutralization can be conducted before or during the thinning. Volatile neutralizing agents are preferred. By the term "volatile", it is meant that the neutralizing agent leaves the applied coating when it is dried or baked. For an acid-functional polymer, neutralization is affected with a base. Illustrative examples of the bases can be ammonia, including ammonium hydroxide, primary or secondary amines, e.g., ethanolamine, diethanolamine, N-methylethanolamine, dimethylethanolamine, methylamine, ethylamine, triethylamine and morpholine. For a base-functional polymer, neutralization can be affected with an organic or inorganic acid such as acetic acid, lactic acid, phosphoric acid or the like.
Additives, such as defoamers, wetting agents, or additional cosolvents, may be employed herein. It is a distinct feature of this invention that the protective coating compositions are free of or substantially free of an external surfactant which can cause water sensitivity and poor corrosion resistance.
In the practice of the invention, the protective coating compositions can be applied to metallic substrates by a conventional method such as spraying, brushing, dipping, roller coating, curtain coating or the like. Coating weights of about 0.3 to 4, preferably about 0.5 to 3, and more preferably about 1.0 to 2.0 milligrams per square inch can be applied. It would, of course, be realized that substrates with a different surface roughness and porosity may require a different film thickness of the applied protective coating compositions. The applied coatings are air dried or forced dried or baked in a remarkably short period of time. The resultant coatings have been found to be block resistant, i.e., the coated substrates are resistant to sticking together when stacked.
Removal of the applied coatings are easily effected by contacting the coated substrate with an aqueous alkaline or acidic solution. Contacting means such as spraying, flooding, dipping (immersion) or the like can be employed. It is noteworthy that in actual production practice, conventional lubricants are not satisfactorily removed from inside, enclosed portions of a manufactured article which are not subject to the direct impingement of sprayed cleaners. The coating compositions of this invention can remarkably improve the corrosion resistance of manufactured articles. In essence, the complete removability of the coatings from enclosed areas by immersion enables proper pretreatment of all areas of an article. Consequently, adhesion of subsequently applied paint layers is significantly improved. The concentration of the solution will depend on the nature of the particular alkali or acidic solution, the temperature of removal, and the degree of neutralization by the solution. With the protective coatings removed therefrom, the substrate can be used as such, or subjected to other coating processes such as conversion coating.
It is a distinct feature of the invention that the protective coatings of this invention can be removed effectively by immersion cleaning.
Since it is relatively easy to remove the protective coating compositions of this invention, it is believed that the compositions may be employed by themselves or with mill oils applied thereon in relatively low amounts. The combination of the protective coatings will be removable, drawable, formable, weldable and corrosion resistant. With the combination of protective coatings removed therefrom, the substrate can be used without further treatment or subjected to subsequent coating processes.
The invention is further illustrated by the following non-limiting examples.
EXAMPLE IA
This example illustrates the preparation of a water-based acrylic resin containing wax.
A reaction vessel equipped with thermometer, stirrer, dropping funnels, reflux condenser and means for maintaining a blanket of nitrogen was charged at room temperature with a composition consisting of a mixture of 135 grams of butyl Cellosolve, 22.5 grams of butanol, and 101.3 grams of SHELLMAX (a petroleum wax having a softening point of about 60° C., available from Shell Oil Company). The composition was heated over a period of about 30 minutes to reflux. When the reflux temperature was attained, the simultaneous, gradual addition to the vessel of Charge A and Charge X were started and continued for three hours while maintaining reflux. Charge A consisted of a mixture of 317.2 grams of butyl acrylate, 202.5 grams of styrene, 135.0 grams of acrylic acid, 20.3 grams of diethyl aminoethyl methacrylate, and Charge X consisted of a mixture of 6.8 grams of butyl Cellosolve and 20.3 grams of t-butyl perbenzoate. When the addition of Charges A and X were completed at 150° C., Charge B comprising 2.3 grams of butyl cellosolve plus 2.3 grams of t-butyl perbenzoate was added and the reaction mixture was held for two hours. Charge C comprising 2.3 grams of t-butyl perbenzoate and 2.3 grams of butyl cellosolve was added at 141° C. and the reaction mixture was held for one hour. The reaction mixture was then cooled to 79° C. (A 50/50 resin/M-pryol mixture had a Z-5 Gardner-Holdt viscosity at 41.1 percent solids.) Feed D comprising 112.5 grams of deionized water and 107.1 grams of ammonium hydroxide was added over 15 minutes and held for 15 minutes. Feed E comprising additional 1968.0 grams of deionized water was added to the reaction mixture for 1.5 hours at 72° C. Analysis: Milliequivalents of acid was 0.429, milliequivalents of base was 0.453, weight average molecular weight (Mw) was 10,924, viscosity was 4320 centipoise (Brookfield No. 4 spindle) at 20 revolutions per minute (RPM), pH was 9.30 and percent solids was 22.9 (measured at 110° C. for two hours).
EXAMPLE IB
This example further illustrates the preparation of the water-based acrylic polymer containing wax. The following were used in the preparation:
______________________________________Ingredients Parts by Weight______________________________________Reactor ChargeButyl Cellosolve 140.0Butanol 23.3SHELLMAX 483.0Charge XButyl Cellosolve 7.00t-Butyl perbenzoate 9.7Charge AAcrylic acid 322.01 Dodecanethiol 4.8Charge BButyl Cellosolve 2.4t-butyl perbenzoate 2.4Charge CButyl Cellosolve 2.4t-butyl perbenzoate 2.4Charge DDeionized water 117.0Ammonium hydroxide 271.1Charge EDeionized water 2040______________________________________
A reaction vessel equipped with thermometer, stirrer, dropping funnels, reflux condenser and means for maintaining a blanket of nitrogen was charged at room temperature with a composition consisting of the reactor charge. The composition was heated over a period of about 30 minutes to reflux. When the reflux temperature was attained, the simultaneous, gradual addition to the vessel of Charge A and Charge X was started and continued over three hours while maintaining reflux. When the addition of Charges A and X were completed at 135° C., Charge B was added and the reaction mixture was held for two hours. Charge C was added at 125° C. and the reaction mixture was held for one hour. The reaction mixture was then cooled to 80° C. (resin solids was 82.2 Percent). Feed D was added into the reaction mixture for over 15 minutes and held for 15 minutes. Feed E was added to the reaction mixture over 1.5 hours at 72° C. Analysis: Milliequivalents of acid was 0.921, milliequivalents of base was 0.805, weight average molecular weight was 1410, viscosity was 465 centipoise (Brookfield No. 4 spindle) at 20 RPM, pH was 7.10 and percent solids was 26.8 percent (measured at 110° C for two hours).
EXAMPLE II
The water-based acrylic polymer of Example I was thinned to 12 percent solids with water and flow coated over freshly cleaned electrogalvanized panels. After air drying for 15 minutes until tack-free, the panels were force dried for 5 minutes at 105° C. A film weight of 0.8 to 0.9 milligrams per square inch resulted.
EXAMPLE III
The water-based acrylic polymer of Example IB was thinned to 20 percent solids, applied by a No. 6 wire-wound drawbar to a freshly cleaned electrogalvanized panel, baked for 50 seconds at 550° F. to a peak metal temperature of 420° F. and quenched. A film weight of 1.1 milligrams per square inch resulted. This coated sheet was immersed in a commercial alkaline cleaner for one minute at 140° F. and rinsed for 30 seconds in hot tap water. A clean, water break-free panel resulted, indicating a high degree of cleanliness.
COMPARATIVE EXAMPLE I
As an experimental control for the panels of Example II, freshly cleaned electrogalvanized panels were coated with a commercially available mill oil which is supplied to protect galvanized and other steels from corrosion. Quaker 61A-US oil, available from Quaker Chemical Company, was applied by putting two drops on a 4×12-inch panel and rubbing with the finger of a clean white cotton glove which had been soaked in the same oil. A film weight of 0.6 to 0.8 milligrams per square inch resulted, which is higher than the approximately 0.4 milligrams per square inch of oil found on commercially available electrogalvanized steel as shipped.
EVALUATION
HUMIDITY CORROSION TEST
Panels from Example II and the Comparative Example I were stacked together, clamped, and stored in a humidity cabinet for one week at 100 percent relative humidity and 115°±5° F.
After removal from the humidity cabinet, the test panels from Example II were cleaned by immersion in a one percent solution of an alkaline cleaner for 30 seconds at 150° F. The cleaner, CHEMKLEEN 49, is available from Chemfil Corporation. After rinsing, the panels were "water break free" indicating a high degree of cleanliness. When these humidity-tested panels were compared visually to untested panels cleaned in the same way, there was little, if any, color change apparent in the humidity-tested panels. The lack of color change indicated that very little oxidation of the zinc layer had taken place.
After removal from the humidity cabinet, panels from the Comparative Example I (mill oil) were immersed for three minutes in the same one percent solution of alkaline cleaner. After rinsing, water beaded up on the panels indicating that the panels were not clean. After solvent wiping and additional immersion cleaning for 30 seconds, the panels were water break free and judged to be clean. When these humidity-tested panels were compared visually to untested panels (which were cleaned in the same manner), it was found that the humidity-tested panels were significantly darker than the untested panels. A gray swirling pattern indicated that significant oxidation of the zinc had occurred.
EXAMPLE IV
To test the drawability and lubricity of the protective coating composition of Example II, additional electrogalvanized panels were coated by the same method as in Example II. Approximately 1.0 to 1.1 milligrams per square inch of coating resulted.
COMPARATIVE EXAMPLE II
As an experimental control for Example IV, a commercially available waterborne drawing lubricant, Pillsbury FB-27MC, was applied to freshly cleaned electrogalvanized panels. Eighteen drops of the FB-27MC lubricant were distributed over a 5×13-inch panel area with the finger of a clean cotton glove which was soaked in the same lubricant and allowed to dry. Approximately 0.6 milligrams per square inch of lubricant resulted.
FABRICATION TEST
To test drawability and formability (fabrication) and cleanability, panels from Example IV and Comparative Example II were drawn into square cups one inch in height and 1 7/16 inches along each side. One area on the sides of the cups was deformed to a major strain of +20 percent and a minor strain of -12 percent. Another area on the sides of the cups was deformed to a major strain of +60 percent and a minor strain of -35 percent. The cup's corners were deformed to a major strain of +160 percent and a minor strain of -40 percent. Panels from Example IV, temporary coating compositions were fabricated dry with no additional lubricant. Panels from Comparative Example II coated with a drawing lubricant were additionally smeared with an excess of fluid FB-27MC lubricant before forming into the cup shape.
After being drawn into cups, the panels from Example IV, temporary coating composition, showed a uniform film over the entire square cup. Only minimal galling of the zinc substrate was noted at the corners of the drawn cups. A few scratches were noted on the sides of the cups. After cleaning by immersion in a one percent solution of CHEMKLEEN 49 for one minute, at 150° F. and rinsing, a completely clean "water break free" formed part resulted.
After being drawn into cups, the panels from Comparative Example II, waterborne drawing lubricant, showed a heavily galled and polished appearance on areas of all four sides of the cup. The galling and polishing of these areas showed that the lubricant did not provide an effective fluid barrier between the stamping dye and the substrate. After cleaning one cup by immersion in a one percent solution of CHEMKLEEN 49 for one minute at 150° F. and rinsing, the rinse water beaded up on it indicating that the lubricant was not removed effectively.
It is concluded that in comparision to conventional drawing lubricants, the temporary coating compositions of Examples II and IV provide significantly better protection of the zinc surface from corrosion and fabrication. Yet, the protective coating compositions exceed the removability of conventional lubricants and thus allow the proper cleaning of formed parts.
WELDABILITY TEST
To study the spot-weldability of the protective coating compositions of this invention, protective coating compositions of various glass transition temperatures and applied film thicknesses were prepared. The weldability was tested by two methods. In the first method, coated sheets were continuously spot-welded for at least 500 spot welds while observing whether the welding electrodes became coated with an insulating, current-insulating char, or whether they remained clean enough to conduct approximately 10,000 amps necessary for spot welding.
In the second method, the coating's ability to be penetrated by spot welding electrodes during a small number of welds was tested. Electrodes which had been degraded to some extent by continuous welding were used. When approximately 10,000 amps could be passed through the electrodes and the coated sheet, the welding was considered successful. When a loud cracking sound was heard, accompanied by black charring of the surrounding coating, but approximately 10,000 amps still flowed through the sheet, the spot welding was judged to be marginally acceptable. When the welding electrodes squeezed the panels together in the usual manner and no current flowed because of excessive electrical resistance, the spot welding was judged to be unacceptable. When some welds occurred normally with a current flow of approximately 10,000 amps, but some welds were unsuccessful because of excessive electrical resistance, the weldability was judged to be barely weldable.
A pedestal-type spot-welding machine with a maximum electrical output of 22,000 amps at 6 volts was used for the welding tests. The machine used was a Model 150AP, available from Lors Corporation of Union, New Jersey. The electrodes squeezed the two sheets to be welded together with a force of 525 pounds which was a conventional, recommended squeezing force for spot welding two 0.030-inch galvanized steel panels.
EXAMPLE V
The water-based polymer of Example I was thinned to 12 percent solids with water and flow coated onto both sides of freshly cleaned electrogalvanized steel sheets, air dried until tack free, and forced dried for five minutes at 105° C. A film weight of 0.96 to 1.37 milligrams per square inch resulted. After making 750 spot welds on these sheets, the welding electrodes were still able to conduct approximately 10,000 amps through additional coated sheets. During the 750 weld test, occasional charring of the coating was noted on the side of the panels with the thicker coating weight of 1.3 milligrams per square inch, but no charring was noted on the area of the panels having about 1.0 milligrams per square inch of coating. Approximately 10,000 amps passed through each spot weld of the 750 weld test. The spot weldability of this particular coating was judged to be acceptable at about 1.0 milligrams per square inch and marginally acceptable at about 1.3 milligrams per square inch.
It was surprising and unexpected that the coating-lubricant of this invention flowed away from the spot-welding electrodes under continual exposure to pressure and heat and that a progressive buildup of current insulating char did not occur.
EXAMPLE VI
The worn and degraded welding electrodes from the first welding test in Example V was used in the second welding test method which tests coating-lubricant's ability to be penetrated by spot-welding electrodes when using a conventional amount of squeezing force.
The following table shows protective compositions of various glass transition temperatures which were tested for welding electrode penetration.
TABLE I__________________________________________________________________________ % % Dimethyl % Butyl Acrylic aminoethylPolymerTg Acrylate Styrene Acid Methacrylate % Wax__________________________________________________________________________A 5° C. 47 30 20 3 15B -11° C. 60 20 20 -- 15C -27° C. 73 7 20 -- 15__________________________________________________________________________
The electrode penetration test yielded the following weldability results at the film weight stated in Table II, hereinbelow:
TABLE II______________________________________ Milligrams per SquarePolymer Tg Inch Electrode Penetration Test______________________________________A +5° C. 1.0 AcceptableA +5° C. 1.3 Marginally acceptableB -11° C. 1.4 AcceptableB -11° C. 1.84 Marginally acceptableB -11° C. 2.58 Barely weldableC -27° C. 2.12 AcceptableC -27° C. 2.97 Marginally acceptableC -27° C. 5.5 Barely weldable______________________________________
OTHER PROPERTIES OF THE PROTECTIVE COATING COMPOSITIONS
Additional properties desired of temporary protective coating compositions are flexibility, and resistance to "blocking" or sticking together when the coated substrates are stacked.
Flexibility
To test flexibility, electrogalvanized steel sheets coated with the protective coating compositions of this invention were bent to a radius of 0.075 inches to what is called a "5T" bend, i.e., the coated sheet was bent over five thicknesses of the same sheet. The bent pieces were then immersed in a five-percent Cupric Nitrate (Cu(NO 3 ) 2 ) solution for ten seconds and then rinsed. A copper-containing deposit would form on any area of exposed zinc metal. Cracks or porosity of the protective coating compositions on a bent area would be evidenced by a brown or black color after the test.
Coating-lubricants of the following composition were tested for flexibility:
TABLE III__________________________________________________________________________ % % Dimethyl % % Butyl Acrylic aminoethyl 5T Bend +PolymerTg °C. Styrene Acrylate Acid Methacrylate % Wax CU(NO.sub.3).sub.2 Test__________________________________________________________________________D 35 50 30 20 -- 2 Black depositE 5 30 47 20 3 15 Light gray depositF -12 17 60 20 3 15 No effect__________________________________________________________________________
Block-resistance
To test the block resistance, substrates coated with the protective coating compositions of this invention were pressed together in a stack with a force of 150 pounds per square inch of coated sheet at 120° F. for 16 hours and then cooled. The stack of panels was then taken apart and the individual sheets tested for any film damage caused by the heat and pressure combined with any damage caused by separating the pieces, (referred to as "uncoiling pickoff"). To test film damage, the block-tested pieces were immersed in a five-percent Cupric Nitrate solution and rinsed, to observe any brown or black copper deposition at areas of extremely low film thickness, or at areas where the film has suffered from "pickoff" by adhering to another coated sheet during the block test.
The following protective coating compositions were tested at 1.4 to 1.5 milligrams per square inch of dry film on electrogalvanized steel:
TABLE IV______________________________________Protective %Coating % Butyl % AcrylicComposition Tg Acrylate Styrene Acid % Wax______________________________________G -11° C. 60 20 20 15H -27° C. 73 7 20 15______________________________________
After the block test, coating composition H was found to have a dark dense copper deposition over most of the tested pieces indicating poor film integrity after exposure to heat, pressure, and sheet separation. After the block test, coating-lubricant G showed only a very slight copper deposition over the tested area, indicating that this film was still capable of protecting the underlying metallic surface from physical abuse and corrosion.
In addition to the properties of removability, drawability, and weldability, the protective compositions in certain embodiments can be flexible and block resistant. While the invention has been described and illustrated with particularity herein, it will be understood that various modifications will be apparent to one skilled in the art without departing from the scope or spirit of the invention. Accordingly, it is intended that the claims directed to the invention be construed as encompassing all aspects of the invention which would be treated as equivalents by those skilled in the art to which the invention pertains.
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A formable, weldable, temporary protective coating for use on metals, said coating comprising a base-neutralized acid or base-functional copolymer which contains wax.
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BACKGROUND OF THE INVENTION
This invention relates to the feeding of flat articles, such as cigarette packets.
In the packaging of cigarettes it is usual for cigarette packets (whether of the hinged lid or soft pack type) to be wrapped in an outer transparent wrapper which includes a tear tab for opening the packet. There are a number of different positions for such tear tabs, consequently it is required for the packets to enter the wrapping machine in the correct orientation.
Where the supply of packets from the packing machine is via a reservoir (such as the Molins packet reservoir known as PACER) the packets may often be unloaded in batches, i.e. in intermittent streams of packets touching end to end, whereas the wrapping machine requires packets to be fed to it in a regular spaced manner.
SUMMARY OF THE INVENTION
It is an object of the present invention to propose a manner of feeding flat articles, such as cigarette packets, which satisfies at least one of these requirements.
According to one aspect of the invention there is provided apparatus for feeding flat articles, such as cigarette packets, having two major axes parallel to their flat faces, comprising a wheel mounted for rotation about a substantially horizontal axis, driving means for continuously rotating the wheel, resilient means formed on the periphery of the wheel for engaging the articles, an upright inlet chute for leading the articles to the wheel in an orientation parallel to one of said major axes, a short substantially vertical outlet extending radially of the wheel for receiving the articles from the wheel in a direction perpendicular to said two major axes, passage means defining a substantially arcuate passage around the wheel between said inlet chute and said outlet, and horizontal conveyor means mounted beneath the outlet for removing the lowermost articles at least one at a time in a direction parallel to one of said major axes.
Preferably the resilient means comprises a plurality of equispaced resilient arms which in use extend backwards relative to the direction of rotation of the wheel. Each arm may be provided at its free end with a rounded enlargement which is engageable with the rear of a respective article.
A portion of the passage means may extend outwards from the axis of the wheel to such a radius that said enlargement is disengageable from the rear of an article. This has the effect of reducing forward forces on the articles downstream of such extended portion of the passage means.
Preferably the angle subtended between the inlet chute and the outlet is less than about 180° but greater than 90°.
According to another aspect of the invention there is provided a method of converting an irregular flow of articles into a regular flow, each article having a pair of opposed flat faces and moving in a direction parallel to its flat faces, comprising the steps of forming a queue of abutting articles from the irregular flow, feeding articles from the front of the queue at an increased speed along a non-linear path, so that a slight gap is formed between the articles, moving each foremost article transversely of the path to form a stack of articles so that their flat faces are abutting, and regularly feeding articles away from the end of the stack.
BRIEF DESCRIPTION OF THE DRAWINGS
An embodiment of the invention will now be described, by way of example only, with reference to the accompanying drawings in which:
FIG. 1 is a side elevation of an apparatus for feeding cigarette packets, and
FIG. 2 is a section taken on the line II--II in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The apparatus essentially comprises a relatively narrow wheel 10 mounted on a horizontal shaft 11 and driven in an anti-clockwise direction as shown by the arrow. Mounted in an annular groove on the periphery of the wheel are some twenty-five regularly spaced spring arms 12 each having a rounded end 13 formed at its free end. The arms 12, which may be fabricated from spring strip material or moulded from a resilient thermoplastic material, are so mounted that even in their relaxed position they extend backwards relative to the direction of rotation of the wheel. The middle portion of the free end 13 of each arm is provided with a rectangular cut-out 12A (see FIG. 2) thus forming a forked end.
Around the right-hand half of the wheel 10, as viewed in FIG. 1, is an idle passageway 15 formed by a semi-circular wall 14 having a smooth inner surface against which the free ends 13 are in light contact. And around the left-hand half is provided an arcuate passage 17 formed by a thick flexible strip 16 of low friction material, such as polytetrafluoroethylene (PTFE) or ultra-high molecular weight polyethylene (UHMPE).
The lower end of the strip 16 is secured around a fixed member 18, while its upper end extends around a large roller 19 which is normally fixed, but which can be rotationally adjusted to increase or decrease the radial width of the passage 17.
Extending into the inlet of the passage 17 adjacent the upper end of the strip 16 is a vertical chute 20 of rectangular section, down which cigarette packets P are adapted to pass. The chute 20 may be longitudinally twisted, as shown, by an angle of up to 90° to enable packets to be fed to the wheel 10 in a direction other than in the plane of FIG. 1. Opposite the upper end of the strip 16 is a curved triangulated guide 21 extending from the right-hand wall of the chute 20 and straddling the arms 12 of the wheel 10.
Mounted on the chute 20 are two packet detectors 22 which are spaced apart by a distance of some ten packet lengths to monitor the queue of packets formed in the chute.
At the lower end of the passage 17, adjacent to the right of the fixed member 18, is an outlet 23 defined by a vertical stop 24 against which in use the leading ends of successive packets abut. The upper end of the stop 24 has two cut-outs 25 (FIG. 2) through which the forked ends 13 of the spring arms 12 can move.
Under the outlet 23, and spaced by more than the thickness of one packet from the bottom of the stop 24, are a pair of ledges 26 which are fixedly mounted just above the surface of a conveyor band 27. The band 27 is trained around two pulleys 28 (only one shown) and carries a succession of regularly spaced flights or pushers 29.
In operation, packets P are fed in an irregular manner into the top of the chute 20 in a longitudinal direction, i.e. in the direction of one of the narrow packet sides. The packets may be fed intermittently in batches from a reservoir, such as the Molins packet reservoir PACER.
As the packets P pass down the chute 20 they are sensed by the detectors 22, and on meeting the guide 21 each successive packet begins to move towards the left, around the curve of the strip 16 formed by the roller 19. At this point a small gap has been formed between adjacent packets and each packet comes under the influence of one or more of the spring arms 12, whose rounded forked ends 13 engage the rear corners behind the large inner faces of the packets and convey them around the arcuate passage 17.
On reaching outlet 23 the spring arms 12 urge successive packets to move radially away from the wheel 10 to form a short stack abutting against the stop 24 and resting on the ledges 26. From here each lowermost packet is removed by a pusher 29 of the conveyor band 27 and fed in timed succession directly into a wrapping machine.
The speed of the rotation of the wheel 10 is slightly greater than that at which the packets are being removed by the conveyor band 27, so that the stack of packets at the outlet 23 will usually be running full. In this normal situation the rounded ends 13 of the arms 12 will disengage from the rear corners of the packets and will slide forwards with a slow relative speed against the large faces of the packets. By adjusting the roller 19 to slacken the flexible strip 16 and thereby increase the radial width of the passage 17, the forward force exerted by the arms 12 on the packets in the passageway 17 can be reduced.
If the level of packets in the chute 20 is sensed to have descended to the lower of the two detectors 22, then the latter is arranged to reduce the speed of the wrapping machine (including the conveyor band 27), or to momentarily bring it to rest.
It will be appreciated that if it is desired for the packets to enter the wrapping machine upside-down relative to the attitude shown, it is only necessary to disconnect the chute 20 and to turn the axis of the wheel 10 through 180°, so that it rotates clockwise. And in either of such attitudes of the packet it is possible for the packets to enter the wrapping machine with any of its four narrow sides leading, simply by changing the direction of the conveyor band 27 accordingly, i.e. making the band travel to the left, or into or out of the plane of the drawing.
Thus in addition to the variation in packet inlets allowed for by the twisted chute 20, the apparatus can cater for any desired orientation of packets into the wrapping machine. Furthermore the apparatus provides a convenient means of converting an intermittent or irregular flow of packets into a regular timed flow.
It will also be appreciated that by having packets fed to the chute 20 at a high level above that of the operators manning the machines, it is possible to have a neat, unobstructed layout of machines, particularly as the length of the conveyor band 27 from the wrapping machine can be arranged to be very short.
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A device for feeding and orienting cigarette packets includes a driven wheel 10 having a plurality of rearwardly directed resilient members, such as spring arms 12, mounted on the periphery of the wheel. Packets P are fed to the wheel down a twisted chute 20, and they leave from an outlet 23 under the wheel, where the packets are pushed out by the spring arms 12 to form a short stack. At the bottom of the stack each packet is transported away in a regular manner by a flighted horizontal conveyor 27.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a timer circuit used for a motor drive control apparatus or the like and a time count method.
2. Description of the Related Art
Hitherto, in an image forming apparatus such as an MFP (MULTI FUNCTION PERIPHERAL), a copying machine or a printer, a stepping motor is used in order to control the rotation of a photoconductive drum or a transfer belt. The stepping motor is a motor to supply a specified exciting pattern to a driver and to perform driving, can perform a rotation control by a step angle corresponding to the supplied exciting pattern, and is used in a wide field.
A control device of the stepping motor includes a timer, generates a clock signal based on a reference timing signal generated by the timer, and creates the exciting pattern by using this clock signal. Accordingly, the rotation speed can be controlled by arbitrarily setting the period of the timing signal from the timer.
There are needs for further improvement in performance and for speedup in the image forming apparatus. In order to address the needs, the speedup of the stepping motor control is indispensable, and therefore, the timer is required to achieve higher resolution and to have more bits.
In general, in order to increase the resolution of the timer, it is possible to take measures of raising the clock frequency as the reference. At this time, unless the number of bits of the timer is increased, the countable maximum time becomes small, and therefore, in the motor control in which acceleration and declaration are gradually made to a specified speed, the count number of the timer is insufficient.
In a technique disclosed in JP-A-10-63357, two timers each having a small number of bits are used to realize the control equivalent to the case were one timer having a large number of bits is used, and further, the PWM period is made long to realize the control in which the resolution can be made fine.
BRIEF SUMMARY OF THE INVENTION
According to a first aspect of the invention, a timer circuit includes a storage unit configured to store a series of first data content relating to a time into a specified address area, a target value generation unit configured to read the first data content from a read address of the storage unit and to generate, as a target value, third data content in which second data content is added to the first data content, a counter to perform counting and to output a count-up signal when the counting is performed up to the target value, and a control unit configured to sequentially designate a next read address of the storage unit at each count-up and to cause the series of operations of the target value generation unit and the counter to be executed.
According to a second aspect of the invention, a time count method of a timer circuit includes the steps of storing a series of first data content relating to a time into a specified address area of the storage unit, reading the first data content from a read address of the storage unit and generating, as a target value, third data content in which second data content is added to the first data content, performing a count and outputting a count-up signal when the counting is performed up to the target value, and sequentially designating a next read address of the storage unit at each count-up and causing the series of operations at the step of generating the target value and the step of performing the count to be executed.
Additional objects and advantages of the invention will be set forth in the description which follows, and in part will be obvious from the description, or may be learned by practice of the invention. The objects and advantages of the invention may be realized and obtained by means of the instrumentalities and combinations particularly pointed out hereinafter.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING
The accompanying drawings, which are incorporated in and constitute a part of the specification, illustrate embodiments of the invention, and together with the general description given above and the detailed description of the embodiments given below, serve to explain the principles of the invention.
FIG. 1 is a view showing a structure of an image forming apparatus in which a timer circuit of a first embodiment is used.
FIG. 2 is a view showing a structure of a control system of the image forming apparatus.
FIG. 3 is a view for schematically explaining an operation procedure of a stepping motor control of the image forming apparatus.
FIG. 4 is a view for explaining a setting example of a ring sequence by a control unit.
FIG. 5 is a view showing a timer value table provided in a RAM.
FIG. 6 is a block diagram showing a structure of a timer circuit of the first embodiment.
FIG. 7 is a block diagram showing a structure of a timer circuit of a variation of the first embodiment.
FIG. 8 is a view for explaining a basic way of thinking of a timer circuit of a second embodiment.
FIG. 9 is a block diagram showing a structure of the timer circuit of the second embodiment.
FIG. 10 is a view for explaining a setting example of a ring sequence by a control unit.
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, embodiments of the invention will be described with reference to the drawings.
FIG. 1 is a view showing a structure of an image forming apparatus in which a timer circuit of a first embodiment of the invention is used. Incidentally, in the following description, although the description will be given to an example in which the timer circuit is applied to the image forming apparatus such as an MFP, a printer or a copying machine, it can also be applied to another equipment.
A continuous printing operation of a color image will be described with reference to the four-tandem type image forming apparatus shown in FIG. 1 .
Photoconductive drums 703 a , . . . , 703 d are OPC (Organic Photo receptor), and are provided to be rotatable in illustrated arrow directions. A transfer belt 711 is wound and stretched between a drive roller 716 rotated in an arrow direction by a not-shown motor and driven rollers 717 , 718 and 719 spaced from the drive roller 716 by specified distances, and is traveled in an endless way at a constant speed in an arrow “a” direction.
An image formation process will be described by using an image forming unit a 7 .
First, a scorotron charging unit 705 a uniformly negatively (−) charges the photoconductive drum 703 a . The charged photoconductive drum 703 a is exposed to light corresponding to image information by an exposure device 50 , so that an electrostatic latent image is formed.
A two-component developing unit 709 a containing yellow developer (toner) is disposed at the downstream side of the exposure by the exposure device 50 . The electrostatic latent image on the photoconductive drum 703 a is inversion-developed with the yellow toner and a toner image is formed on the photoconductive drum 703 a.
A transfer roller 723 a is disposed at the downstream side of the developing unit 709 a . A bias (+) of a polarity reverse to the charging property of the toner is applied to the transfer roller 723 a by a DC power source 727 a . As a result, the toner image on the photoconductive drum 703 a is primarily transferred onto the transfer belt 711 by a transfer electric field formed between the photoconductive drum 703 a and the transfer roller 723 a.
Next, the photoconductive drum 703 a is diselectrified by an electricity removing device 721 a , and then again repeats the process of charging→exposure→development.
In synchronization with the timing when the toner image is formed in the image forming unit a 7 , the same process is performed also in image formation units b 7 , c 7 and d 7 . Toner images of magenta, cyan and black formed on the photoconductive drums 703 b , . . . , 703 d of the image formation units b 7 , . . . , d 7 are also sequentially primarily transferred onto the transfer belt 711 .
A sheet P as a transfer member is transferred from a not-shown sheet cassette, and is sent to the transfer belt 711 by an aligning roller 714 in timing with the toner image on the transferred belt 711 .
A transfer roller 729 a is disposed at the right end of the transfer belt 711 in the drawing. A bias (+) of a polarity reverse to the charging polarity of the toner is applied to the transfer roller 729 a by a DC power source 728 a . As a result, the toner image on the transfer belt 711 is transferred onto the sheet P by a transfer electric field formed between the transfer belt 711 and the transfer roller 729 a.
At this time, partial toner (residual transfer toner) not completely transferred to the sheet P but remaining on the transfer belt 711 is cleaned by a cleaner 730 .
At the downstream side (the upper part in the drawing) of the transfer belt 711 , a not-shown fixing unit to fix the toner on the sheet P is disposed. A fixed image is obtained by causing the sheet P to pass through the fixing unit.
The exposure device 50 to form color-decomposed electrostatic latent images on the outer peripheral surfaces of the respective photoconductive drums 703 a , 703 b , 703 c and 703 d includes a semiconductor laser oscillator 60 emission-controlled based on image data (y, m, C, k) of the respective colors color-decomposed by a not-shown image processing apparatus.
A stepping motor is used for rotation driving of the photoconductive drums 703 a , . . . , 703 d used for the image formation processing and for rotation driving of the aligning roller 714 used for the sheet transport, the transfer roller 729 and the like. Especially in the case where a color image is formed, since the sheet passes through the four image formation units of black, cyan, magenta and yellow, the transport and positioning of the sheet is important, and the stepping motor is suitable for performing an accurate image formation processing.
Besides, in the image forming apparatus of the transfer belt system, there is also a case where a stepping motor is used for driving the transfer belt. In the case where there are a plurality of stepping motors to be controlled, a plurality of control devices are provided. In the case where the plurality of stepping motor control devices are provided, the timer is provided for each of them.
FIG. 2 is a view showing a structure of a control system of the image forming apparatus. The control system includes a control unit 11 , a ROM (Read Only Memory) 12 , a RAM (Random Access Memory) 13 , a timer 14 , an output port 15 , a current driver 17 , a phase driver 18 and a stepping motor 1 . The control unit 11 , the ROM 12 , the RAM 13 , the timer 14 and the output port 15 are electrically connected to one another through a bus line 16 .
The control unit 11 controls the operation of the image forming apparatus overall. The control unit 11 can be constructed of a CPU (Central Processing Unit) or a sequencer. The ROM 12 stores program data and the like used by the control unit 11 to control the respective units. The RAM 13 is provided with a timer value table 131 , together with various memories and tables for data processing. Based on the timer value table 131 , the control unit 11 operates the timer 14 and controls the operation of the stepping motor 1 .
The output port 15 includes various modules to control the stepping motor 1 . The current driver 17 controls the amount of current flowing through a stator winding of the stepping motor 1 in accordance with a signal from the output port 15 . The phase driver 18 changes and controls the phase of the stator winding in accordance with a signal from the output port 15 .
The output port 15 is provided with a start waiting control module 15 a , a one-shot control module 15 b , a continuous output control module 15 c , a table reference control module 15 d and an end (off) control module 15 e . Control from the start to the stop of the stepping motor is classified into a plurality of basic control items, and these modules execute processings relating to the respective items. The details will be described later.
FIG. 3 is a view for schematically explaining the operation procedure of the stepping motor control of the image forming apparatus. As shown in FIG. 3 , the control unit 11 produces a ring sequence of a plurality of sequences, for example, from a sequence 0 to a sequence 7 , assigns the processing of each of the control modules 15 a , . . . , 15 e to each of the sequences, and effects a transition so that the processing is executed in a previously set order.
The control unit 11 starts from the sequence 0 of the start point, effects a transition in the order of the sequence 1 , sequence 2 , sequence 3 , . . . , sequence 7 and sequence 1 and executes the processing. In the case where sequence disable setting is performed in the middle of the processing, or in the case where the end control module is declared during the sequence and the sequence changes to the state where the end control module is executed, the control unit 11 ends the processing at the stage, that is, stops the rotation of the motor, and returns the sequence to the sequence 0 . when sequence enable setting is performed, the control unit 11 again starts the sequence from the sequence 0 . For example, the start waiting control module 15 a is set in the sequence 0 of FIG. 3 , and one of the modules 15 a , . . . , 15 e to execute the hardware processing is arbitrarily set in the sequence 1 , . . . , 7 .
As described before, the control of the stepping motor can be classified into 1) start waiting control, 2) one-shot control, 3) table reference control, 4) continuous output control, and 5) end control. The plurality of modules 15 a , . . . , 15 e execute the five hardware processings in the order set by the control unit 11 , and the motor control with a high degree of freedom becomes possible. Here, the processing functions of the respective modules 15 a , . . . , 15 e will be described.
The start waiting control module 15 a is the module to change the sequence to a next one at the time point when a start factor occurs. At the time of the stepping motor control, it is used in an off state or in a normally holding state, and in this embodiment, it is fixed to the sequence 0 . In a standby state, when a selected start factor satisfies a condition, a transition is effected to a next sequence, that is, the sequence 1 in this embodiment.
The one-shot control module 15 b is the module to effect a transition to a next sequence after counting is performed for a specified time, and after the set count value is counted, the processing is stopped and shifts to a next sequence. In addition to the time count value to be counted, a motor holding current value and the like during the control execution are stored in a not-shown register. At the time of the control of the stepping motor, when pre-hold or post-hold control is performed, this one-shot control module 15 b is used.
That is, since the phase state of the motor is not clear immediately after the power is turned on, a specified signal is outputted and is held for a fixed time, so that the stepping motor 1 can reach the start position of driving. This period is the pre-hold period. Besides, since the motor rotates by inertia at the time of motor stop, a specified period until a minute vibration disappears is set. This period is the post-holding period. When this one-shot control module 15 b is used, the phase change can be selected at the time of processing execution start/stop.
The continuous output control module 15 c is the module to change the output at every set time. This continuous output control module 15 c generates a count-up signal at every set time count value, and when the execution end condition is satisfied, the module is stopped and shifts to a next sequence. At the time of the stepping motor control, it is used as the constant speed drive module.
The table reference control module 15 d reads data from the timer value table 131 of the RAM 13 , uses it as the count value and performs counting in cooperation with the timer 14 . After the end of the counting, the count-up signal is outputted, data of a next address is read, and the counting is similarly performed. The table reference control module 15 d repeats this operation for the respective set address areas, ends the processing, and shifts to a next sequence. At the time of the stepping motor control, it is used for the slow-up or slow-down control.
At the time of the slow-up, the timer period is shortened at every step to raise the rotation number gradually, and when the number of steps reaches a specified number, a shift is made to a constant speed processing as a next sequence. On the other hand, at the time of slow-down, the timer period is lengthened at every step to reduce the rotation number gradually, and when the number of steps reaches a specified number, a shift is made to a stop processing as a next sequence. When the motor is stopped, when it is abruptly stopped, the phase state is disturbed and a trouble such as a loss of synchronization can occur, and therefore, the slow-down control is performed.
The end control module 15 e is the module to forcibly effect a transition to the sequence 0 . The end control module 15 e returns the sequence to the sequence 0 and shifts the sequence to the start waiting sequence.
FIG. 4 is a view for explaining a setting example of the ring sequence by the control unit 11 , and shows a case where the basic acceleration and declaration control of the stepping motor is performed. In FIG. 4 , one of the modules 15 a , . . . , 15 e is set in the sequence 0 , . . . , 7 , and the processings in the modules 15 a , . . . , 15 e are sequentially executed.
This example shows the control procedure from the start of the motor to the acceleration, constant speed, declaration, and stop. The start waiting control module 15 a is set in the sequence 0 , and the stepping motor 1 is in the wait state. The one-shot control module 15 b is set in the next sequence 1 , and the stepping motor 1 is brought into the state of the pre-hold period. The table reference control module 15 d is set in the sequence 2 , and the stepping motor 1 is slow-up controlled and is brought into the state in which the rotation speed is gradually increased.
Further, the continuous output control module 15 c is set in the sequence 3 , and the stepping motor 1 is brought into the state of the constant rotation control. The table reference control module 15 d is set in the sequence 4 , and the stepping motor 1 is slow-down controlled and is brought into the state in which the rotation speed is gradually reduced. The one-shot control module 15 b is set in the sequence 5 , and the stepping motor 1 is brought into the state of the post-holding period. The end control module 15 e is set in the sequences 6 and 7 , and the stepping motor 1 is stopped.
Next, the basic way of thinking of the timer circuit of the embodiment will be described.
FIG. 5 is a view showing the timer value table 131 provided in the RAM 13 . Time data sequentially set when the stepping motor 1 is controlled from the hold state to the pre-hold→slow-up driving→constant rotation→slow-down driving→post-hold→hold state are stored in the timer value table 131 . When the stepping motor 1 is driven, the control unit 11 sequentially reads the time data from the timer value table 131 and sets it in the timer 14 .
As described above, in the case where the number of bits of the timer 14 is increased in order to speed up the stepping motor control, it is necessary to pay attention to that the capacity of the RAM 13 is increased. For example, in the case where the number of bits is increased so that the timer 14 can handle a count of 16 bits or more, since the time data stored in the timer value table 131 also comes to have 16 bits or more, the capacity of the RAM 13 is remarkably increased. Besides, since the normal RAM 13 is often constructed in a unit of 8 bits, in the case where the maximum count value of the timer 14 has a fraction relative to multiples of 8, a wasteful portion exists in the RAM 13 .
In this embodiment, this problem is solved as described below. For example, even in the case where the maximum count value of the timer 14 requires 17 bits, the RAM 13 has 16 bits. Then consideration will be given to the case where slow-down control of the stepping motor 1 is executed.
A reference start address and a reference end address are determined in the timer value table 131 for execution of the slow-down control. The control unit 11 sequentially reads the time data from the reference start address of the timer value table 131 , and sets it in the timer 14 . At this time, since the stepping motor 1 is declaration-controlled, the time data set in the timer is sequentially simply changed from a short time to a long time. At the initial stage, the time data can be counted in 16 bits. However, after a certain address, 17 bits are required in order to count the time data. The address requiring the bit change is previously known for each slow-down control. This address is called a data change address.
Then, the data of the lower-order 16 bits of the count value are stored in the RAM 13 , and it is changed whether the upper-order one bit is made “0” or “1” according to the reference address of the RAM 13 . By this, while the increase of the RAM capacity is suppressed, the timer circuit with high resolution can be constructed.
For example, in the case where the capacity of the timer value table 131 is 2K words, and the data change address is 3FFh, during the period when reference is made to address 000h, . . . , 3FFh, the most significant bit is made “0”. In the case where reference is made to address 400h or higher, the most significant bit is made “1”. By this, even in the case where the counter of 17 bits is used, the RAM capacity can be suppressed.
FIG. 6 is a block diagram showing a structure of the timer circuit of the first embodiment.
The timer circuit of this embodiment includes the table reference control module 15 d , the timer value table 131 of the RAM 13 and the timer 14 . The respective parts cooperate with each other under the control of the control unit 11 so that a desired timer operation is realized.
Hereinafter, the operation of the timer circuit will be described with reference to FIG. 6 . Incidentally, the timer 14 has a resolution of 17 bits.
The control unit 11 specifies a desired timer operation in the sequence processing. That is, an address of the RAM 13 in which timer values are stored is set in a reference RAM address counter 30 . Based on this address value, a timer value is extracted from the timer value table 131 and is temporarily stored in an intermediate buffer 31 . Here, the extracted timer value has a length of 16 bits.
On the other hand, the data change address shown in FIG. 5 is stored in an upper-order data change address designation register 32 . An address comparison circuit 33 compares magnitudes between the data change address and the RAM address to which reference is made. Based on the comparison result of the address comparison circuit 33 , an upper-order data selection circuit 34 determines whether the value of the most significant bit (MSB) is made “0” or “1”. Incidentally, although not clearly shown in the drawing, data to specify the correspondence between the address comparison result and the value of the most significant bit is inputted in the upper-order data selection circuit 34 through a not-shown register from the control unit 11 . The upper-order data selection circuit 34 considers this data and determines the value of the upper-order bit.
Incidentally, this embodiment handles the case where the 17-bit counter is used and the number of bits of the fraction is 1. In the case where the number of bits of the fraction is 2 or higher, the number of upper-order data change address designation registers 32 is also increased according to the number of bits of the fraction, and further, registers to designate values to be given to the upper-order data selection circuit 34 between the respective data change addresses are individually provided, so that general versatility can be enhanced.
A comparison data unit 35 extracts the timer value stored in the intermediate buffer 31 , adds the upper-order bit inputted from the upper-order data selection circuit 34 , and generates a timer value of 17 bits.
A timer counter 36 has 17 bits and continues counting. The count value is outputted to a comparison circuit 37 . When the count value outputted from the timer counter 36 becomes equal to the count value outputted from the comparison data unit 35 , the comparison circuit 37 outputs a count-up signal. This signal causes a toggle circuit 38 to output a toggle signal, resets the count value of the timer counter 36 and causes a new timer count to be started.
Incidentally, in this embodiment, although the timer counter 36 integrates the timer value, the timer circuit may be constructed so as to decrease the timer count value. For example, the timer value of 17 bits generated by the comparison data unit 35 is treated as a set value, the set value is decreased in accordance with the passage of time, and a count-up signal may be outputted when the value becomes 0.
Incidentally, in this embodiment, as shown in FIG. 6 , although the functions of the timer 14 and the table reference control module 15 d are divided, no limitation is made to this example, and they may be divided at a suitable position.
FIG. 7 is a block diagram showing a structure of a timer circuit of a variation of the first embodiment. The timer circuit of the variation has a structure dealing with the case where a plurality of timer circuits operate at random. That is, in addition to a circuit for a usual timer 1 , a circuit for a timer 2 is provided. A RAM access adjustment circuit 40 to adjust access to a RAM 13 is newly provided. Incidentally, since a timer 14 a , a table reference control module 15 da constituting the circuit for the timer 2 have the same functions as a timer 14 and a table reference control module 15 d provided in the timer 1 , their detailed description will be omitted.
The RAM access adjustment circuit 40 performs, for example, a service to an access request from a plurality of timers to the RAM in a time sharing system. Accordingly, when the RAM access adjustment circuit 40 is used, even in the case where the plurality of timers are used, the timer circuit can be structured while avoiding the contention to the RAM 13 .
Next, a timer circuit of a second embodiment of the invention will be described. Incidentally, portions having the same functions as those of the first embodiment are denoted by the same reference numerals and their detailed description will be omitted.
FIG. 8 is a view for explaining the basic way of thinking of the timer circuit of the second embodiment.
A timer count value used for slow-down or slow-up is generally simply changed. Accordingly, as shown in FIG. 8 , the timer value at the time of slow-down expressed in four bit data is simply increased. However, in the lower-order three bit data, the value is decreased after the time point when a carry occurs in the most significant bit. On the contrary, the timer value at the time of slow-up expressed in four-bit data is simply decreased. However, in the lower-order three bit data, the value is increased after the time point when a borrow occurs in the most significant bit.
That is, at the time of slow-down or slow-up, even in the case where the upper-order bit is not provided, when the increase or decrease tendency of the read timer value is reversed, it is possible to determine that the carry or borrow occurs in the most significant bit at the time point.
FIG. 9 is a block diagram showing a structure of the timer circuit of the second embodiment.
The timer circuit of this embodiment includes a table reference control module 15 d , a timer value table 131 of a RAM 13 , and a timer 14 . The respective parts cooperate with each other under the control of a control unit 11 , so that a desired timer operation is realized.
Hereinafter, the operation of the timer circuit will be described with reference to FIG. 9 . Incidentally, the timer 14 has a resolution of 17 bits or higher.
The control unit 11 specifies the desired timer operation in sequence processing. That is, an address of the RAM 13 in which timer values are stored is set in a reference RAM address counter 41 . A timer value is extracted from the timer value table 131 based on this address value, and is temporarily stored in an intermediate buffer 42 . Here, the extracted timer value has a length of 16 bits. Incidentally, a timer value extracted at the last time is stored in an intermediate buffer 43 . A comparison circuit 44 compares the timer value at the last time with the timer value at this time, and outputs a comparison result to an upper-order data addition counter 46 .
On the other hand, initial values of upper-order data at the start time of slow-down and slow-up operations are set in an upper-order data addition counter initial value register 45 . This initial value is set at, for example, the operation start time from the control unit 11 . The upper-order data addition counter 46 increments or decrements the initial value according to the comparison result from the comparison circuit 44 .
For example, in the case where the timer value which should generally have an increase tendency is decreased during the slow-down operation, 1 is added to the upper-order data addition counter. In the case where the timer value which should generally have a decrease tendency is increased during the slow-up operation, 1 is decreased from the upper-order data addition counter. The comparison data generation unit 47 adds the value of the upper-order data addition counter to the upper order of the timer value stored in the intermediate buffer 42 , and generates comparison data.
A timer counter 48 has 17 bits or higher and continues counting. The count value is outputted to a comparison circuit 49 . When the count value outputted from the timer counter 48 becomes equal to the count value outputted from the comparison data generation unit 47 , the comparison circuit 49 outputs a time-up signal. This signal causes a toggle circuit 50 to output a toggle signal, resets the count value of the timer counter 48 , and causes a new timer count to be started.
Incidentally, in this embodiment, although the timer count 48 integrates the timer value, the timer circuit may be constructed so that the timer count value is decreased. For example, a timer value of 17 bits or higher generated by the comparison data generation unit 47 is treated as a set value, the set value is decreased in accordance with the passage of time, and the count-up signal may be outputted when the value becomes 0.
Incidentally, in this embodiment, as shown in FIG. 9 , although the functions of the timer 14 and the table reference control module 15 d are divided, no limitation is made to this example, and they may be divided at a suitable position.
According to the embodiment as described above, with respect to the lower-order bit of the timer, reference is made to the RAM, and the upper-order bit becomes a value selected based on the value of the reference address counter of the RAM. Alternatively, with respect to the lower-order bit of the timer, reference is made to the RAM, and the upper-order bit becomes a value generated by an arithmetic operation result based on the reference value of the RAM. As described above, the timer is generated by combining two values, so that the RAM capacity can be suppressed. Accordingly, the timer with high resolution and low cost can be constructed.
Incidentally, even in the case where the timer circuit of this embodiment is used, flexible pulse motor drive control is possible.
FIG. 10 is a view for explaining a setting example of a ring sequence by the control unit 11 , and shows a case where acceleration and declaration control of repetition of the stepping motor is performed.
This example shows the control procedure in which the motor is started and is accelerated, and after a specified speed is attained, the acceleration and declaration are repeated. When the acceleration is performed from the stop time to the specified speed, the timer value of, for example, 17 bits is required. However, in the operation after the specified speed is attained, it is possible to sufficiently control the operation by the timer value of 16 bits.
The timer circuit of this embodiment can be applied also to the control operation as stated above. During the repeated control operation, the upper-order bit is a fixed value and is not changed. Accordingly, in the case where the timer circuit shown in FIG. 6 is used, for example, the value of the upper-order data change address designation register 32 is set so that the value of the upper-order data always becomes a specified value, and as a result, a desired operation can be realized. Incidentally, also in the case where this operation is controlled, the ring sequence shown in FIG. 3 can be applied.
Incidentally, the respective functions described in the foregoing embodiments may be structured by using hardware, or may be realized by using software and loading a program describing the respective functions into a computer. Besides, the respective functions may be structured by appropriately selecting one of the software and hardware.
Further, the respective functions can be realized by causing a computer to read a program stored in a not-shown recording medium. Here, in the recording medium in this embodiment, as long as the program can be recorded and can be read by the computer, any recording form may be adopted.
Additional advantages and modifications will readily occur to those skilled in the art. Therefore, the invention in its broader aspects is not limited to the specific details and representative embodiments shown and described herein. Accordingly, various modifications may be made without departing from the spirit or scope of the general inventive concept as defined by the appended claims and their equivalents.
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A timer circuit includes a storage unit to store a series of first data content relating to a time into a specified address area, a target value generation unit to read the first data content from a read address of the storage unit and to generate, as a target value, third data content in which second data content is added to the first data content, a counter to perform counting and to output a count-up signal when the counting is performed up to the target value, and a control unit to sequentially designate a next read address of the storage unit at each count-up and to cause the series of operations of the target value generation unit and the counter to be executed.
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BACKGROUND OF THE INVENTION
The present invention relates to improved process for producing a film of Sm (samarium)-Co(Cobalt) alloy, and more particularly relates to an improvement in production, by means of plating, of a Sm-Co alloy film well suited to magnetic applications such as magnetic recording media.
Production of Sm-Co alloy films is conventionally carried out by sputtering and vacuum evaporation. Such conventional processes are in general very high in cost of installation but rather low in productivity. In addition, these conventional processes are quite unsuited for production of Sm-Co alloy films on intricate and/or large configurations.
As a substitute for such defective processes, wet-plating process has recently been proposed. For example, see pages 30 and 31 of "the Summary of Lectures at the 72nd Academic Seminar" issued by the corporation aggregate, Institute of Metal Surface Technology in Japan. This newly proposed process is carried out in a non-aqueous plating bath which includes samarious nitrate and cobalt nitrate dissolved with propylene carbonate. In this case, however, the nitrates used both contain crystal water. As a consequence, aqueous component is inevitably contained in the plating bath through dissolution of the nitrates. It is generally known that presence of such aqueous component in a plating both of non-aqueous solvent disturbs smooth electrocrystallization of base metal such as Sm-Co alloy. So, no plated film of high qualities can be obtained by such a wet-plating process.
SUMMARY OF THE INVENTION
It is the object of the present invention to enable smooth production of a Sm-Co alloy film or layer of high qualities through plating which is well suited for treatment of even intricate and/or large configurations.
In accordance with the basic aspect of the present invention, plating is carried out in a bath which contains samarium chloride and cobalt chloride dissolved with non-aqueous solvent.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 are graphs for showing magnetic characteristics of Sm-Co alloy films produced in Examples of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
As stated above, in plating bath used in the present invention contains samarium chloride and cobalt chloride dissolved with non-aqueous solvent. The samarium chloride used herein is given in the form of anhydrous SmCl 2 and SmCl 3 . In the case of water containing SmCl 3 , the material is heated in dry HCl stream for dehydration. The cobalt chloride used herein is given in the form of anhydrous CoCl 2 . In the case of water containing CoCl 3 , the material is heated in dry HCl stream. Although formamide is majority used for the non-aqueous solvent, acetoamide is usable too. Amines such as ethylenediamine and pyridine may be added to the plating bath as a complexing agent. All the materials should have high purity and should preferably be prepared by means of distillation and/or recrystallization.
The concentration of the samarium chloride in the plating bath should preferably be in a range from 0.001 to 2 mol., and more preferably from 0.005 to 0.5 mol. per 1l. of the non-aqueous solvent. Whereas the concentration of the cobalt chloride in the plating bath should preferably be in a range from 0.001 to 2 mol., and more preferably from 0.005 to 0.5 mol. per 1 l of the non-aqueous solvent. The content ratio in mol. between the samarium chloride and the cobalt chloride should preferably be in a range from 1:1 to 1:20, and more preferably from 1:2 to 1:15. The concentration of the amines in the plating bath should preferably be in a range from 0.01 to 1 mol., and more preferably from 0.02 to 0.2 mol. per 1l. of the non-aqueous solvent.
In order to avoid mixing of moisture and oxygen in the air into the plating bath, preparation of the bath should preferably be carried out in a deoxidized dry nitrogen environment, e.g. in a globe box.
Production of a Sm-Co alloy film or layer is carried out in such a plating bath via electrolysis. Insoluble material such as platinum and carbon is used for the anode and material such as copper, nickel, platinum and electro-conductive glass is used for the cathode in order to electrodeposit a Sm-Co alloy film on the cathode. The plating bath should preferably be kept at a temperature in a range from the room temperature to 120° C. The bath may either be stirred or not stirred. For electrolysis, direct current, direct-alternative superposed current or pulse current is usable. The current density should preferably be in a range from 10 to 200 mA/cm 2 . A high current density would result in high content of samarium in the alloy film. Thus, the composition of the alloy film can be freely adjusted by choice of the current density. Plating time depends on the desired thickness of the alloy film and plating conditions. Generally, plating is continued for a period of 1 to 30 min.
After electrodeposition of the smooth Sm-Co alloy film on the cathode, the same is heated in order to exhibit magnetic properties.
Thus, in accordance with the present invention, a high quality Sm-Co alloy film can be obtained by means of wet plating process which is very simple in control. Since almost no aqueous component is present in the plating bath, the produced alloy film is notably high in purity and high in quality. In addition, as stated above, content of samarium in the produced alloy film can be freely adjusted by choice of the current density for the electrolysis.
DESCRIPTION OF EXAMPLES.
Example
Hexahydro SmCl 3 used for the samarium chloride was heated at about 300° C. in dry HCl stream for dehydration. Dehydrated CoCl 2 was used for the cobalt chloride. Formamide on market and distilled under reduced pressure in nitrogen was used for the non-aqueous solvent and ethylene diamine was used for the amine. These components were blended at the following concentrations to form a plating bath.
Cobalt chloride: 0.09 mol. per 1l. of solvent
Samarium chloride: 0.01 mol. per 1l. of solvent
Ethylene diamine: 0.01 mol. per 1l. of solvent A closed-type container was used for electrolysis and the bath and the space in the container were substituted with deoxidized dry nitrogen.
A platinum plate was used for the anode and a conductive glass plate, i.e. a glass plate coated with a thin film of oxidized indium tin, was used for the cathode. During electrolysis, the bath was stirred with a magnetic stirrer and kept at 20° C. Direct current of 10 mA/cm 2 current density and 10 C/cm 2 current quantity was used.
A plated film of a metallic luster was formed on the cathode with a thickness of about 1μm. The film contained 16% by weight of samarium and 84% by weight of cobalt.
The plated film was heated at 600° C. for 1 hour in a vacuum environment and the resultant magnetic characteristics is shown in FIG. 1. As is clear in the graph, the plated film exhibited a coercive force of 404 oersted.
Example 2
The components of Example 1 were blended at the following concentrations.
Cobalt chloride: 0.09 mol. per 1l. of solvent
Ethylene diamine: 0.09 mol. per 1l. of solvent
After this initial blending, samarium chloride was added at a concentration of 0.01 mol. per 1l. of solvent. The conditions in the container were adjusted as in Example 1.
A platinum plate was used for the anode and a conductive glass plate was used for the cathode. Electrolysis was carried out at 20° C. under emanation of ultrasonic waves of 47kHz frequency. Current density was 20mA/cm 2 and current quantity was 10 C/cm 2 .
A plated film of a metallic luster was obtained on the cathode with a thickness of about 1μm. The film contained 22% by weight of samarium and 78% by weight of cobalt. The plated film was then heated at 600° C. for one hour in an argon environment and the resultant magnetic characteristics is shown in FIG. 2. It is clearly seen from the graph that the plated film exhibited a coercive force of 447 oersted.
Example 3
A plated film was produced with components and in a manner same as in Example 2 except 40 mA/cm 2 current density. The film contained 27% by weight of samarium and 73% by weight of cobalt.
Example 4
A plated film was produced with components and in a manner same as in Example 2 except 50mA/cm 2 current density. The film contained 31% by weight of samarium and 69% by weight of cobalt.
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Formation of a Sm-Co alloy film is carried out by means of wet plating system which is easily practicable and well suited for treatment intricate and/or large configurations. The system uses a plating bath which contains chlorides of samarium and cobalt dissolved with non-aqueous solvent such as formamide. Substantial absence of any aqueous components in the plating bath assures production of a plated film of high purity and quality. Content of samarium in the product can feeely be adjusted by choice of the current density of direct current to be employed in the electrolytic plating.
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FIELD OF THE INVENTION AND PRIOR ART
In the following description, since the door system is identical to the window system, the description of the invention of the window system will be applied to the description of the door system.
In the present invention, a sliding window and door system includes a rectangular window frame having upper, lower, left and right members. The rectangular window frame is mounted on a wall, and a rectangular window having upper, lower, left and right members is mounted on the rectangular window frame, thereby preventing dust, water, noise, and heat from coming into the interior of the room.
A conventional window and door system will be described hereinafter with reference to the drawings.
FIG. 1 shows a front view of a conventional window and door system, and a sectional view taken along line A—A will be illustrated in FIG. 2 .
FIG. 2 is a sectional view taken along line A—A of FIG. 1, illustrating a conventional window and door system.
The conventional window and door system comprises a lower member 1 on which exposed rails 11 are formed and lower members 2 which are opened and closed while being guided by the rails 11 and mohairmohair members 22 . Rollers 21 are disposed on the rails 11 .
PROBLEM TO BE SOLVED BY THE INVENTION
In the above described window and door system, since the door or window is opened and closed along the exposed rails, a water drain portion should be formed on the rails. This limits the improvement of airtightness, watertightness, and thermal insulation, deteriorating the energy efficiency.
In addition, although it is easy to assemble and disassemble the door or window from the frame because of a simple insertion of the door or window into the frame, there may be a possibility that the window and door can be removed from the frame by a strong wind or when it is opened and closed. Accordingly, when it is used for a multistory building, the removal of the window or door can cause an accident.
Since it is not easy to remove dust gathered between the rails and traces of water, the air can be contaminated by the dust when opening and closing the window. When the drain hole formed on the rail is blocked, the water can infiltrate into the interior.
The lower member formed in the prominence and depression manner also deteriorates the aesthetic aspect.
Therefore, the present invention has been made in an effort to solve the above described problems. It is an object of the present invention to provide a window and door system that can improve airtightness, watertightness, thermal isolation, aesthetic aspect and prevent the window (door) from detaching by providing a flattened rail structure.
To achieve the above object, a railless window and door system of the present invention is characterized in that a flat surface member is formed on a window (or door) frame lower member to provide a flat structure, a guide device is provided on the window (or door) frame lower member and window (or door) lower members to provided a railless structure, and since the window (or door) lower members are opened and closed by being guided by the guide devices, the window (or door) lower members are not inadvertently separated from the window frame lower member even when the rollers are operated on the flat surface member.
In addition, a railless window and door system of the present invention is further characterized in that to provide a railless structure, guide devices 131 include guide grooves 132 formed on a window (or door) lower member 130 and guide rollers mounted on lower extension portions extended from lower portions 143 of a window (or door) lower members 140 a and 140 b, and since the window (or door) lower members 140 a and 140 b are opened and closed while being guided by the guide devices 131 , the window (or door) lower members 140 a and 140 b are not inadvertently separated from the window (or door) frame lower member 130 even when rollers are driven on the railless surface members.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a schematic view of a conventional window and door system viewed from an outside of a room;
FIG. 2 is a sectional view taken along line A—A of FIG. 1;
FIG. 3 is a schematic view of a railless window and door system according to the present invention;
FIG. 4 is a sectional view taken along line B—B of FIG. 3;
FIG. 5 is a sectional view of a guide system of FIG. 4 according to another embodiment of the present invention;
FIG. 6 is a sectional view of a guide system of FIG. 4 according to another embodiment of the present invention;
FIG. 7 is a schematic view of a window and door system viewed from an outside of a room, in which an outside window (or door) is replaced with a fixed window (or door) according to the present invention;
FIG. 8 is a sectional view taken along line C—C of FIG. 7;
FIG. 9 is a sectional view taken along line D—D of FIG. 8;
FIG. 10 is a schematic view of a window and door system viewed from an outside of a room, in which an inside window (or door) is replaced with a fixed window (or door) according to the present invention;
FIG. 11 is sectional view taken along line E—E of FIG. 10;
FIG. 12 is a sectional view taken along line F—F of FIG. 10;
FIG. 13 is a sectional view taken along line B—B of FIG. 3 according to another embodiment of the present invention;
FIG. 14 is a sectional view taken along line C—C of FIG. 5 according to another embodiment of the present invention; and
FIG. 15 is a sectional view taken along line D—D according to another embodiment of the present invention.
DESCRIPTION OF THE INVENTION
The embodiments of the present invention will be described hereinafter with reference to the accompany drawings.
In the following description, the terms “upper,” “lower,” “outside,” and “inside” mean “upper side,” “lower side,” “left side,” and “right side,” respectively.
First Embodiment
FIG. 3 shows a railless window and door system view from an outside of a room according to the present invention and the sectional view taken along line B—B is shown in FIGS. 4, 5 and 6 .
FIG. 4 shows a sectional view of a railless window and door system taken along line B—B of FIG. 4 .
To provide a railless structure, a window frame lower member 3 includes guide devices 31 provided with guide grooves 32 and guide inlets 33 for guiding lower extension portions 41 of window lower members 4 a and 4 b, and a railless surface 34 for providing a flat structure.
The window lower members 4 a and 4 b include guide rollers 42 mounted on the lower extension portions 41 , a gasket 43 for preventing the infiltration of water and air into the room, a mohair member groove 44 , mohair members 45 inserted into the mohair member groove 44 , and height adjustable rollers 46 mounted to be disassembled.
Since the window lower members 4 a and 4 b are opened and closed by the guide devices 31 guiding the guide rollers 42 to be operated in the vicinity of the guide grooves 32 formed in the guide inlets 33 , the window is not separated from the window frame lower member 3 even when the rollers 46 are operated on the railless surface 34 .
When separating the window, the guide rollers 42 are first separated from the guide grooves 32 by lowering the height adjustable rollers 46 , then the window is separated.
FIG. 4 shows a window separable state in a state where the window is assembled.
The railless surface 34 is provided with a molding type slope so that water can be easily expelled out of the system while improving the aesthetic aspect.
FIG. 5 is a view similar to FIG. 4 to illustrate another embodiment of the guide devices.
In the guide devices 51 , guide rails 52 are formed on the window frame lower member, and sliding member grooves 54 are formed on lower extension portions 53 extended from a lower portion of the window lower members. The sliding member grooves 54 are formed to correspond with each other on the basis of the guide rails mohair members 55 or sliding members 56 are inserted into the sliding member grooves 54 such that the window can slide by the mohair members 55 or the sliding members 56 mounted on left and right sides of the guide rails.
FIG. 6 is a view similar to FIG. 4 to illustrate another embodiment of the guide devices.
In the guide devices 61 , guide rails 62 are formed on window frame lower members, and guide rollers 64 are provided on lower extension portions 63 extended from the lower portion of the window lower members. The guide rollers 64 are mounted in the vicinity of the guide rails 62 .
FIG. 7 shows a schematic view of a window and door system viewed from an outside of a room, in which an outside window (or door) is replaced with a fixed window (or door) according to the present invention. The sectional views taken along lines C—C and D—D of FIG. 7 are shown in FIGS. 8 and 9, respectively.
FIG. 8 is a sectional view taken along line C—C of FIG. 7, in which the outer window 4 a depicted in FIG. 4 is replaced with a fixed window 8 .
To replace the outer window 4 a of FIG. 4 with the fixed window 8 , a window frame lower member 7 is provided with a fixed window groove 71 on which the fixed window 8 is mounted and a railless surface 72 designed to easily expel water out of the window. After mounting the fixed window 8 on the fixed window groove 71 , silicon members 81 are used as a final material.
FIG. 9 shows a sectional view taken along line D—D of FIG. 7, in which a fixed window groove cover 73 is mounted on a section where the fixed window 8 is not mounted.
FIG. 10 shows a schematic view of a window and door system viewed from an outside of a room, in which an inner window (or door) is replaced with a fixed window (or door) according to the present invention. Sectional views taken along lines E—E and F—F of FIG. 10 are shown in FIGS. 11 and 12, respectively.
FIG. 11 shows a sectional view taken along line E—E of FIG. 10, in which the inner window 4 b depicted in FIG. 4 is replaced with a fixed window.
To replace the inner window 4 b with the fixed window 10 , the window lower member 9 is provided with a fixed window groove 91 for mounting the fixed window 10 a and a railless surface 92 formed to easily expel water. The fixed window 10 is mounted on the fixed window groove 91 and finalized by silicon members 101 .
FIG. 12 shows a sectional view taken along line F—F of FIG. 10, in which a fixed window groove cover 93 is mounted on a section where the fixed window 10 is not mounted.
Second Embodiment
FIG. 13 shows a sectional view of a railless window and door system taken along line B—B of FIG. 4 according to another embodiment of the present invention.
To provide a railless structure, a window frame lower member 130 includes guide devices 131 provided with guide grooves 132 and a railless surface 134 on which a molding type slope having an outward trajectory 133 is used as a water outlet. Guide groove covers 135 are formed covering the guide grooves 132 . The guide devices 131 are further provided with guide inlets 136 for guiding lower extension portions 141 of the window. Roller support grooves 137 are provided to mount roller support members 138 that can prevent the surface 134 or the cover 135 from being damaged by rollers 142 when the windows 140 a and 140 b are opened and closed. Gaskets 139 are provided to prevent water from infiltrating into the guide grooves 132 , and mohair members 130 a are provided to prevent interior air from going out of the room. A lower rail 130 b is formed to mount a mothproof window.
Window lower members 140 a and 140 b include guide rollers 42 mounted on the lower extension portions 141 . Height adjustable rollers 142 for adjusting opening/closing height of the window are formed on the lower portions of the window lower members 140 a and 140 b. Gaskets 145 and mohair members 146 are provided to prevent the flow of air and water.
Since the windows are opened and closed by the guide devices 131 guiding the guide rollers 142 to be operated in the vicinity of the guide grooves 132 , the window is not inadvertently separated from the window frame lower member 131 even when the rollers 142 are operated on the railless surface 134 or cover 135 .
FIG. 14 shows a sectional view taken along line C—C of FIG. 14, in which the outer window 140 a depicted in FIG. 13 is replaced with a fixed window 160 according to another embodiment of the present invention.
To replace the outer window 140 a with a fixed window 160 , the window frame lower member 150 is provided with a fixed window groove 151 to mount the fixed window and railless surfaces 152 for easily expelling water out of the surface 152 . The fixed window 160 is mounted on the fixed window groove 151 and finalized by silicon members 161 .
FIG. 15 shows a sectional view taken along line D—D of FIG. 5, in which a section of a fixed window groove 151 on which the fixed window 160 is not mounted is covered by a fixed window groove cover 153 .
EFFECT OF THE INVENTION
As described above, since the window frame lower members 4 a and 4 b are opened and closed while being guided by the guide devices 31 , the rollers 46 can be operated on a railless flat surface 34 .
Accordingly, since the water drain hole which has been required in the conventional rail structure is not necessary, improvements in the airtightness and water tightness occur. It is easy to remove collected dust, making the surface clean. Furthermore, the sloped surface smoothly expels water out of the frame, thus damage caused by the water can be prevented.
In addition, since the window is not inadvertently removed from the frame, safety can be improved.
Since a gap between the window frame lower member and the window lower member is sealed by the gasket and mohair members, the airtightness, watertightness, and thermal insulation can be greatly improved.
Since the surface is formed with a smooth molding type, the aesthetic aspect can be improved, thereby providing a high quality window and door system.
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The present invention relates to an improved lower member of a sliding window and door system, and it is an object of the present invention to provide a convenient, safe and high quality window and door system by solving problems of the conventional window and door system. To provide a flat structure of a railless window and door system of the present invention, a surface member is formed on a window (or door) frame lower member, and to provide a railless structure, a guide device is provided on the window (or door) frame lower member and the window (or door) lower member such that the window (or door) lower member is not inadvertently separated from the window (or door) frame lower member even when the roller is driven on the railless surface member as the window (or door) lower member is guided by the guide device.
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FIELD OF THE INVENTION
The present invention relates to office panelling systems and, in particular, relates to frame based office panels in combination with bridge arrangements for defining a work station.
BACKGROUND OF THE INVENTION
Frame based office panelling systems provide a very valuable system for subdividing a large office space into individual work stations. The office space is easily rearranged from time to time to accommodate a completely different layout. These office panelling systems typically use office panels which have a frame structure to which releasable elements are secured. These releasable elements are normally rectangular in shape and when removed from the frame, expose a hollow interior of the panel.
Teknion Furniture Systems offers such a frame based panelling system and the structure of this panelling system is generally shown in U.S. Pat. No. 4,535,577 which is incorporated herein by reference.
Frame based office panelling systems do provide for convenient distribution of both electrical power and communication wires to the individual work stations and also provide flexibility to reconfigure the work space.
Desking systems provide an alternate approach and are more common in Europe. The desks or work tables provide the support structure and light-weight screening members can be attached to the work surfaces to provide visual privacy.
Teknion Furniture Systems also offers a combined office panelling system and desking system which is disclosed in U.S. Pat. No. 5,428,928 which is incorporated herein by reference. This system allows desks or other work surfaces to be attached to an office panelling system and to depart from the panelling system at a point intermediate to the length of a panel.
In addition to these two basic types of office systems, there have always been separate stand alone conference tables which can move about the office to suit the particular needs of the users. In addition, there have been mobile file storage units and mobile computer stations to allow many different users to use the equipment from time to time.
Prior to frame based office panelling systems, it was known to have a cooperating free standing partition screens which typically had a fixed core, such that access to the interior of the partition was not available. These screens could support different office accessories, either from the top of the screen or from the vertical edges of the screens.
SUMMARY OF THE INVENTION
An office panelling system according to the present invention comprises a series of connected office panels in combination with bridge arrangements which combination collectively sub-divides an open office space into a plurality of work stations. The office panels comprise a structural frame to which releasable rectangular-like elements are secured. These releasable elements define the dominant exterior finish to either side of the frame. The frame includes freely accessible support structures adjacent the elements for securing work station components from the panels via the support structure. Each bridge arrangement includes a partition forming a wall section of a work station with one end of the partition connected to one of the panel frames and an opposite end of the partition connected to a floor structural support member. The structural support member can be a further office panel, a floor engaging column member or other structure. The bridge component is supported at either end by structural members which render the bridge component stable. The partition is many times lighter to an equivalent length of an office panel.
According to an aspect of the invention, the partition of each bridge member has an exterior finish the same as the removable elements of the office panels.
According to a further aspect of the invention, the partition of each bridge arrangement is rectangular in shape and defines a large gap between a lower edge thereof and the floor along the length of the bridge.
According to a further aspect of the invention, the partition of each bridge member has a cardboard honeycomb interior to which the exterior finish is secured.
According to a further aspect of the invention, each bridge arrangement includes a structural frame about the partition which is releasably attached to one of the panel frames.
According to a further aspect of the invention the floor engaging column member is of a weight to oppose any accidental movement of the end of the bridge arrangement attached to the floor engaging column member.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention are shown in the drawings, wherein:
FIG. 1 is a partial perspective view showing a series of office panels connected in an end to end manner with a bridge arrangement connected at an angle to the panels;
FIG. 2 is a side view of a bridge arrangement attached to an office panel;
FIG. 3 is a partial top view showing a long spline of connected office panels with other office panels connected at 90° thereto, as well as bridge arrangements connected at 90° to the spline of panels;
FIG. 4 is a partial perspective view showing attachment of a bridge arrangement to an office panel;
FIG. 5 is a partial perspective view showing attachment of a partition to a column member which in turn is attached to an office panel; and
FIG. 6 is a partial perspective view showing securement of the partition to a column member at the free end of the bridge arrangement.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The office panelling system 2 comprises a series of connected office panels 4 which are of the type having an interior frame to which removable, decorative or functional elements 14 are secured. In FIG. 1, the panel structural frame is generally shown as 10, but the precise details of the frame are shown in U.S. Pat. No. 4,535,577. Basically, the office panel frame is made of metal, having a exterior frame and a series of horizontal channel members which extend across the frame. These channel members are "U" shaped and each "U" shaped channel is accessible through the gap between adjacent vertically spaced panels. One such "U" shaped channel is shown as 12 in FIG. 4.
In FIG. 1, a series of office panels 4 are connected in an end to end manner forming a spline to which bridge arrangements 6 or other office panels can extend in a perpendicular or angled manner. A combination of office panels and bridge arrangements at an angle to the spline are shown in the top view of FIG. 3. The spline of connected office panels is generally shown as 5 and at one end of the spline, office panels 4 form a "T" junction for support of the spline 5 of office panels. In addition, the bridge arrangements 6 also extend at an angle from the spline 5 and define a series of work stations 8. The office panels 4 at position 7, indicated in FIG. 3, are perpendicular to the spline and are connected to an office panel frame intermediate the length thereof (off module). Similarly, the bridge arrangement 6 can be connected to an office panel at any point along the length of the office panel. The office panelling system, partially shown in FIG. 3, is defined by a series of bridge arrangements 6 and a series of office panels forming a spline 5 with other office panels at an angle to the spline.
In FIG. 1, the bridge arrangement 6 provides visual privacy between two work stations, but does leave a gap, generally shown as 13, between a lower edge of the bridge arrangement and the floor. Preferably, the top of the bridge arrangement is positioned at the same height as the office panels 4 or at least at predetermined heights thereof (typically as a function of the elements). For example, it would be common to connect to the spline 5 of office panels a bridge arrangement or further office panels which are basically at any of the heights indicated as 15, 17 and 19. This defines a modular relationship between the office panels and the bridge arrangements and they need not all be the same height. The position indicated as 15 typically requires a bridge arrangement which extends to the level indicated as 21, preferably still leaving a small gap between the lower edge of the bridge and the floor. In many cases, the lower edge of the bridge terminates at a height indicated at 23 and in the case of the office panels shown in FIG. 1 would extend to the top of the office panels, i.e. at 19. It can be appreciated other arrangements are possible and these positions are preferred merely in that they are coordinated with the element position of the office panels.
The bridge arrangement 6 includes an extension or floor engaging column member 50 at the free end of the rectangular partition 30. The rectangular partition 30 has a perimeter frame 32 thereabout made of extruded members that act as a structural frame about the partition 30. The partition 30 includes an exterior finish surface shown as 35 which can be upholstered, for example, to match the office panels 4 or can be of a related surface, such as a whiteboard or tackboard or other suitable surface. The rectangular partition 30 is preferably lightweight and it has been found that a lightweight honeycomb cardboard core 38 formed with two cardboard skins 36 as shown in FIG. 6 provides a strong tackable core.
The perimeter frame 32 adds a structural stiffness to the bridge arrangement and distributes loads to the spline 5 of office panels. Preferably, the partition includes a finish surface 34 which can be appropriately applied to the core prior to securement of the perimeter frame 32. The frame 32 at the end face 33 has a number of channel brackets 70 secured by fasteners 72 to the perimeter frame. These channel brackets also engage the central support 60 of the stanchion 50. The stanchion 50 has a curved foil shape and is relatively heavy in comparison to the rectangular partition 30. The stanchion 50 includes a curved exterior surface 52, in this case which is shown with a series of punched holes therein. This surface is attached to a frame. The frame includes the base 54, side frames 58, the central support 60, the horizontal support 62 and the top member 55. Height adjustable glides 56 can be secured to the base member 54. The stanchion 50 is designed to have substantial weight to anchor the bridge and oppose bridge movement if accidental forces are applied to the end of the bridge arrangement 6. It is found that the bridge arrangement has a very robust appearance and it provides the impression that it would be of similar strength to the office panels. The bridge arrangement, less the stanchion 50, is many times lighter than an equivalent length of office panels and, although strong, is easily moved if an accidental force is applied to the free end thereof. This problem is essentially solved by the stanchion 50 which, due to its weight, does not move easily. It can also be appreciated that in some layouts there will be desks to opposite sides of the bridge member which would oppose movement of the bridge, as the bridge is trapped between the two desks. The frame of the bridge arrangement is typically below desk level and would contact the desks and oppose accidental movement of the bridge.
The frame of the bridge arrangement is connected to the office panel frames and to the stanchion 50 forming a structural support maintaining the spline of office panels in a vertical orientation. The partition or core of the bridge strengthens this structural support and the bridge arrangement. This provides the necessary stability for the spline of office panels and forms a bridge frame arrangement which is strong but is not typically designed to carry the same loads as an office panel. If desired equipment can be supported by the bridge arrangement and the frame of the bridge could be robust for high load carrying capability.
The perimeter frame 32, in cooperation with the channel brackets 70, provide a simple means for securing of the partition 30 to the stanchion 50.
The opposite end of the bridge arrangement 6 and its attachment to an office panel frame is shown in FIG. 4. The perimeter frame 32 uses the channel brackets 70 which are secured to a cylindrical post 90. Again, a simple mechanical securement of the channel brackets 70 to the post 90 is preferred.
The opposite side of the post has a hook 92 positively secured thereto which, in cooperation with the pivoting cam latch 94 is used to secure the post 90 to the securing channel 12 of the office panel frame 10. Once the hook 92 has been inserted into the channel 12, the cam latch 94 may be pivoted to lock the hook in the channel. Details of this can further be appreciated from a review of FIG. 5. It is preferred that the post 90 is secured in at least two places to the panel frame by means of a pair of hooks 92 and the latches 94. Two such securements are shown in FIGS. 1 and 2.
The bridge arrangement 6 can also include an accessory slotted rail 40 at a lower edge thereof. This slotted rail is designed to receive the wiring trough 100, having a hook 102 for receipt in one of the slots 41. Other lightweight accessories can also use this rail.
As previously mentioned, the office panels 4 can have electrical wiring as well as communication wiring through the frame members to provide power and communication to the individual work stations 8. The bridge arrangement includes wire management preferably along the lower edge of the bridge. With a work surface placed to one side of the bridge, such as the work surface 9 shown in FIG. 3, a wiring trough 100 is secured to the lower edge of the bridge member and receives the communication wiring or power wiring generally indicated as 104 in FIG. 5. Preferably the office panels 4 allow for electrical connection of equipment to electrical outlets interior to the panel. Thus, in the work station which includes the surface 9, the normal electrical connection is made with a receptacle of the office panel 6 either interior to the office panel, such as shown in our earlier patent, or along an appropriate surface thereof in accordance with other systems. The wiring for the equipment supported on work surface 9 is placed in the casual wiring trough 100 attached to a bridge. Wiring is maintained off the floor and excess wiring is accumulated in the trough. This wiring can include a multi outlet extension cord. In this way, the work surface 9 remains uncluttered, and the full advantage of having convenient power at all locations within the work station is achieved. This wiring distribution can also be used for mobile tables adjacent a bridge arrangement. Such mobile tables can also have a casual wiring trough attached thereto immediately below the work surface.
The bridge arrangement 6 is at least three times lighter and is more cost effective than a similar length of office panels. The bridge arrangement is easy to handle, making installation of the system less labor demanding. With this arrangement, work stations are easily defined and advantageouly use office panels in critical locations where their full function can be utilized. In other locations where the full function of an office panel is not required and privacy is desired, the lightweight bridge members is used. These bridge arrangements provide excellent visual privacy and can also mimic the appearance of the office panels, including the full height of office panels, if desired. Each of the bridge arrangements can be detached from an office panel and moved to another location. The bridge arrangement, when secured to the stanchion and having the post 90 secured thereto is self supporting in the normal orientation thereof. The securement of the bridge to the horizontal channels of the frame also allow the position of the bridge to be adjusted as indicated by arrow 3, shown in FIG. 3. If desired, a stanchion 50 can be used at each end of the framed partition 30 to provide a freestanding screen or display structure.
The bridge arrangement has been described with respect to the preferred embodiment where there is a significant gap between the lower edge of the bridge member and the floor. This area has been maintained free of wiring used for equipment placed on the work surfaces associated with the bridge as the wiring is placed in the casual wiring trough secured to the lower surface of the bridge. This arrangement provides improved circulation of air from work station to work station. The lower surface of the bridge is also separated from the floor and is less prone to accidental forces caused by kicking of the lower surface of the bridge, banging of equipment into the lower surface of the bridge, or cleaning equipment banging the lower surface of the bridge. It also allows for reduced costs in manufacturing of the bridge. Although this reduced size is desired the bridge arrangement can be full height. It can also be appreciated the lightweight partition could be designed to connect aligned panels where the panels and the lightweight partition form a generally planer surface. In this case, the lightweight partition is designed to connect with the ends of the office panel frame.
The bridge arrangement, as shown in FIG. 3, are typically of a length of approximately 8 feet. In this case, the rectangular partition 30 includes two separate components 30A and 30B as shown in FIG. 2. These are separately upholstered components, or separately manufactured components which are trapped within the common perimeter frame 32. This simplifies manufacturing of the rectangular partition 30. It can also be appreciated that it allows the surfaces of 30A and 30B to be different, if desired, in the particular work station. For example, 30A might be a whiteboard surface, whereas 30B can be upholstered.
Although various preferred embodiments of the present invention have been described herein in detail, it will be appreciated by those skilled in the art, that variations may be made thereto without departing from the spirit of the invention or the scope of the appended claims.
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Workstations are defined using a combination of office panels and bridge arrangements which are attached to and project at an angle from a spine of office panels. The office panel frames which partially define a workstation provide the convenience of power and communication cabling within the panel frames. The bridge arrangements provide a lower cost alternative defining other walls of the workstation while also providing a system which can be rearranged easily. The bridge arrangements are preferably self supporting in an upright orientation and can easily be detached from a horizontal securing channel of an office panel frame and moved to a new position.
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BACKGROUND
Components of gas turbine engines are subject to wear and damage. Even moderate wear and damage in certain components may interfere with optimal operation of the engine. Particular areas of concern involve the airfoils of various blades and vanes. Wear and damage may interfere with their aerodynamic efficiency, produce damaging dynamic force and imbalances, and even, in more extreme cases, structurally compromise or damage parts.
Because blades tend to be forced outwardly within a rotor due to centrifugal forces during operation, wear between interlocking portions of a blade and the rotor in which the blade is disposed is an area of interest.
SUMMARY
According to an exemplar disclosed herein, a disk made of a first material has a groove in which a blade made of a second material is retained. A strip is placed between the blade and the disk to minimize rubbing damage to the blade and the disk and an insulating material is place between the rub strip and the blade for minimizing damaging responses of the blade to galvanic forces created by rubbing of the first material and the second material.
According to a further exemplar disclosed herein, a blade made of a first material for retention within a disk made of a second material has a strip placed thereon for minimizing rubbing damage to the blade from the disk, and an insulating material is disposed between the rub strip and the blade for minimizing response of the blade to galvanic forces.
According to a still further exemplar disclosed herein, a die has an electroforming body having a shape conforming to a portion of a shape of a root of a blade. The portion conforms to areas of the root in which rubbing between the blade and a disk occurs. The body has a non-conductive strip to create a gap in a part electroformed on the die so that the part may be easily removed from the die.
According to a still further exemplar disclosed herein, rub strip for use with a disk made of a first material and having a groove that holds a blade root made of a second material, has a strip having a contour closely mimicking a contour of the blade root and the groove for placement between the blade root within the groove, the strip minimizing rubbing damage to the blade, and an insulating material disposed on a inner surface of said strip between the rub strip and the blade for minimizing damaging responses of the blade to galvanic forces between the first material and the second material.
These and other features of the disclosed examples can be best understood from the following specification and drawings, the following of which is a brief description.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of a rotor having a blade seated therein.
FIG. 2 is a cross-sectional view taken along the lines 2 - 2 of FIG. 1 partially cutaway.
FIG. 3 is a cutaway view of the blade and rotor taken along the lines 2 - 2 of FIG. 2 .
FIG. 4 shows a view of the root structure of the blade of FIG. 3 .
FIG. 5 shows a perspective view of the blade of FIG. 3 .
FIG. 6 is a view of an example die.
DETAILED DESCRIPTION
Referring to FIGS. 1 and 2 , a disk 201 for use in a gas turbine engine, not shown, having an annular shape, a front face 205 , a rear face 207 and an outer surface 209 is shown. Grooves 211 , which may follow a rectilinear path through the outer surface 209 of the disk 201 from the front face 205 to the rear face 207 , extend at an angle to an axial centerline A. Though grooves 211 form a dovetail (see FIG. 3 ) shape 213 , other shapes that secure a blade 203 to the disk 201 are contemplated herein. The disk may be made of titanium or an alloy thereof.
As seen in FIGS. 2 and 3 , a blade 203 has a root portion 214 placed within the grooves 211 of the disk 201 . The root portion 214 has a contour 216 that closely mimics the dove tail shape 213 of the grooves 211 for retention of the blade 203 therein. Though the fit between the contour 216 and the shape 213 is close to an interference fit, space between the root portion 214 and the groove 211 exists due to imperfection in manufacturing techniques and to enable the blade 203 to be inserted and removed efficiently. The root portion 214 has a tab 219 depending therefrom towards the axial center line A that abuts a shoulder 212 in the disk 201 to position properly and limit the travel of the blade 203 during insertion of the blade 203 into the groove 211 . A split lock ring 222 is placed behind the blades and the disk 201 to minimize forward movement of the blades 203 . The tabs 219 also minimize rearward movement of the blades. The blade 203 may be constructed of aluminum or other alloys.
Referring now to FIGS. 3 , 4 and 5 , the blade 203 includes a platform 221 between the root portion 214 and an airfoil 215 . After installing the blades 203 into the grooves 211 of the disks 201 , the platform 221 serves the fill in gaps 223 , 224 and 225 which are exaggerated for ease of viewing. The platform 221 defines a small portion of the inner boundary of the core engine flow path (not shown). As seen in FIG. 3 , the platforms 221 are flush with the outer surface 209 of the disk 201 . Though the gap 225 may be small, during operation, as the disk spins, centrifugal forces move the blades 203 radially outwardly away from centerline A so that gap 225 is eliminated and potentially damaging rubbing between the root portion 214 and the disk 201 may occur.
Referring now to FIGS. 4 , 5 and 6 , a rub strip 230 , which may be electroformed, as will be discussed hereinbelow, is disposed on the contour 216 , a bottom portion 235 , and the tab 219 of the root portion 214 . The rub strip 230 closely mimics the shape of the contour 216 , a bottom portion 235 , and the tab 219 of the root portion 214 so that the gap 225 is minimized. During operation, the rub strip contacts the disk 201 and minimizes damage to the root portion 214 of the blade 203 .
A bonding agent 300 , such as an epoxy glue as is known in the art, is used to electrically isolate the rub strip 230 from the blade 203 and its root portion 214 . The bonding agent 300 minimizes galvanic reaction caused by moisture and rubbing of dissimilar metals between the rub strip 230 and the root portion 214 that might tend to degrade the root portion 214 . The bonding agent 300 also minimizes rub strip 230 slippage.
Referring to FIG. 6 , a die 250 shaped like the contour 216 of the blade 203 is plated by using electric current to reduce cations of a desired material to coat the die 250 . The die 250 may be made of a conductive nickel titanium and the layer of material deposited thereon forms a rub strip 230 . A nano-nickel/cobalt or a conventional nickel material, or the like could be a suitable material for electroplating on the die 250 . The rub strips 230 provide wear resistance and corrosion protection. The rub strips have complementary halves 231 , 232 formed on the die 250 so that the halves 231 and 232 are easily removed from the die 250 . The halves are created by positioning a non-conductive strip 255 on the bottom of the die to create a gap 260 between the halves. Because the die 250 mimics that contour 216 , the halves 231 and 232 are easily glued to the root portion 214 .
If a blade 203 is placed within groove 211 as the disk 201 spins, the blade is moved radially outwardly from centerline A and the rub strip halves 231 , 232 are brought into contact with the grooves 211 . The rub strip halves 231 , 232 absorb rubbing to minimize fatigue and wear within the blade root.
Although a combination of features is shown in the illustrated examples, not all of them need to be combined to realize the benefits of various embodiments of this disclosure. In other words, a system designed according to an embodiment of this disclosure will not necessarily include all of the features shown in any one of the Figures or all of the portions schematically shown in the Figures. Moreover, selected features of one example embodiment may be combined with selected features of other example embodiments.
The preceding description is exemplary rather than limiting in nature. Variations and modifications to the disclosed examples may become apparent to those skilled in the art that do not necessarily depart from the essence of this disclosure. Thus, the scope of legal protection given to this disclosure can only be determined by studying the following claims.
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A disk made of a first material has a groove in which a blade made of a second material is retained. A strip is placed between the blade and the disk to minimize rubbing damage to the blade and the disk and an insulating material is place between the rub strip and the blade for minimizing damaging responses of the blade to galvanic forces created by rubbing of the first material and the second material.
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RELATED APPLICATION
This disclosure claims the benefit of Provisional Patent Application No. 60/895,284, filed on Mar. 16, 2007.
FIELD OF THE INVENTION
The disclosure relates to a power distribution module and to a device for conveying power to an electrical accessory.
DESCRIPTION OF THE RELATED ART
It is known in the art that vehicles that are manufactured by an original equipment manufacturer (OEM) may not include one or more options, features, or accessories that are desired by a consumer when the vehicle is purchased by the consumer in a new or previously-owned condition. Is such situations, the consumer may resort to purchasing one or more “aftermarket” accessories, which may be permanently or removably integrated with the vehicle, that provides the function of the one or more options, features, or accessories desired by the consumer.
Exemplar aftermarket accessories may include video entertainment systems, navigation systems, cellular telephones, seat heating systems, computers, battery chargers, lighting systems, and the like. As in most situations, such aftermarket accessories may require power from the vehicle's on-board power source to provide the intended function of the accessory. Typically, the power for the accessory is obtained from a wiring infrastructure extending from the power source, the wires of which may be conveniently located, for example, proximate/behind a dashboard, trim panel, headliner, or the like.
Historically, such aftermarket accessories are typically divided into two categorizations: 1) key-on/ignition-hot accessories that require power only when the vehicle's ignition is on; and 2) key-off/constant-hot accessories that require power at all times, irrespective of the on/off state of the ignition. Because modern vehicles now have dozens, or, even hundreds of wires located, for example, proximate the dashboard area, it may be difficult to locate a dedicated key-on or key-off wire in order to “rewire” and integrate the aftermarket accessory with the vehicle.
Further, because copper wiring is heavy and expensive, and, because vehicle manufacturers are under continuous pressure to decrease vehicle weight while improving fuel economy, many wires are designed to specifically supply an intended electrical load without being able to accommodate the provision for larger electrical loads, as may be associated with an aftermarket accessory. Accordingly, the above factors may lead to a formidable challenge in locating an appropriate key-on/off wire so as to be able to supply the desired electrical load to the accessory.
In addition to the above concerns, the vehicle wiring infrastructure typically interfaces with electronic control modules (ECMs), which are a) relatively fragile, b) intolerant of electrical overloads, and c) potentially operate in conjunction with sensitive electronic switches. Accordingly, in an exemplar aftermarket installation scenario, a digital video disc (DVD) system may, for example, utilize a wire that is dedicated, in design, to a fuel injection ECM.
In an example, a DVD system may share a common wire and operate amicably with a fuel injection ECM even though the common wire is not intended to provide power to the DVD system. However, as an operating dynamic of the DVD system (e.g. soundtrack volume, which may be quantified in decibels) is increased by a user, the DVD system may ultimately cause failure of the ECM. One probable cause of the failure of the ECM is an increased current drain on the wire that may be attributed to a situation when soundtrack volume of the DVD system is increased from a low volume/decibel level past a second, higher volume/decibel level. Accordingly, although the DVD system may operate amicably with the fuel injection ECM when the soundtrack volume/decibel level is set to a relatively low level, the change in soundtrack volume/decibel level from the low level to a higher level may result in the failure of the ECM and subsequent stalling of the vehicle.
Further, if an aftermarket accessory is positively rewired according to an appropriate key-on/off operation, the correct rewiring of the accessory may ultimately prove to be unacceptably noisy due to a power sensitivity of the aftermarket accessory. As a result of these and other factors, even a seemingly simple installation of an aftermarket accessory can therefore become frustratingly difficult, unreliable, expensive, and time-consuming to trouble-shoot should a failure of the accessory and/or vehicle occur.
Accordingly, there is a need in the art for an apparatus that enables an installer/end user to easily select either one or more key-on/off operating modes for one or more aftermarket accessories without the complexities or concerns associated with the rewiring of an aftermarket accessory with the vehicle's existing key-on/off wire infrastructure.
BRIEF DESCRIPTION OF THE DRAWINGS
The disclosure will now be described, by way of example, with reference to the accompanying drawings, in which:
FIG. 1 is a circuit diagram of a power distribution module in accordance with an exemplary embodiment of the invention;
FIG. 2 is a circuit diagram of a power distribution module in accordance with an exemplary embodiment of the invention; and
FIG. 3 is a circuit diagram of a power distribution module in accordance with an exemplary embodiment of the invention.
FIGS. 4 a and 4 b are schematic depictions of a fuse placed in first and second positions respectively.
DETAILED DESCRIPTION OF THE INVENTION
The Figures illustrate an exemplary embodiment of a power distribution module in accordance with an embodiment of the invention. Based on the foregoing, it is to be generally understood that the nomenclature used herein is simply for convenience and the terms used to describe the invention should be given the broadest meaning by one of ordinary skill in the art.
Referring to FIG. 1 , a power distribution module is shown generally at 10 according to an embodiment. The module 10 may be operable from power supplied by a vehicle power source, such as, for example, a vehicle battery. A terminal that permits the module 10 to be connected to the power source is shown generally at 12 . When the module 10 is installed in a vehicle, the module 10 reduces the potential of damage to or the averse functioning of vehicle operation electronics (e.g. electronic control modules (ECMs) and the like).
In an embodiment, the module 10 may be powered by a single key-off/constant-hot wire, which is shown generally at 14 , extending from the power source terminal 12 . In an embodiment, the wire 14 may be, for example, approximately a 10-to-8 gauge wire.
In an embodiment, the positive lead of the wire 14 may be connected to a main fuse, which is shown generally at 16 . According to an embodiment, the main isolation fuse 16 may be, fore example, a 50-ampere fuse, such that an overload condition of the module 10 will result in the failure of the isolation fuse 16 to ensure that an overload caused by the module 10 , or, any accessory, A 1 -A n , attached to the module 10 does not adversely affect devices (not shown) connected to the remaining wiring infrastructure of the vehicle.
In an embodiment, the module 10 has a plurality of ports, which are shown generally at 18 . Each of the plurality of ports 18 are connected to a respective fuse 20 .
A key-off/constant-hot power bus is shown generally at 25 a for providing power to an accessory, which is shown generally at A 1 -A n . The power bus 25 a is disposed between the main fuse 16 and the respective fuses 20 . Accessories, A 1 -A n , that are connectable to the plurality of ports 18 include, but is not limited to, for example, video entertainment systems, navigation systems, cellular telephones, seat heating systems, computers, battery chargers, lighting systems, and the like.
In an embodiment, the ports 18 may include a polarized, positive-locking connector system to provide a simple and secure plug-in-type connection feature for the accessories, A 1 -A n . Polarized connectors prevent connectors from being connected improperly (which, if connected improperly, may cause electrical damage to an accessory). Although eight ports 18 are illustrated in FIG. 1 , it will be appreciated that any number of ports 18 may be provided, as desired. In an embodiment, each port 18 may provide, for example, up to 11-amperes from the power bus 25 a , which is typically adequate for the majority of accessories, A 1 -A n ; however, it will be appreciated that the ports 18 are not limited to providing 11-amperes and that the ports 18 may provide any desirable amount of power for a particular application associated with a particular accessory, A 1 -A n .
To provide a) convenience, b) minimum supply impedance, c) simplified installation, and d) reduced noise, each port 18 also includes a ground lead 22 connected to ground 24 and a power lead 26 extending from a corresponding port fuse 20 . The provision of a power lead 26 and a ground lead 22 at each output 18 may a) reduce the ground impedance and b) provide a low-impedance path directly to the ground terminal 24 . In an embodiment, one or more of the ports 18 may be selected according to the position of the corresponding fuse 20 , which is explained in greater detail below.
In addition, it will be appreciated that the availability of a ground lead 22 at each port 18 provides several advantages over conventional methodologies associated with providing power to prior art key-on/off accessories. As is known in the art, conventional methodologies for providing power may include, for example, a) drilling a hole through metal structure of the vehicle, b) scraping away paint, c) crimping on a ground terminal, and d) installing a ground screw. Such a conventional creation of a power system ground is subject to reliability problems, as moisture may cause corrosion of the vehicle body and degrade the makeshift ground. Conversely, in the present invention, the provision of a ground lead 22 at each port 18 results in a ready-to-use ground connection such that little or no alteration is provided to the vehicle body.
Referring to FIG. 1 , an ignition control input terminal is shown generally at 28 . In operation, the ignition control input terminal 28 connects to a wire (i.e., a key-on/ignition-hot wire) in the vehicle to turn on relays, which are shown generally at 30 a , 30 b , with a low current of, for example, about 250 milliamps to provide key-on power for a key-on power bus, which is shown generally at 25 b . This small amount of current can be supplied by most ignition-hot wires in a vehicle, without overload. The power bus 25 b is disposed between the relays 30 a , 30 b and the respective fuses 20 .
Referring to FIG. 1 , a polarity protection diode, which is shown generally at 32 , is connected between the ignition control input terminal 28 and the relay coil terminal(s) 34 a , 34 b , to prevent the relay(s) 30 a , 30 b from actuating if the voltage polarity connected to the power source terminal 12 and ground 24 is reversed. Accordingly, the polarity protection diode 32 isolates and prevents potentially serious damage to key-on/ignition-hot accessories, A 1 -A n , that could otherwise occur. Still referring to FIG. 1 , a diode 38 protects and isolates the module 10 against inductive transients from the relay coil(s) 34 a , 34 b.
The relays 30 a , 30 b are inexpensive and robust. It will be appreciated, however, that the module 10 is not limited to the use of relays 30 a , 30 b and that other switches, such as, for example, Field Effect Transistor(s) (FET), could be used instead. In the case where less output current is required, the relay 30 a may be deleted from the circuit diagram of the module 10 , and, in place of the relay 30 a , a jumper 40 may be installed such that a single relay 30 b provides the switching function for key-on/ignition-hot power for the power bus 25 b.
Still referring to FIG. 1 , a light emitting diode (LED) 42 , whose operating current is limited by resistor 44 , provides an illumination, I, according to the qualification of one or more specified conditions of the module 10 . For example, the LED 42 may be illuminated, I, when all of the following conditions are met: a) leads of the battery 12 and ground 24 are connected, b) the polarity of the leads of battery 12 and ground 24 are correct, c) the main fuse 16 is intact, d) the ignition control input terminal 28 is active, and e) the relay(s) 30 a , 30 b are functioning correctly. Accordingly, when the LED 42 is lit, the LED 42 gives the installer/end user a high degree of confidence that the module 10 is installed properly and functioning, as desired.
In operation, the module 10 employs a fusing scheme that permit the ports 18 to provide easy selection of key-on/ignition-hot or key-off/constant-hot power according to the power needs of a particular accessory, A 1 -A n . As seen in FIG. 1 , each port 18 is associated with a selectable fusing configuration. In operation, the fuse 20 may be connected to a single pole double throw switch 21 to provide desired key-on/ignition-hot power from the power bus 25 b or key-off/constant-hot power from the power bus 25 a to a particular accessory, A 1 -A n , depending on the up/down position of the switch 21 . Alternatively, as shown in FIGS. 4A and 4B , in an embodiment, a physical switch 21 as shown in each of FIGS. 1-3 may be eliminated and the fuse 20 may be physically plugged in to one of two ports 23 a ( FIG. 4A ) or 23 b ( FIG. 4B ) to provide desired key-on/ignition-hot power from the power bus 25 b or key-off/constant-hot power from the power bus 25 a to a particular accessory, A 1 -A n . Whether a switch 21 is used or the approach set forth in FIGS. 4A and 4B is used, both techniques are electrically equivalent (although the technique set forth in FIGS. 4A and 4B may be more cost effective because it eliminates the need for an electrical switch 21 ).
According to the embodiment of FIGS. 4A and 4B , the port fuse 20 may be selectively inserted in one of two positions. For example, in a first, “up” position shown in FIG. 4A , the fuse 20 provides for key-off/constant-hot power from the power bus 25 a , whereas, in the second, “down” position shown in FIG. 4B , fuse 20 provides for key-on/ignition-hot power from the power bus 25 b . Accordingly, the selectable fusing configuration enables the installer or end user to quickly and easily select key-on/ignition-hot or key-off/constant-hot power delivery mode for a chosen accessory, A 1 -A n , connected at a particular port 18 without having to locate and physically connect a wire from the vehicle's existing wire infrastructure to an accessory, A 1 -A n . In an embodiment, and without limitation, the port fuse 20 may be referred to as an Automotive Type Miniature (ATM) fuse.
Referring now to FIG. 2 , a power distribution module is shown generally at 100 according to an embodiment. The power distribution module 100 is substantially similar to the module 10 with the exception that that module 100 includes a current-limiting resistor 102 and LED 104 connected at each power lead 26 .
According to an embodiment, the LED 104 will illuminate if power is present and if the associated fuse 20 is intact. Thus, when the LED 104 is not illuminated, a non-illuminated LED 104 will serve as an indicator of a situation where power is not available such that the fuse 20 is “blown” or missing.
According to an embodiment, a means for inhibiting illumination of the LED 104 is also shown generally at 106 . The means 106 includes a jumper 108 , a transistor 110 , and resistors 112 , 114 . In operation, the means 106 prevents the LED 104 from being illuminated unless an ignition control input seen at the ignition control input terminal 28 is activated (i.e., the ignition is “on”).
In an embodiment, if the jumper 108 is included without the transistor 110 and resistors 112 , 114 , the LEDs 104 associated with key-off/constant-hot outputs will illuminate without regard to the status of the ignition control input terminal 28 . However, as explained above with regarding to certain aftermarket accessory installation scenarios, the resulting current drain on the vehicle's battery may be undesirable, in which case, the jumper 108 can be deleted and transistor 110 and resistors 112 , 114 may be included. In this case, even the key-off/constant-hot LED(s) 104 will not illuminate unless the ignition control input terminal 28 is active. Accordingly, in the latter implementation without the jumper 108 , the means 106 reduces the operating current to zero when the ignition is off.
Referring now to FIG. 3 , a power distribution module is shown generally at 200 according to an embodiment. The power distribution module 200 is substantially similar to the module 100 with the exception that that module 200 includes an amplifier 202 connected between the ignition control input terminal 28 and the relay coils 34 a , 34 b . In operation, the amplifier 202 reduces drive current needed to activate the ignition control input terminal 28 .
In an embodiment, the amplifier 202 reduces the input current to a few milliamps, which may be supplied by virtually any desirable ignition-hot wire. In an embodiment, the amplifier 202 includes resistors 204 , 206 and a transistor 208 . If necessary, it will be appreciated that an FET could be used in place of the transistor 208 to further reduce the drive current.
In an embodiment, diode 210 functions substantially similarly as diode 32 such that the diode 210 functions as a polarity-protection diode so that relays 30 a , 30 b will not activate if the power polarity is reversed. In an embodiment, diode 212 functions substantially similarly as diode 38 such that the diode 212 functions as an inductive transient clamp to protect transistor 208 . In an embodiment, diode 214 protects transistor 208 from reverse base-emitter breakdown if the power to the main terminals 14 and 24 is reversed.
The present invention has been described with reference to certain exemplary embodiments thereof. However, it will be readily apparent to those skilled in the art that it is possible to embody the invention in specific forms other than those of the exemplary embodiments described above. This may be done without departing from the spirit of the invention. The exemplary embodiments are merely illustrative and should not be considered restrictive in any way. The scope of the invention is defined by the appended claims and their equivalents, rather than by the preceding description.
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A power distribution module for conveying power to one or more accessories is disclosed. The power distribution module includes a constant-hot power bus; an ignition-hot power bus; and at least one output terminal for conveying power to said one or more accessories, wherein the at least one output terminal is selectively capable of providing one of ignition-hot power to said one or more accessories from the ignition-hot power bus, and constant-hot power to said one or more accessories from the constant-hot power bus.
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BACKGROUND OF THE INVENTION
This invention relates to plastic-bonded explosives and more particularly to energetic plasticizers for plastic-bonded explosives.
Examples of energetic plasticizers which are currently used in plastic-bonded explosives (PBXs) are bis(2-fluoro-2,2-dinitroethyl)formal (FEFO), butanetriol trinitrate (BTTN), and trimethylolethane trinitrate (TMETN). These compounds have various disadvantages which include limited thermal stability (BTTN, TMETN), high volatility (FEFO), toxicity (FEFO), and high melting point (FEFO). In addition, these energetic plasticizers are not miscible with fluoropolymers and can therefore not be used with these desirable new binder materials for PBXs.
It would be desirable to provide a new high energy, thermally stable plasticizer which is also miscible with polyfluoro- and polynitropolymers but with a lower melting point.
SUMMARY OF THE INVENTION
Accordingly, an object of this invention is to provide a new energetic plasticizer for plastic-bonded explosives.
Another object of this invention is to provide an energetic plasticizer having good thermal stability.
A further object of this invention is to provide an energetic plasticizer having a low melting point.
Still another object of this invention is to provide an energetic plasticizer that is miscible with fluoropolymers.
These and other objects of this invention are achieved by providing a new compound bis(2-fluoro-2,2-dinitroethoxy) 2,2,3,3,4,4,4-heptafluorobutoxymethane and a method of preparing it.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
This invention provides bis(2-fluoro-2,2-dinitroethoxy) 2,2,3,3,4,4,4-heptafluorobutoxymethane (HFBF) which has been found to act as a general plasticizer for polyethylene glycol as well as various nitro-containing prepolymers, and also for highly fluorinated prepolymers such as the polyformal of 2,4,4,5,5,6,6-heptafluoro-2-trifluoromethyl-3-oxa-1,7-heptanediol, HOCH 2 CF 2 CF 2 OCF(CF 3 )CH 2 OH. It is thermally stable up to 150° C. HFBF has a density of 1.68 g/cm 3 (22° C.) and its heat of formation is estimated to be -594 kcal/mol, and the calculated detonation pressure is 228.9 kbar. HFBF has a very low melting point (-18° to -19° C.) compared with other nitroplasticizers of similar energy content such as FEFO (+14° C.) or trifluoroethoxyFEFO (-1° to -3° C.). Its volatility is slightly lower than that of FEFO (0.0108 vs. 0.0167 mg/min at 117° C.). Thus HFBF exhibits a set of properties which is unmatched by any other energetic plasticizer of comparable energy content. In addition to being useful as a unitary plasticizer, HFBF may also be used in admixture with other plasticizers to further improve and/or modify specific properties such as energy content or melting point.
Bis(2-fluoro-2,2-dinitroethoxy) 2,2,3,3,4,4,4-heptafluorobutoxymethane, CF 3 CF 2 CF 2 CH 2 OCH[OCH 2 CF(NO 2 ) 2 ] 2 , is prepared from 2-fluoro-2,2-dinitroethanol, CF(NO 2 ) 2 CH 2 OH, and 2,2,3,3,4,4,4-heptafluoro-1-butanol, CF 3 CF 2 CF 2 CH 2 OH, by the following reaction sequence as illustrated in Examples 1, 2, and 3: ##STR1##
Tris(2-fluoro-2,2-dinitroethoxy)methane, CH[OCH 2 CF(NO 2 ) 2 ] 3 , is a prior art compound which is synthesized by reacting three moles of 2-fluoro-2,2-dinitroethanol with one mole of chloroform by refluxing the reactants in the presence of ferric chloride as a catalyst. The conditions of this reaction are illustrated by example 1 which is incorporated from U.S. Pat. No. 3,388,147, entitled "2-Fluoro-2,2-Dinitroethyl Carbonates and Production Thereof," which was issued on June 11, 1968, to Mortimer J. Kamlet et al. (see col. 3, example III).
Next the tris(2-fluoro-2,2-dinitroethoxy)methane is refluxed with aluminum chloride and acetyl chloride to produce chloro bis(2-fluoro-2,2-dinitroethoxy)methane as illustated by example 2.
Finally, one mole of 2,2,3,3,4,4,4-heptafluoro-1-butanol is reracted with each mole of chloro bis(2-fluoro-2,2-dinitroethoxy)methane to produce the desired product bis(2-fluoro-2,2-dinitroethoxy) 2,2,3,3,4,4,4-heptafluorobutoxy)methane under conditions illustrated by example 3. The choice of a solvent for this step is not critical. Any inert solvent in which the reactants are soluble and which has a suitable boiling point may be used. Suitable solvents include dichloromethane, 1,1-dichloroethane 1,2-dichloroethane, 1,1,2-trichloroethane, or mixtures thereof.
The general nature of the invention having been set forth, the following examples are presented as specific examples thereof. It will be understood that the invention is not limited to these specific examples but is susceptible to various modifications that will be recognized by one of ordinary skill in the art.
EXAMPLE 1
Prior Art
Tris(2-fluoro-2,2-dinitroethoxy)methane [i.e., tris(2-fluoro-2,2-dinitroethyl)orthoformate]
"A mixture of 0.5 g. anhydrous ferric chloride and 10 ml. chloroform was placed in a 30 ml. round-bottom flask fitted with a magnetic stirre and a reflux condenser connected through a bubbler to a methanol gas trap. 2-fluoro-2,2-dinitroethanol, 2.0 g. (0.013 mole) was added and the mixture stirred and refluxed for 24 hours, after which time the mixture was collected [sic] to room temperature and the solvent removed in vacuo.
"The residue was drowned in iced water, stirred until the ferric chloride dissolved and the crystalline product collected. Recrystallization of this material from chloroform-hexane gave 1.39 g. (68%) pure tris(2-fluoro-2,2-dinitroethyl)orthoformate (FDNEOF) as fine colorless needles, M.P. 110°-11.2°."
EXAMPLE 2
Chloro bis(2-fluoro-2,2-dinitroethoxy)methane
A solution of tris(2-fluoro-2,2-dinitroethoxy)methane (23.6 g, 0.050 mol), aluminum chloride (12.0 g, 0.090 mol) and acetyl chloride (200 g) was refluxed for 1.5 hours and then concentrated on a rotary evaporator to a viscous liquid. This was extracted with chloroform (2×50 ml). After treatment with activated charcoal (2 g.), this solution was filtered and concentrated (rot. evap., 40° C. bath) to 23 g. of residue from which 8.53 g. (87%) of 2-fluoro-2,2-dinitroethyl acetate (bp 40°-3° C./0.1 mm) was removed by distillation. The residual liquid (14.14 g, 80% yield) was chloro bis(2-fluoro-2,2-dinitroethoxy)methane, free of contaminants by 1 H NMR analysis. Anal. Calcd for C 5 H 5 ClF 2 N 4 O 10 : C, 16.94; H 1.42; Cl, 10.00; F, 10.72; N, 15.80. Found: C, 17.10; H, 1.78; Cl, 10.08; F, 10.71; N, 15.42
EXAMPLE 3
Bis(2-fluoro-2,2-dinitroethoxy) 2,2,3,3,4,4,4-heptafluorobutoxymethane(HFBF)
A solution of 9.26 g (0.026 mol) of the chloro bis(2-fluoro-2,2-dinitroethoxy)methane (Example 2), 6.00 g (0.030 mol) of 2,2,3,3,4,4,4-heptafluoro-1-butanol, and 20 ml of 1,2-dichloroethane was refluxed for four hours. Volatiles were removed on a rotary evaporator (40° C. bath) and the residue absorbed on 6 g of silica gel (Silica Gel 60, 70-230 mesh). The product mixture was separated on a 100 g Silica Gel column with hexane/dichloromethane (4/1) to give 1.68 g. of bis(2,2,3,3,4,4,4-heptafluorobutoxy) 2-fluoro-2,2-dinitroethoxymethane and 11.57 g (86%) of bis(2-fluoro-2,2-dinitroethoxy) 2,2,3,3,4,4,4-heptafluorobutoxymethane, (HFBF), mp -19° C. to -18° C.; 1 H NMR (CDCl 3 ) δ5.67 (s, 1), 4.79 (d, 4, J=16 Hz), 4.16 (t, 2, J=14 Hz). Anal. Calcd for C 9 H 7 F 9 N.sub. 4 O 11 : C, 20.86; H, 1.36; N, 10.81; F, 33.01. Found: C, 20.88; H, 1.32; N, 10.68; F, 32.81.
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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Bis(2-fluoro-2,2-dinitroethoxy) 2,2,3,3,4,4,4-heptafluorobutoxymethane, (F), CF 3 CF 2 CF 2 CH 2 OCH[OCH 2 CF(NO 2 ) 2 ] 2 , is an energetic plasticizer with a melting point of -18° C. and thermal stability up to 150° C. HFBF is miscible with polyfluoro- and polynitropolymers and useful as a plasticizer in plastic-bonded explosives.
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BACKGROUND OF THE INVENTION
This invention relates to a novel method for casting a base directly on an electron tube and particularly to producing the base by injection molding.
Many types of electron tubes, such as television picture tubes, comprise an evacuated envelope including a stem and an array of relatively-stiff stem leads sealed in, and extending out from, the stem. Typically, the stem is a circular glass disc having a central opening from which the exhaust tubulation extends and a circular array of stem leads around the tubulation.
It is common practice to attach a prefabricated base, usually of some type of plastic material, over the stem with the stem leads extending therethrough where it is held by friction or with an adhesive. Where one or more leads are to carry relatively high voltages, the lead may be surrounded by a dielectric material to suppress interelectrode arcing. The prefabricated bases are usually assembled to the stems manually, a process that often leads to high cost and great variation in quality.
It has been suggested in U.S. Pat. No. 2,433,373 issued Dec. 30, 1947 to N. B. Krim to cast the base directly to the stem by injection molding. That prior method provides a mold with a temporary pressure seal radially around the tube above the glass stem in order to prevent leakage from the pressure of the injection molding material. Soft leads that extend from the stem attach to stiff leads that are mounted in an auxiliary plate. The stiff leads are inserted in bores in the mold during molding. With this arrangement, little or no stress is applied to the stem through the leads when the pressure seal is applied. However, this prior method is relatively slow, is laborious, uses excessive casting material and requires a special arrangement of base leads. The novel method is faster, can be practiced with an automatic or semi-automatic machine, uses substantially less casting material, and can be practiced on electron tubes having stiff stem leads extending from the stem of the tube. The novel method also overcomes the problem of producing a pressure seal over protuberances which may have been produced when the neck-to-stem seal was formed.
SUMMARY OF THE INVENTION
The novel method for casting a base directly on an electron tube comprising a stem and stem leads sealed in and extending out from said stem includes
A. detachably coupling a mold to said leads and said stem, the mold and stem substantially defining a chamber for casting the base,
B. producing a temporary pressure seal between the mold and the stem including applying static pressure therebetween in a direction that is substantially perpendicular to the stem surface,
C. and injecting liquid castable material into said chamber at substantial hydraulic pressure while maintaining the static pressure on the temporary seal.
By constituting the temporary pressure seal between the mold and the stem (instead of the neck of the tube), and by applying the static pressure to the seal longitudinally (instead of radially), the temporary pressure seal may be produced rapidly by machine without stressing the stem through the leads. The mold may include a gasket of compressible material opposite the perimeter of the stem. When the static pressure is applied, the gasket conforms to any variation in spacing between the mold and the stem. The novel method is economical of casting material, can be easily adapted to many stem lead arrangements, and produces bases of substantially uniform high quality.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1 and 2 are respectively a perspective view and a broken-away elevational view of the stem-containing portion of a CRT (cathode-ray tube) having a cast-in-place base prepared by the novel method.
FIG. 3 is a partially-sectional elevational view of essential parts of an apparatus for practicing the novel method showing the stem-containing portion of a CRT in position just prior to injecting casting material into an attached mold.
FIG. 4 is a partially broken-away elevational view of a key fragment of an apparatus for practicing the novel method including the parts shown in FIG. 3.
FIG. 5 is an elevational view of parts shown in FIG. 3 at the start of an embodiment of the novel method.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 2 show a cast-in-place base 21 that was prepared by the novel method. The base 21 is cast on the glass stem 23 of the glass envelope of a CRT. During the fabrication of the CRT, a portion of the cylindrical glass neck 25 was melted and collapsed upon the stem 23 forming the neck-to-stem seal 27. Some characteristics of the neck-to-stem seal are (a) the indented portion 29 of the neck 25 which has a smaller outside diameter than that of the neck 25 and (b) occasional protuberances 31 perpendicular to the stem surface which are produced when excess neck glass is cut off. These protuberances 31 are fire-polished and ordinarily vary in height up to about 0.1 mm (40 mils) above the main surface of the stem 23. The stem 23 has a central aperture 33. A glass tubulation 35, through which the CRT was evacuated of gas to very low gas pressure, is attached to the stem 23 around the aperture 33. A plurality of relatively-stiff metal stem leads 37 is sealed into and extends through and outwardly from the stem 23. One particular stem lead 37A is connected to a focusing electrode inside the CRT and is dedicated to carry a relatively-high voltage. The stem leads 37 and 37A are arranged concentrically around the aperture 33 and the tubulation 35. The base 21 is comprised of a solid flange portion 41 against the outer surface of the stem 23, a solid cylinder portion 43 around the tubulation 35 and attached to the flange portion 41 at one end, and silo walls 45 attached to the flange portion at one end and to the cylinder portion 43 along the sides. The silo walls 45 and the cylinder portion 43 define a hollow chamber 47 open at the distal end around the dedicated lead 37A. All of the parts of the base 21 are integral with one another and are cast at the same time of a foamed polysulfone plastic material. While a particular arrangement of stem leads, a particular plastic material and a particular design of base are described, many other designs of bases can be made advantageously by the novel method. The described design is merely exemplary for the novel method. Also, any of a large number of organic polymeric materials may constitute the base 21.
FIG. 3 shows essential parts of an apparatus for casting the base shown in FIGS. 1 and 2 directly on the stem 23 of a CRT by injection molding at the point just prior to injection of the cathode material. A fragment of the complete apparatus is shown in FIG. 4. The apparatus includes a cylindrical one-piece inner mold 51 and a two-piece outer mold 53A and 53B which together enclose the inner mold 51. The outer mold is cylindrical and split into two equal parts 53A and 53B along a plane towards the viewer. An injection nozzle 55 extends down into a matching recess 57 therefor in the outer mold parts 53A and 53B.
The inner mold 51 has matching bores 59 therein for receiving the stem leads 37 of a tube and also has suitably-shaped recesses for receiving the tubulation of the tube and for defining surfaces of the base to be cast. A tube with a neck 25 is shown in position with the stem leads 37 up and inserted in the bores 59 of the inner mold 51. The neck 25 is held in position by rubber-lined neck jaws 61A and 61B. The outer mold also has surfaces for defining surfaces of the base that is to be cast. The outer mold also has a circular lip 61 between the inner mold 51 and the stem 23 which extends inwardly a short distance. A ring-shaped gasket 63 is compressed between the lip 61 and the stem 23. A compression ring 65 between the outer mold part 53A and 53B has an inward-extending circular flange 67 which presses the gasket 63 against a recess in the bottom sides of the outer mold parts 53A and 53B, which pressure ring 65 is urged by the lever arms 69.
Thus, a temporary pressure seal is formed by the upward static pressure of about 100 to 600 pounds of the stem 27 and the pressure ring 65 against the gasket 63 which is counterbalanced by the downward static pressure on the gasket 63 by the outer mold parts 53A and 53B. The thickness of the gasket 63 is at least 1.5 times the height of the protuberances 31 on the stem 23. Typically, the gasket 63 is about 1.5 mm (60 mils) thick and has a compressibility of about Shore A-65. At compression, the gasket is compressed over the protuberances and leaves a small spacing of no more than 0.1 mm (4 mils) between the gasket 63 and the main surface of the stem 23, which provides an adequate pressure seal for injected material.
The inner mold 51, the outer mold parts 53A and 53B and the stem 23 define a chamber into which liquid castable material is injected at hydraulic pressures in the range of about 290 to 1740 kilograms per square centimeter (about 100 to 600 pounds per square inch). Such hydraulic pressures are resisted by the seal to prevent leakage by having no more than 0.1 mm (4 mils) clearance between the gasket 63 and the stem 23. The hydraulic pressure exerted on the stem 23 is resisted by the jaws 61A and 61B and/or the holding means 89. Lower static pressures are used with lower hydraulic pressures.
The novel method may be practiced with the apparatus shown in FIG. 4 which includes a frame 71, an upper slide 73 on which are mounted outer mold holders 75A and 75B to which are attached the outer mold parts 53A and 53B, and hydraulic means 77 for moving the outer mold parts 53A and 53B apart and together. The frame 71 also includes a lower slide 79 on which are mounted the two jaws 61A and 61B adapted for holding a glass neck 25, and pneumatic means 81 for moving the jaws 61A and 61B apart and together. The lever arm 69 is attached to and is rotatable around a shaft 83 which is mounted on a shaft support 85 on the frame 71. A pneumatic means 87 connected to the shaft 83 can rotate the lever arm 69 into and out of engagement with the pressure ring 65. The apparatus also includes a tube-holding means 89 for holding the tube, and moving means (not shown) for moving the tube-holding means up and down.
The apparatus shown in FIGS. 3 and 4 may be operated in the following manner. In the starting position, the nozzle 55 is raised, the tube-holding means 89 is lowered, the outer mold holders 75A and 75B and the outer mold parts 53A and 53B are apart and the jaws 81A and 81B are apart. Referring to FIGS. 4 and 5, a tube is positioned on the tube-holding means 89 with the neck 25 up. The pressure ring 65 is dropped over the neck where it rests in the recess 29. Then, the compression gasket 63 is dropped over the stem leads 37 where it rests on the stem. The inner mold 51 is placed on the stem leads 37. The bores 59 are about 2 mils larger in diameter than the stem leads. Since the injected castable material requires at least 4 mils clearance in order to flow through, this clearance provides an adequate seal around the stem leads 37.
The tube holder 89 and the tube are moved upward to the desired position for the stem 23. The outer mold parts 53A and 53B are moved together around the inner mold 51. This also positions the inner mold 51 with respect to the stem 23 and the outer mold. Next, the lever arm 69 is rotated into engagement with the pressure ring 65 so that the lip 67 presses the gasket 63 against the outer mold parts 53A and 53B. The tube holder 89 now moves upward positioning the stem 23 below the gasket 63 and pressing the protuberances 31 into the gasket 63 so that the maximum clearance between the stem 23 and the gasket 63 is no more than about 0.1 mm (4 mils), thereby forming the pressure seal. Ordinarily, the protuberances 31 would prevent the formation of an adequate seal. However, in the novel method, the combination of longitudinal pressure, the use of a compressible gasket and the permitted maximum clearance permit a practical seal to be made rapidly.
The jaws 61A and 61B move inward engaging and holding the tube in position. Next, the nozzle 55 is moved downward pressing on the outer mold parts 53A and 53B while the tube is held in position by the jaws 81A and 81B. All of the parts are now in the positions shown in FIG. 3. A controlled amount of castable material is injected through the nozzle 55 into the chamber formed by the mold parts and the stem 23, and held there for a sufficient time; e.g., about 60 seconds, at least until the injected material can maintain its shape. Following this, the nozzle 55 is raised, and all of the parts are returned to the starting position. Then, the inner mold 51 is slid upwards off the stem leads 37, and the gasket 63 and pressure ring 65 are removed, producing the base shown in FIGS. 1 and 2.
The plastic castable material needs a minimum clearance between surfaces in order to flow through therebetween. The maximum clearance, as between lead and bore, or between stem and gasket, to prevent leakage may be between 0.5 and 5.0 mils depending upon the viscosity and surface tension of the viscous casting material. Other factors may offset the minimum clearance that can be provided without leakage.
The castable material is preferably an organic polymeric material that is used for injection molding of parts. Such polymeric materials are heated to temperatures up to about 200° C. just prior to injection into the mold. Some suitable polymeric materials are polysulfones and polystyrenes. These materials can be foamed in the manner known in the art.
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Method for casting a base directly on an electron tube comprising a stem and stem leads sealed in and extending out from the stem includes: A. detachably coupling a mold to the leads and stem, B. producing a temporary pressure seal between the mold and the stem including applying static pressure in a direction that is substantially normal to the surface of the stem and C. injecting liquid castable material into the mold at substantial hydraulic pressure while maintaining the static pressure at the temporary seal.
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RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Patent Application Ser. No. 60/608,578, filed Sep. 10, 2004, the disclosures of which is incorporated herein by reference.
TECHNICAL FIELD
The present invention relates generally to embroidery machines and more specifically to a clamp for securing articles as they are being embroidered. The invention will be disclosed in connection with a low profile clamp that prevents damage to the embroidery machine if the panagraph moves the clamp into the space between the presser feet and the throat plate.
BACKGROUND OF THE INVENTION
In the sewing and embroidery industry, fabric holding clamps are widely used for holding individual work pieces during the embroidery process. While such holding clamps are been used for many years, one problem has persisted. Since it is necessary for a holding clamp to apply a compressive force to hold a article being embroidered between a pair of clamping windows, mechanism used to apply the clamping force have relatively large and bulky. For this reason, the base or body portions prior art holding clamps generally have a relatively thick profile. This profile thickness of the prior art holding clamps has lead to considerable problems, including substantial damage to embroidery machines. The holding clamps generally are moved in an X-Y plane by a panagraph to move the fabric being embroidered along the appropriate path to achieve the desired embroidery. On occasion, the panagraph will move the base or body portion of the fabric holding clamp in the space between the presser feet and the throat plate. This is particularly problematic during initialization of the panagraph controls, as the panagraph my move the clamp throughout the panagraph's entire X-Y movement Unfortunately, this space generally is less than the profile of the clamp, and the thick profile portion of the fabric clamp may be moved into the presser feet and needles, both of which are relatively fragile. As a consequence of this movement, substantial machine damage results, necessitating expensive repairs and downtime.
SUMMARY OF THE INVENTION
It is an object of at least one embodiment of the present invention to obviate one or more of the shortcomings of prior art clamps for embroidery machines.
It is another object of at least one embodiment of the present invention to provide a clamping system that will not damage the embroidery machine if the clamp is moved along a path traversing the space between the presser feet and needles, and the throat plate of an embroidery machine.
Another object of at least one embodiment is to provide an improved clamping mechanism for an embroidery machine that applies a clamping force between clamping windows with a simplified clamping mechanism.
The above objects are provided merely as non-limiting examples, and do not define the present invention or necessarily apply to every aspect thereof. Additional objects, advantages and other novel features of the invention will be set forth in part in the description that follows and will also become apparent to those skilled in the art upon consideration of the teachings of the invention.
To achieve one or more of these objects, one embodiment of the present invention includes an embroidery machine with a base, a throat plate, a head extending outwardly from the base, and a plurality of presser feet extending from the head toward the throat plate. Each of the presser feet are movable relative to the head toward and away from the throat plate and are associated with a needle adapted to pass through an article to be embroidered. Each of the presser feet also are movable between a retracted position in which the presser feet are spaced by a predetermined space from the throat plate and an extended position in which the presser feet are adapted to engage an article to be embroidered. The article to be embroidered is positioned in a sewing location between the presser feet and the throat plate while the needles pass through the article to be embroidered. A first clamping window is provided with a first embroidery opening. A a second clamping window with a second embroidery opening is also provided with the first and second clamping windows being movable between first relative positions in which the second clamping window is spaced from the first clamping window and second relative positions in which the first and second openings are aligned with each other. The first and second clamping windows are cooperatively operative to clamp an article to be embroidered in the sewing location between the presser feet and the throat plate when the clamping windows are in their second relative positions. A clamp is provided for effectuating relative movement between the first and second clamping windows and applying a compressive force between the first and second windows when the clamping windows are in their second relative positions. When in these second positions, the clamping windows securing an article to be embroidered therebetween. The clamp is secured to the panagraph. The panagraph is operative to effectuate two dimensional movement to the clamp and to move an article secured between the clamping windows relative to the needles in two-directional movement perpendicular to the predetermined space between the presser feet and the throat plate. The clamp is dimensioned and configured to pass through the predetermined space between the presser feet and the throat plate so as to prevent damage if the panagraph positions the clamp in the space between the plates and the throat plate.
In one exemplary embodiment, the clamp further includes at least one arm interconnecting with the clamping windows.
In another exemplary embodiment, the at least one arm is formed of resilient material and the clamp utilizes the resilient properties of the at least one arm to apply a compressive force between the clamping wi the at least one arm is rotatably mounted on a first shaft.
According to one exemplary embodiment, the clamp includes an actuator with at least one roller, and the at least one roller is moved along a portion of the arm to apply a bending moment on the arm and to apply a compressive force between the clamping windows.
In another exemplary embodiment, the at least one roller is mounted on a rotatable actuating shaft extending parallel to the first rotatable shaft. The actuating shaft includes a portion that is offset from the rotatable axis of the actuating shaft with the roller being rotatably mounted on the offset portion. With such a configuration, rotation of the actuating shaft results in arcuate movement (i.e., movement in an arc) of the roller.
According to another exemplary embodiment, the at least one arm extends around the first rotatable shaft with a relatively long window interface portion extending on one side the first shaft and interfacing with the clamping windows. A relatively short return portion extends on the opposite side of the shaft. With this configuration, arcuate movement of the at least one roller applies a clamping force to the interface portion by engaging the return portion and applying a bending stress against the return portion. This tends to separate the interface and return portions of the arm.
In another embodiment, the actuating shaft is movable between first and second positions. The first position corresponds to the first relative positions of the clamping windows and the second position corresponds to the second relative positions of the clamping windows.
According to another exemplary embodiment, a spring is provided for urging the actuating shaft toward the first position.
In another exemplary embodiment, an actuator handle is provided for rotating the actuating shaft.
In another exemplary embodiment, the clamp further includes a pair of arms interconnecting with the clamping windows. The arms are mounted on a first shaft and are formed of material having sufficient resiliency so as to permit the arms to act as leaf springs. An actuator with a rotatable actuating shaft is provided extending parallel to the first shaft with an offset portion onto which a pair of rollers are mounted. Thus, rotation of the actuating shaft results in arcuate movement of the roller. The actuating shaft is rotatably movable between first and second positions. The first position corresponds to the first relative positions of the clamping windows and the second position corresponds to the second relative positions of the clamping windows. Each of the arms extends around the first shaft and includes a relatively long window interface portion extending on one side the first shaft and interfacing with the clamping windows. A relatively short return portion extends on the opposite side of the shaft. Thus, arcuate movement of the rollers applies a clamping force to the interface portion of the arms by engaging the return portions and applying a bending stress against the return portions. This also tends to separate the interface and return portions of the arms whereby arcuate movement of the rollers applies a clamping force to the interface portion by engaging the return portion and applying a bending stress against the return portion.
In another exemplary embodiment, a clamp is provided for use in an embroidery machine. The clamp includes a clamp body adapted to secure a first embroidery clamping window. A clamp arm formed of a resilient material and having a window interface for interconnecting with a second embroidery clamping window, is pivotally attached to the clamp body. The clamp arm is adapted to move a second embroidery clamping window relative to the first clamping window. The clamp is further adapted to operatively apply a force against the window interface to urge the second clamping window into compressing relationship to the first clamping window so as to compressingly hold an article to be embroidered between the first and second windows. An actuator is provided for pivotally rotating the clamp arm with respect to the clamp body. The actuator is further operative to apply a bending stress on a portion of the clamp arm remote from the window interface. The resilient properties of the clamp arm operate to apply a compressive force to the window interface in response to the bending stress.
According to another exemplary embodiment, the clamp arm is formed of spring tempered stainless steel.
In another embodiment, the clamp is d dimensioned and configured to pass through a space between presser feet and a throat plate on an embroidery machine so as to prevent damage to the embroidery machine if the clamp is positioned between the presser feet and the throat plate of an embroidery machine.
In another exemplary embodiment, an embroidery machine having a base, a head extending outwardly from the base is provided. The head has a plurality of needles extending therefrom. The needles are movable between a first retracted position and an extended position. A clamping mechanism is provided for holding an article to be embroidered beneath the head. The clamping mechanism includes first and second clamping frames having a first and second embroidery openings respectively. The first and second clamping frames are movable between first relative positions in which the clamping frames are separated and second relative positions in which the clamping frames compressingly engage an article to be embroidered therebetween. The clamping mechanism is dimensioned and configured to fit in the space between the retracted position of the needles and the throat plate.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings incorporated in and forming a part of the specification, illustrate several aspects of the invention, and together with the description serves to explain the principles of the invention. In the drawings:
FIG. 1 is a perspective view showing an embroidery machine and clamp constructed according to the principles of the present invention;
FIG. 2 is a perspective view of the embroidery illustrated in FIG. 1 with an article to be embroidered clamped between the two clamping windows;
FIG. 3 is a perspective view showing the clamp and embroidery windows of FIG. 1 partially unassembled;
FIG. 4 is a plan view of the clamp and embroidery windows utilized on the embroidery machine illustrated in FIG. 1 ;
FIG. 5 is a side view of the clamp shown in FIG. 6 as it is assembled and in a clamp open position;
FIG. 6 is a side view of the clamp of FIG. 7 showing the clamp in a clamp closed position;
FIG. 7 is a plan view of the clamp of FIG. 1 with the clamping windows removed depicting the clamp mechanism in the clamp open position of FIG. 5 ;
FIG. 8 is a perspective view of the clamp mechanism of FIG. 7 showing one of the rollers in the clamp open position;
FIG. 9 is a plan view similar to FIG. 7 , but depicting the clamp mechanism in the clamp closed position of FIG. 6 ;
FIG. 10 is a perspective view of the clamp mechanism of FIG. 9 showing one of the rollers in the clamp closed position;
FIG. 11 is a perspective view of the embroidery machine illustrated in FIG. 1 showing the clamp positioned between the presser feet and the throat plate; and
FIG. 12 is a perspective view showing the tubular arms attached to the clamp.
Reference will now be made in detail to exemplary embodiments of the invention, an example of which is illustrated in the accompanying drawings.
DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS
Referring now to the drawings, FIG. 1 shows one form of an embroidery machine 10 constructed in accordance with the principles of the present invention. The machine, which is conventional except for the low profile clamp, which is described in detail below, includes a base 12 , which supports a head 14 extending outwardly therefrom. A plurality of presser feet, collectively referenced by the numeral 16 , extend downwardly from the head 14 . As those skilled in the art will readily appreciate, the presser feet are movable from a first retracted position (shown in FIG. 1 ) to an extended position where they engage an article to be embroidered. Each of the presser feet 16 is associated with a needle 18 . The outer end of each of the needles 18 pass though a fabric or other article (not shown in FIG. 1 , see FIG. 2 ) interposed between the presser foot 16 and a throat plate 20 . As will be apparent to those skilled in the art, the lower (in the illustrated orientation) end of the needles interact with a bobbin or other type of hooking mechanism (not shown) positioned beneath the article being embroidered. As also will readily appreciated by those in the art, the bobbin or other mechanism (not shown) grabs a loop of the thread carried by the needles and wraps it around either another piece of thread or another loop in the same piece of thread, as is conventional in sewing machines.
As best seen in FIG. 2 , a fabric 21 or other article to be embroidered is secured by a clamping mechanism, generally designed by the numeral 23 , constructed in accordance with the principles of the present invention. As more easily appreciated from viewing FIGS. 1 and 2 in conjunction with FIG. 3 , this clamping mechanism 23 is located beneath the presser feet 16 and includes a pair of clamping windows, a lower clamping window 22 and an upper clamping window 24 . The lower clamping window 22 is obscured by the fabric 21 in FIG. 2 and partially obscured by the upper clamping window 24 in FIG. 1 , but is clearly shown in FIGS. 3–5 . In the exemplary embodiment illustrated, each of the clamping windows 22 , 24 have centrally disposed openings of generally rectangular configuration. It may be desirable to vary the size and configuration of the central openings in the clamping windows. Toward that end, the clamping windows 22 , 24 preferably are interchangeably fitted to a clamp body 26 so that different sized and shaped clamping windows can be utilized with the same clamp body 26 , depending upon the article to be embroidered. Depending upon the article to be embroidered, the window openings may be circular, oval or any other configuration.
The clamp body 26 moves the clamping windows 22 , 24 between a first clamp open position and a second clamp closed position, as shown in FIGS. 5 and 6 respectively. In the second closed position, also shown in FIG. 1 , the centrally disposed openings of the windows 22 and 24 are aligned with each other and windows 22 , 24 are compressingly urged against each other to secure an interposed article, such as fabric 21 shown in FIG. 2 to be embroidered.
In the exemplary embodiment illustrated, relative movement of the windows 22 , 24 is achieved through the agency of one or more clamp arms 28 . The clamp arms 28 preferable are formed of a resilient material, such as spring tempered stainless steel. As most clearly illustrated in FIGS. 7 and 9 , the clamp arms 28 are pivotally secured to the body portion of the clamp along a first rotatable shaft or rod 29 , with each clamp arm including a window interface 31 that pivotally attaches the clamp arm to the upper window 24 . An actuator 30 effectuates rotational movement of the clamp arm relative to the clamp base.
As perhaps best seen in FIG. 8 , the illustrated clamp arms 28 extend around the rod 29 . Each arm 28 includes a relatively long window interface portion 28 a on one side (as illustrated, the top side) of the rotatable shaft 29 and a relatively short (relative to the window interface portion) return portion 28 b on the opposite side. The actuator 30 includes a rotable shaft 30 a that extends parallel to the first rotatable shaft 29 . The actuator shaft includes an offset portion 30 b . Rollers 33 are rotatably mounted on this offset portion 30 b of actuator shaft 30 . When the actuator 30 is rotated and moved from the clamp open position of FIG. 5 to the clamp closed position of FIG. 6 , the rollers 33 move along an arcuate path in contact with the return arm portion 28 b . The positions of the rollers relative to the arm in the clamp open position and clamp closed position are shown in FIGS. 8 and 10 respectively. This movement of the rollers 33 applies a bending stress against the return portion of the clamp arms 28 a , and tends to separate the interface 28 a and return portions 28 b of the arm 28 . The resilient properties of the clamp arms are then operative to apply a compressive force to the window interfaces in response to the bending stress applied to the return portions 28 a of the clamp arms 28 . A spring 35 mounted around the first shaft 29 with its opposite ends secured to the clamp body 36 and the offset portion 30 b of actuating shaft 30 . This spring 35 urges the actuating shaft 30 toward the clamp open position. The clamp arms 28 thus operate both as arms to effectuate relative movement of the windows and as leaf springs to apply a compressive force between the windows to secure an article therebetween.
Among other advantages, the above-described configuration permits an extremely low profile clamp. More particularly, as illustrated in FIG. 11 , this configuration permits it has a sufficiently low clamp profile that the clamp can be configured and dimensioned to pass in the vertical space between the presser feet (while in the retracted position) and the throat plate. Such a low profile is highly advantageous, as it significantly reduces serious damage to the embroidery machine. For example, when the clamp is attached to an X-Y drive bar 37 of a panagraph, no damage will be caused to the needles or presser feet if the panagraph cycles the clamp through its full X-Y movement while the clamp is secured to the paragraph. Such full X-Y movement occurs on many machines during machine initialization.
The foregoing descriptions of the exemplary embodiments of the invention have been presented for purposes of illustration and description only. They are not intended to be exhaustive or to limit the invention to the precise forms disclosed, and modifications and variations are possible and contemplated in light of the above teachings. While a number of exemplary and alternate embodiments, methods, systems, configurations, and potential applications have been described, it should be understood that many variations and alternatives could be utilized without departing from the scope of the invention. It should be reiterated that not all aspects of the invention need to be used in combination with all other aspects, and a variety of combinations of such aspects are possible.
Thus, it should be understood that the embodiments and examples have been chosen and described in order to best illustrate the principals of the invention and its practical applications to thereby enable one of ordinary skill in the art to best utilize the invention in various embodiments and with various modifications as are suited for particular uses contemplated. Accordingly, it is intended that the scope of the invention be defined by the claims appended hereto.
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A low profile clamp for an embroidery machine uses resilient arms that function as a leaf spring to transmit compressive closing forces to secure articles to be embroidered between clamping windows. A roller is moved in an arcuate path to apply bending stresses to clamp arms. The low profile of the clamp allows it to pass between the presser feet and throat plate protecting the presser feet and needles from serious damage if the panagraph moves the body of the clamp in the space between presser feet and throat plate during machine initialization or at any other time.
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This is a divisional of application Ser. No. 282,654, filed Dec. 12, 1988, now U.S. Pat. No. 4,945,134 issued July 31, 1990.
BACKGROUND OF THE INVENTION
The present invention incorporates using vinylidene chloride monomers in combination with ethylenically unsaturated comonomers to prepare an emulsion polymerized interpolymer that is color stable, thermally and chemically stable, and provides barrier properties.
Vinylidene chloride copolymers are well known in the art to exhibit oxygen barrier properties. However, such vinylidene chloride copolymers are also thermally sensitive, exhibiting degradation and discoloration upon processing at elevated temperatures. The higher temperatures cause a breakdown of the copolymer which then causes discoloring in the article into which the copolymer is fabricated. The polymers of ethylenically unsaturated monomers exhibit a greater degree of clarity and a greater degree of heat stability than do vinylidene chloride copolymers but do not have the barrier properties of vinylidene chloride copolymers. Therefore, a polymer useful for applications requiring the properties of each copolymer that is, both clarity and low oxygen permeability, would be desirable.
SUMMARY OF THE INVENTION
Accordingly, the present invention is an emulsion polymerized interpolymer particle of (1) a vinylidene chloride monomer and at least one ethylenically unsaturated comonomer phase and (2) an ethylenically unsaturated monomer phase wherein the vinylidene chloride monomer and ethylenically unsaturated comonomer phase is miscible with the ethylenically unsaturated monomer phase. The latex can then be coagulated and subsequently undergo meltprocessing and simultaneously provide thermal stability, clarity and oxygen barrier properties to the resulting interpolymer. Specifically, the present invention is an emulsion polymerized interpolymer having two miscible phases which comprises (a) a first phase of an effective amount of at least one ethylenically unsaturated monomer and (b) a second phase of an effective amount of vinylidene chloride monomer and at least one ethylenically unsaturated comonomer wherein the first phase and the second phase are miscible.
The present invention also provides for a method of preparing emulsion polymerized interpolymer particles, the particles having two miscible phases, the method comprising (a) polymerizing an effective amount of at least one ethylenically unsaturated monomer to form a polymer and (b) further polymerizing the polymer from (a) in the presence of an effective amount of vinylidene chloride monomer and an effective amount of at least one ethylenically unsaturated comonomer and (c) coagulating the resulting dispersion of polymerized interpolymer particles.
The present invention also provides for an alternate method of preparing emulsion polymerized interpolymer particles, the particles having two miscible phases, the method comprising (a) polymerizing an effective amount of vinylidene chloride monomer and at least one ethylenically unsaturated comonomer to form a polymer and (b) further polymerizing the polymer from (a) in the presence of an effective amount of at least one ethylenically unsaturated monomer and (c) coagulating the resulting dispersion of polymerized interpolymer particles.
DETAILED DESCRIPTION OF THE INVENTION
The present invention is an interpolymer particle and the process for preparing the interpolymer particle which entails emulsion polymerization of a first phase of at least one ethylenically unsaturated monomer and polymerizing the first phase with a second phase of monomer comprising vinylidene chloride monomer and at least one ethylenically unsaturated comonomer. The terms "first and second phases" are not meant to indicate the relative additions of one phase to another but merely to label and differentiate one phase from the other. The ethylenically unsaturated monomer phase can be added to the vinylidene chloride and comonomer phase or the vinylidene chloride and comonomer phase can be added to the ethylenically unsaturated monomer phase. The addition of the vinylidene chloride monomer and comonomer phase to the ethylenically unsaturated monomer phase is preferred to avoid exposing the vinylidene chloride monomer to high temperatures during the addition of the ethylenically unsaturated monomer phase.
"Miscibility" as used herein means the two phases defined as miscible with each other are, under polymerization conditions, solubilized in each other and result in a mixture which is transparent (i.e., clear) or at least translucent. Phases which are not miscible will maintain discrete phase structures and typically retain individual glass transition temperatures resulting in a latex copolymer particle having two discrete phases each phase having its own glass transition temperature. Further, "miscibility" as used herein, is defined to mean that the phases defined as miscible with each other are to be distinguished from different phases which when added to each other under similar conditions, are merely dispersible in each other wherein the dispersion is characterized by a white, milky appearance.
Suitable ethylenically unsaturated monomers and mixtures of monomers for the ethylenically unsaturated monomer phase include those monomers which will be miscible with the vinylidene chloride monomer and comonomer phase. Examples of such monomers include: alkyl acrylates, alkyl methacrylates, acrylonitrile, methacrylonitrile and mixtures of these monomers. Also suitable are styrene/acrylonitrile monomer mixtures. The alkyl acrylates and alkyl methacrylates are generally selected to have from about 1 to about 8 carbon atoms per alkyl group. Preferably, alkyl acrylates and alkyl methacrylates are selected to have from about 1 to about 4 carbon atoms per alkyl group. The alkyl acrylates and alkyl methacrylates are most preferably selected from the group consisting of methyl acrylate, ethyl acrylate, butyl acrylate and methylmethacrylate.
Vinylidene chloride copolymers suitable for use in the present invention are those vinylidene chloride polymers formed from a monomer mixture of vinylidene chloride monomer and one or more ethylenically unsaturated comonomers copolymerizable with vinylidene chloride monomer.
Suitable ethylenically unsaturated comonomers for the vinylidene chloride monomer and comonomer phase include ethylenically unsaturated comonomers copolymerizable with the vinylidene chloride monomer. Examples of such monomers include vinyl chloride, alkyl acrylates, alkyl methacrylates, acrylic acid, methacrylic acid, itaconic acid, acrylonitrile and methacrylonitrile. The alkyl acrylates and alkyl methacrylates are generally selected to have from about 1 to about 8 carbon atoms per alkyl group. Preferably, alkyl acrylates and alkyl methacrylates are selected to have from about 1 to about 4 carbon atoms per alkyl group. The alkyl acrylates and alkyl methacrylates are most preferably selected from the group consisting of methyl acrylate, ethyl acrylate, butyl acrylate and methylmethacrylate.
EFFECTIVE AMOUNTS FOR THE FIRST PHASE
The effective amount of ethylenically unsaturated monomer present in the first phase of the interpolymer particle of the present invention is typically from about 95 to about 5 weight percent based on total monomer present in the total interpolymer particle. Preferably, the effective amount of ethylenically unsaturated monomer present in the first phase of the interpolymer particle of the present invention is typically from about 80 to about 5 weight percent based on total monomer present in the total interpolymer particle. Most preferably, the effective amount of ethylenically unsaturated monomer present in the first phase is typically from about 60 to about 5 weight percent based on total monomer present in the total interpolymer particle.
EFFECTIVE AMOUNTS FOR THE SECOND PHASE
The effective amount of vinylidene chloride monomer and ethylenically unsaturated comonomer present in the second phase of the interpolymer particle of the present invention is typically from about 5 to about 95 weight percent based on total monomer present in the total interpolymer particle. Preferably, the effective amount of vinylidene chloride monomer and ethylenically unsaturated comonomer present in the second phase of the copolymer particle of the present invention is typically from about 20 to about 95 weight percent based on total monomer present in the total interpolymer particle. Most preferably, the effective amount of vinylidene chloride monomer and ethylenically unsaturated comonomer present in the second phase of the interpolymer particle of the present invention is typically from about 40 to about 95 weight percent based on total monomer present in the total interpolymer particle.
The effective amount of ethylenically unsaturated comonomer present in the second phase is from about 5 to about 25 weight percent based on total monomer present in the second phase. Preferably, the effective amount of ethylenically unsaturated comonomer present in the second phase is from about 5 to about 20 weight percent.
Typically, the ratio of vinylidene chloride monomer to ethylenically unsaturated comonomer present in the second phase is from about 75 to 25 to about 95 to 5 respectively. Preferably, the ratio of vinylidene chloride comonomer to ethylenically unsaturated comonomer present in the second phase is from about 80 to 20 to about 95 to 5 weight percent respectively based on the total weight of monomer present in the second phase.
MOLECULAR WEIGHT OF COPOLYMERS
The molecular weight of the composite interpolymer particle is most practical when in the range of from about 50 to about 100 thousand weight average molecular weight (Mw). Conventionally known chain transfer agents are typically used to control the molecular weight of the interpolymer particles.
PROCESS OF PREPARING THE COPOLYMERS
The polymerization of the monomers is by conventional emulsion polymerization techniques. The first phase of ethylenically unsaturated monomer is typically fed into the reactor first, but the vinylidene chloride monomer and ethylenically unsaturated comonomer of the second phase can be initially added to the reactor. Typically, the monomer feed of the first charge is terminated before the second charge of monomer feeds is begun while the initiator feeds and surfactant feeds are continued throughout both the first and second feeds. After the copolymer emulsion is cooled and removed from the reactor, the particles are coagulated. Methods of coagulating the particles include: freezing the latex or shear or chemical coagulation. The polymer particles are then in a form usable for thermal processing. The particles are evaluated for clarity/miscibility and oxygen permeability as follows.
OXYGEN TRANSMISSION RATE (O 2 TR) MEASUREMENTS OF THE INTERPOLYMER
Sample films are prepared by compression molding (at 160° C and 1000 psi for one minute then 35000 psi for two minutes) the emulsion polymerized resin between two sheets of polyester film. The films are prepared at approximately 5-10 mil thickness. The barrier properties of the polyester film alone are evaluated and their contributions to the total permeability eliminated by subtraction prior to evaluating the interpolymer molded sample for barrier properties.
Samples are tested on the Mocon Oxtran 1050 Oxygen Permeability Tester. Oxygen permeability values are calculated from the mv response of the Oxtran 1050 detector at a specific temperature and pressure differential as well as sample thickness. The sample thickness is determined by taking multiple readings with a micrometer and averaging the results. Oxygen permeability values are reported in Dow Units (D.U.) which are cc.mil/100 in 2 .day.atm at 25° C.
EXAMPLE 1
Into a 1-gallon glass-lined reactor are added 780 g of deionized water, and 21 grams of a seed latex containing polystyrene polymer particles which will render a resulting interpolymer particle of 1400 Angstroms. The reactor is purged with nitrogen and heated to 90° C. and over a two-hour period is added a first phase monomer stream containing 533 grams of methylmethacrylate, and 1.1 grams of a chain transfer agent. Beginning at the start of the monomer stream was added over a two-hour period, an aqueous stream containing 106 grams of water, 2.7 grams sodium persulfate and 5.3 grams of a 45 percent active solution of an alkylated diphenyl oxide disulfonate surfactant.
Following the addition of the monomer and aqueous streams, the reactor was cooled to 60° C. and over 5 hours is added the second phase of: 721 grams of vinylidene chloride, 46 grams of methylmethacrylate and 1.5 grams of a chain transfer agent. Added simultaneously over six hours are 0.4 grams of t-butyl hydroperoxide (7 percent solution) and 145 grams of water. Over six hours is also simultaneously added: 0.8 grams of sodium sulfoxylate formaldehyde and 7.67 grams of a 45 percent active solution of an alkylated diphenyl oxide disulfonate surfactant and 162 grams of water.
The latex is then freeze coagulated.
40 Grams of the copolymer is then entered into a Variable Shear Rate Plasti-Corder made by C. W. Brabender Instruments Inc. at 130° C. and 40 rpm, to measure the processability, i.e. heat stability of the copolymer. The compression molded sample is then prepared from 3-4 grams of either the dried coagulated polymer or the polymer exposed to the Shear Rate Plasti-Corder. Samples were molded between polyester film or heavy gauge aluminum foil at 160° C. using a one minute preheat ac 1000 psi followed by 2 minutes at 35000 psi.
The oxygen permeability of the interpolymer is 0.15 DU. The clarity/miscibility of the interpolymer is evaluated by differential scanning calorimetry. The interpolymer exhibits one glass transition temperature at a temperature between those expected for each polymer phase individually and the compression molded samples are clear, indicating miscibility of the phases.
EXAMPLE 2
Example 2 is prepared similarly to Example 1 however, 21 grams of seed latex is used (to yield a particle having an average diameter of about 1400 Angstroms). The reactor is purged with nitrogen and heated to 90° C. and over a two-hour period is added a first phase monomer stream containing 94 grams of methylmethacrylate. Beginning at the start of the monomer stream was added over a two-hour period, an aqueous stream containing 47 grams of water, 0.5 grams sodium persulfate and 1 gram of a 45 percent active solution of an alkylated diphenyl oxide disulfonate surfactant.
Following the addition of the monomer and aqueous streams, the reactor was cooled to 60° C. and over 9 hours is added the second phase of: 1134 grams of vinylidene chloride, 72 grams of methyl acrylate. Added simultaneously over 10 hours are 8.6 grams of t-butyl hydroperoxide (7 percent solution) and 216 grams of water. Over 10 hours is also simultaneously added: 1.2 grams of sodium sulfoxylate formaldehyde and 26.8 grams of a 45 percent active solution of an alkylated diphenyl oxide disulfonate surfactant and 197 grams of water.
The latex is then freeze coagulated.
The oxygen permeability of the interpolymer is 0.22 DU. The clarity/miscibility of the interpolymer is evaluated by differential scanning calorimetry. The interpolymer exhibits one glass transition temperature at a temperature between those expected for each polymer phase individually and the compression molded samples are clear, indicating miscibility of the phases.
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The polymers of ethylenically unsaturated monomers exhibit a greater degree of clarity and a greater degree of heat stability than do vinylidene chloride copolymers but do not have the barrier properties of vinylidene chloride copolymers. The present invention is an emulsion polymerized interpolymer, which provides both clarity and low oxygen permeability to applications where such properties are required of a polymer, having two miscible phases, which comprises (a) a first phase of an effective amount of at least one ethylenically unsaturated monomer and (b) a second phase of an effective amount of vinylidene chloride monomer and at least one ethylenically unsaturated comonomer wherein the first phase and the second phase are miscible.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation of U.S. application Ser. No. 13/872,451, filed Apr. 29, 2013, which is a continuation of U.S. application Ser. No. 13/571,969, filed Aug. 10, 2012, now U.S. Pat. No. 8,432,517, which is a continuation of U.S. application Ser. No. 13/230,252, filed Sep. 12, 2011, now U.S. Pat. No. 8,243,240, which is a continuation of U.S. application Ser. No. 12/962,128, filed Dec. 7, 2010, now U.S. Pat. No. 8,040,478, which is a continuation of U.S. application Ser. No. 12/470,500, filed May 22, 2009, now U.S. Pat. No. 7,859,625, the contents of which are incorporated herein by reference. This application also relates to U.S. application Ser. No. 13/571,930, filed Aug. 10, 2012, now U.S. Pat. No. 8,351,003, which is a continuation of U.S. application Ser. No. 13/230,252, filed Sep. 12, 2011, now U.S. Pat. No. 8,243,240.
CLAIM OF PRIORITY
[0002] The present application claims priority from Japanese application serial No. 2008-133840, filed on May 22, 2008, the content of which is hereby incorporated by reference into this application.
BACKGROUND OF THE INVENTION
[0003] 1. Field of the Invention
[0004] The present invention relates to a liquid crystal display device and a manufacturing method thereof, and more particularly to a liquid crystal display device to which an improvement of an alignment film is applied and a manufacturing method thereof.
[0005] 2. Description of the Related Art
[0006] A liquid crystal display device is a display device which adjusts a quantity of transmitting light from a light source by controlling the direction of liquid crystal molecules with an electric field.
[0007] In a TN (Twisted Nematic) mode, an IPS (In-Plane Switching) mode, and a VA (Vertical Alignment) mode which are applied to many active matrix display devices currently, it is necessary to create a stable alignment state and hence, it is necessary to form an alignment film on at least one of opposedly-facing surfaces of a pair of substrates which sandwich a liquid crystal layer therebetween.
[0008] Particularly, in the TN mode and the IPS mode, in principle, it is necessary to perform treatment which imparts an ability of controlling the alignment in the fixed direction to at least one of opposedly-facing surfaces of the pair of substrates. Further, in the VA mode, it may be possible to control initial driving of the liquid crystal molecules by forming projections or stripes on at least one of opposedly-facing surfaces of the pair of substrates. However, in forming these projections or stripes, there exists a possibility that the throughput is lowered at the time of forming the projections or the stripes. On the other hand, when neither projections nor stripes are formed, it is necessary to impart an ability of controlling the alignment in the particular direction with respect to an alignment film.
[0009] There may be a case where surface unevenness is provided to a background of the alignment film. For example, the liquid crystal display device adopts the constitution in which spacers (hereinafter referred to as pillar-shaped spacers) are arranged on one of opposedly-facing surfaces of the pair of substrates in place of scattering bead spacers as separate members, and spacer pedestals which are arranged to face the pillar-shaped spacers in an opposed manner are formed on another opposedly-facing surface.
[0010] To consider a case where an impact is applied to the liquid crystal display device having such a constitution, when the spacer and the spacer pedestal are brought into contact with each other, an alignment film on a surface of the spacer is abraded or peeled off thus giving rise to drawback that bright spots are generated thus causing a display defect.
[0011] A technique which can overcome this drawback is disclosed in JP-A-2000-267114 (patent document 1).
[0012] Patent document 1 states that the above-mentioned drawback can be overcome by making a film thickness of an alignment film on a top surface of a spacer smaller than a film thickness of the alignment film on portions other than the top surface of the spacer (or setting the film thickness of the alignment film on the top surface of the spacer to zero). In other words, the drawback can be overcome by applying an alignment film material and, thereafter, by performing time-prolonged leveling corresponding to viscosity by prolonging a time for leveling. To be more specific, patent document 1 states “a solution containing polyimide is applied by coating to the whole surface of a glass substrate on which pixel electrodes are formed by offset printing, a coated film is leveled for 60 seconds, and the leveled coated film is dried at a temperature of 100° C., and is baked at a temperature of 180° C. for 1 hour thus forming an alignment film having a thickness of 1000 angstrom. Thereafter, rubbing treatment is applied to the alignment film.” That is, due to (A): “leveling processing”, an organic solvent containing the alignment film material arranged on an upper surface of a projection is moved to a low place around the projection and hence, the organic solvent is leveled. By prolonging this time, “local reduction of film thickness” of the alignment film on the projection can be realized. Further, due to (B): “baking process”, the organic solvent is evaporated so that “the reduction of film thickness at a fixed ratio over the whole surface” of the alignment film can be realized. With respect to the alignment film to which rubbing treatment is applied, the film thickness of the whole alignment film is substantially determined through these two reduction-of-film-thickness processes.
SUMMARY OF THE INVENTION
[0013] In the method disclosed in patent document 1, the projection which constitutes the spacer is sufficiently high, that is, a height of the spacer is 2 to 3 μm and hence, the alignment film is formed such that the leveling of the film can be realized by performing leveling for approximately 60 seconds, thus forming the alignment film such that only the alignment film having a thickness of approximately several nm remains on the upper surface of the spacer. However, when a pedestal which is smaller and lower than the spacer is adopted as the spacer pedestal, a display defect occurs even when the structure disclosed in patent document 1 is adopted.
[0014] Accordingly, it is an object of the present invention to provide a liquid crystal display device which can eliminate such a display defect.
[0015] Inventors of the present invention, upon analysis of a mode of the above-mentioned display defect, arrived at an idea that the display defect is caused not only by the alignment film on the pillar-shaped spacer but also by the alignment film on the spacer pedestal.
[0016] Accordingly, the inventors of the present invention made an attempt to make the alignment film thin by applying leveling (flattening) treatment to the alignment film as in the case of the related art. However, the spacer pedestal arranged on an opposedly facing surface of the pillar-shaped spacer usually has a thickness of only approximately 0.5 μm and hence, the film thickness of the alignment film on the spacer pedestal cannot be sufficiently decreased. To be more specific, although the reduction of the film thickness of the alignment film also depends on viscosity, the film thickness of the alignment film on the spacer pedestal is reduced to only approximately 60 to 80% of the film thickness of the alignment film of the pixel electrode.
[0017] Such a film thickness reducing operation still leaves the alignment film having the large thickness on the spacer pedestal thus giving rise to a display defect which is caused by peeling of the alignment film attributed to a contact between the pillar-shaped spacer and the spacer pedestal.
[0018] Inventors of the present invention then studied a method of increasing a height of a spacer pedestal. The inventors of the present invention made an attempt to form the spacer pedestals by using only line layers and silicon layers of transistors formed on an active matrix substrate on which the spacer pedestals are formed for forming the spacer pedestals at a low cost. It is found difficult to form the spacer pedestals having a height exceeding 1.0 μm without increasing the number of processes. Basically, the spacer pedestal having such a height is weak against an impact and hence, the spacer pedestal is not preferable as a spacer pedestal.
[0019] The inventors of the present invention, then, considered the formation of the alignment film having the small thickness as a whole by decreasing a quantity of an organic solvent containing an alignment film material. However, such a method spends a considerable time in leveling, gives rise to surface irregularities on the alignment film formed on the pixel electrode and hence, there may be a case that the alignment film on the pixel electrode cannot ensure a sufficient film thickness.
[0020] In this manner, the conventional approaches have suffered from the restriction in the manufacture of liquid crystal display devices.
[0021] As disclosed in JP-A-2005-351924 (patent document 2), inventors of the present invention studied the use of a photo alignment film as an alignment film of an IPS type liquid crystal display device and arrived at the following idea through studies on a photo-decomposition-type alignment film material. That is, the inventors of the present invention particularly considered that by forming an alignment film by printing and baking a volatile organic solvent containing a photo-decomposition-type alignment film material, and by radiating a polarized ultra-violet rays to the alignment film under a high temperature environment of approximately 200° C., the alignment film is evaporated in a moment that the alignment film is subject to photo decomposition so that a film thickness of the alignment film is decreased.
[0022] Accordingly, inventors of the present invention manufactured a liquid crystal display device in which a photo-decomposition-type photo alignment film is used as an alignment film of a liquid crystal display device which forms pillar-shaped spacers on one of the pair of substrates and spacer pedestals on another of the pair of substrates, and a linearly polarized light is radiated to the alignment film thus imparting an alignment control function to the liquid crystal display device.
[0023] To be more specific, an organic solvent which uses an alignment film material having a skeleton formed of cyclobutane tetracarboxylic acid-diamine phenyl ether is printed on a layer above the spacer pedestals as an alignment film material, the organic solvent is left for leveling (A: “leveling process”), and, thereafter, the organic solvent is dried and temporarily baked (B: “baking process). A film thickness of the alignment film is measured after such temporary baking. Then, a polarized light is radiated to the alignment film for imparting an alignment control ability to the alignment film and, at the same time, a decomposed material is sublimed under a high-temperature environment of approximately 200° C. (C: “alignment imparting process”), and the film thickness of the alignment film is again measured. As a result, it is found that the thickness of the alignment film is reduced after baking.
[0024] That is, the inventors of the present invention have found the following. In performing a control of the film thickness of the photo-decomposition-type photo alignment film, and more particularly, a control of locally decreasing the film thickness of the photo alignment film on the spacer pedestal using the spacer pedestal which is smaller and lower than the pillar-shaped spacer, it is necessary to control not only the condition on (A) “leveling process” in which “the film thickness is locally reduced” and the condition on (B) “baking process” in which the film thickness is reduced at a rate “a” per hour as in the case of the alignment film to be rubbed but also a condition on (C) “alignment imparting process” in which the film thickness is reduced at a fixed quantity “b” per hour.
[0025] To be more specific, in the above-mentioned (A) “leveling process”, the inventors of the present invention formed, as the alignment film on the spacer pedestal, an alignment film using an organic solvent having the same viscosity as the alignment film on the pillar-shaped spacer on a color filter substrate side as described in the related art. However, the inventors of the present invention could not achieve the sufficient reduction of the film thickness. This is attributed to a fact that the spacer pedestal is lower than the pillar-shaped spacer and hence, there may be a case that, in the adjustment of viscosity of the organic solvent for the alignment film on the pillar-shaped spacer, the viscosity is so high that the sufficient leveling cannot be performed. Accordingly, inventors of the present invention newly sought for a viscosity range of a volatile organic solvent containing an alignment film material to be printed. As a result, the inventors of the present invention have found that a volatile organic solvent having viscosity of 35 Pa·s or less which contains a photo-decomposition-type alignment film material is necessary.
[0026] In the related art, in (A) “leveling” and (B) “baking process”, when the viscosity of the organic solvent is adjusted for forming the pillar-shaped spacer, the relationship of film thickness of alignment film on the spacer pedestal/the film thickness of the alignment film on the pixel electrode is set to approximately 60 nm/120 nm, while when the viscosity of the organic solvent is adjusted for forming the spacer pedestal, the film thickness can be reduced to an extent that the relationship becomes approximately 30 nm/120 nm.
[0027] Further, in (C) “alignment imparting process” found by the inventors of the present invention, the film thickness of the whole alignment film can be reduced by a fixed quantity and hence, the reduction of the film thickness can be realized to an extent that the relationship of the film thickness of the alignment film on the spacer pedestal/the film thickness of alignment film on the pixel electrode becomes approximately 10 to 15 nm/100 nm.
[0028] In this manner, the present invention realizes a novel task of “the display defect attributed to “peeling of alignment film” generated on “the alignment film on the spacer pedestal”” which differs from “the alignment film on the pillar-shaped spacer” by a novel means which controls the condition on (C) “alignment imparting processing” for newly “reducing the film thickness at a fixed quantity b/hour” besides (A) “leveling process” for “locally reducing the film thickness” and (B) “baking process”.
[0029] As a result, it is possible to, for the first time, realize a liquid crystal display device in which a film thickness “d1” of a photo-decomposition-type photo alignment film formed on the spacer pedestal (structure having an upper surface area smaller than the pillar-shaped spacer and being lower than the pillar-shaped spacer) satisfies a following formula 1.
[0000] 0 nm<d1≦30 nm Formula 1
[0030] The thin alignment film formed on the spacer pedestal formed in this manner is hardly peeled off or abraded. This result is brought about by a coupling agent which is added to the alignment film for enhancing adhesiveness of the alignment film with a background substrate. That is, it is considered that the alignment film is chemically coupled to a background layer on an interface between the alignment film and the background layer due to the coupling agent so that the alignment film close to the background layer exhibits high adhesiveness, while the influence of the coupling agent is decreased along with the increase of a distance from the background layer thus lowering the adhesiveness. Accordingly, it is considered that the thinner the formed alignment film becomes, the larger the adhesiveness of the alignment film is influenced by the coupling agent so that the adhesiveness is enhanced whereby the abrasion resistance of the alignment film at a portion thereof which is in contact with the pillar-shaped spacer is increased.
[0031] It must be noted that when the film thickness of the alignment film is extremely reduced over the whole surface of the spacer pedestal, a so-called pin hole phenomenon in which the alignment is not formed partially is generated so that non-alignment portions are formed thus giving rise to a display defect such as bright spots. Accordingly, it is preferable to set a film thickness of the alignment film on a BM opening portion where the spacer pedestal is not arranged larger than the film thickness of the alignment film at portions where the alignment film is in contact with the pillar-shaped spacer.
[0032] It is preferable to form a dedicated pattern for the spacer pedestal without arranging the spacer pedestal on the TFT element. The formation of the dedicated pattern reduces the possibility of generating physical damages or the deterioration of characteristics of existing parts. Further, the dedicated pattern can be formed without additionally performing a photolithography step when the dedicated pattern is arranged using the layered structure formed of the semiconductor layer, the gate electrode layer, the source electrode layer and the like which constitutes the TFT element and hence, the productivity is high.
[0033] The present invention is constituted as follows, for example.
[0034] (1) According to one aspect of the present invention, there is provided a manufacturing method of a liquid crystal display device which, for example, includes: a pair of substrates; a liquid crystal layer which is sandwiched between the pair of substrates; a first alignment film which is formed on one of opposedly-facing surfaces of the pair of substrates; a second alignment film which is formed on another of opposedly-facing surfaces of the pair of substrates; first projecting portions which are provided to the first alignment film and project into the liquid crystal layer from first constitutional members which constitute a layer below the first alignment film; and second projecting portions which are provided to the second alignment film, face the first projecting portions, and project into the liquid crystal layer by second constitutional members which constitute a layer below the second alignment film, the first projecting portion being set lower than the second projecting portion, and an area of an upper surface of the first projecting portion is set smaller than an area of an upper surface of the second projecting portion, wherein the manufacturing method of a liquid crystal display device includes a first step of forming a photo-decomposition-type polyimide film as the first alignment film by baking a volatile organic solvent containing a photo-decomposition-type polyimide acid having viscosity of not more than 35 mPa·s; and a second step of baking the polyimide film by radiating polarized light containing ultraviolet rays to the polyimide film.
[0035] (2) In the above-mentioned manufacturing method of a liquid crystal display device having the constitution (1), for example, the manufacturing method may further include a third step of forming a photo-decomposition-type polyimide film as the second alignment film by baking a volatile organic solvent containing a photo-decomposition-type polyimide acid having viscosity of not more than 35 mPa·s; and a fourth step of baking the polyimide film by radiating polarized light containing ultraviolet rays to the polyimide film.
[0036] (3) In the above-mentioned manufacturing method of a liquid crystal display device having the constitution (1), for example, one of the pair of substrates may include thin film transistors between the substrate and the first alignment film, and the first constitutional member may include at least one of a semiconductor layer, a gate oxide film, a gate electrode, an interlayer insulation film, a source electrode, and a drain electrode which constitute the thin film transistor.
[0037] (4) In the above-mentioned manufacturing method of a liquid crystal display device having the constitution (3), for example, the liquid crystal display device may include pixel electrodes each of which is connected to one of the source electrode and the drain electrode of said thin film transistor, and another substrate includes the counter electrode.
[0038] (5) In the above-mentioned manufacturing method of a liquid crystal display device having the constitution (1), for example, the first projecting portion may have a frusto-conical shape.
[0039] (6) According to another aspect of the present invention, there is provided a liquid crystal display device which, for example, includes: a pair of substrates; a liquid crystal layer which is sandwiched between the pair of substrates; a first alignment film which is formed on one of opposedly-facing surfaces of the pair of substrates; a second alignment film which is formed on another of opposedly-facing surfaces of the pair of substrates; first projecting portions which are provided to the first alignment film and project into the liquid crystal layer by first constitutional members which constitute a layer below the first alignment film; and second projecting portions which are provided to the second alignment film, face the first projecting portions, and project into the liquid crystal layer by second constitutional members which constitute a layer below the second alignment film, the first projecting portion being set lower than the second projecting portion, and an area of an upper surface of the first projecting portion being set smaller than an area of an upper surface of the second projecting portion, wherein
[0040] the first alignment film is made of a photo-decomposition-type alignment film material, and
[0041] a film thickness “d1” of the first alignment film on the first projecting portion and a film thickness “d2” of the second alignment film on the second projecting portion satisfy a formula (1) and a formula (2).
[0000] 0 nm<d1<30 nm (1)
[0000] d2<d1 (2)
[0042] (7) In the above-mentioned liquid crystal display device having the constitution (6), for example, the second alignment film may be made of a photo-decomposition-type alignment film material.
[0043] (8) In the above-mentioned liquid crystal display device having the constitution (6), for example, one of the pair of substrates may include thin film transistors between the substrate and the first alignment film, and the first constitutional member may include at least one of a semiconductor layer, a gate oxide film, a gate electrode, an interlayer insulation film, a source electrode, and a drain electrode which constitute the thin film transistor.
[0044] (9) In the above-mentioned liquid crystal display device having the constitution (8), for example, the liquid crystal display device may include pixel electrodes each of which is connected to one of the source electrode and the drain electrode of each thin film transistor, and another substrate includes the counter electrode.
[0045] (10) In the above-mentioned liquid crystal display device having the constitution (6), for example, the first projecting portion may have a frusto-conical shape.
[0046] The above-mentioned constitutions are provided merely as examples and the various modifications can be suitably made without departing from a technical concept of the present invention. Further, constitutional examples of the present invention other than the above-mentioned constitutions will become apparent from the whole description of this specification and drawings.
[0047] According to the liquid crystal display device and the manufacturing method thereof having the above-mentioned constitutions, the present invention can eliminate or reduce a display defect. Other advantageous effects of the present invention will become apparent from the whole description of this specification.
BRIEF DESCRIPTION OF THE DRAWINGS
[0048] FIG. 1 is a cross-sectional view of an essential part showing an embodiment 1 of a liquid crystal display device according to the present invention;
[0049] FIG. 2 is a table showing constitutional members of the liquid crystal display device shown in FIG. 1 and film thicknesses of these constitutional members;
[0050] FIG. 3 is a table showing the manufacture of alignment films in the liquid crystal display device shown in FIG. 1 , and film thicknesses of the alignment films obtained by the manufacture;
[0051] FIG. 4 is a cross-sectional view of an essential part showing an embodiment 2 of a liquid crystal display device according to the present invention;
[0052] FIG. 5 is a table showing constitutional members of the liquid crystal display device shown in FIG. 4 and film thicknesses of these constitutional members;
[0053] FIG. 6 is a table showing the manufacture of alignment films in the liquid crystal display device shown in FIG. 4 , and film thicknesses of the alignment films obtained by the manufacture;
[0054] FIG. 7 is a cross-sectional view of an essential part showing an embodiment 3 of a liquid crystal display device according to the present invention;
[0055] FIG. 8 is a table showing the manufacture of alignment films in the liquid crystal display device shown in FIG. 7 , and film thicknesses of the alignment films obtained by the manufacture;
[0056] FIG. 9 is a cross-sectional view of an essential part showing an example of a liquid crystal display device which constitutes a comparison example;
[0057] FIG. 10 is a table showing the manufacture of alignment films in the liquid crystal display device shown in FIG. 9 , and film thicknesses of the alignment films obtained by the manufacture;
[0058] FIG. 11 is a table showing a bright-spot-generation withstand voltage level in the above-mentioned respective embodiments;
[0059] FIG. 12 is a table describing a content of references for determining the above-mentioned bright-spot-generation withstand voltage level; and
[0060] FIG. 13 is a view showing a graph which is obtained by converting the table shown in FIG. 11 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0061] Embodiments of the present invention are explained in conjunction with drawings. In respective drawings and respective embodiments, the identical or similar constitutional elements are given same symbols and their explanation is omitted.
Embodiment 1
(Constitution)
[0062] FIG. 1 shows a cross section of a liquid crystal display device (panel) of the present invention. FIG. 1 shows a portion of the liquid crystal display device where a pillar-shaped spacer and a spacer pedestal are formed and a periphery of such a portion. FIG. 1 shows the constitution of the liquid crystal display device corresponding to the examples 1 to 4.
[0063] In FIG. 1 , a so-called electrode substrate and a so-called counter substrate are arranged to face each other in an opposed manner with a liquid crystal layer LC sandwiched therebetween.
[0064] The electrode substrate has following constitution, for example. First of all, the electrode substrate includes a substrate SUB1. On a liquid-crystal-layer-LC-side surface of the substrate SUB1, gate electrodes GT and counter electrodes CT are formed. The gate electrode GT constitutes a gate electrode of a thin film transistor TFT described later, and a scanning signal is supplied to the gate electrode GT from a gate signal line not shown in the drawing. The counter electrode CT is an electrode which is provided for generating an electric field in the liquid crystal layer LC in corporation with a pixel electrode PX described later. The counter electrode CT is a planar electrode formed of an ITO (Indium Tin Oxide) film, for example, which is formed over the substantially whole region of the pixel.
[0065] On a surface of the substrate SUB1, an insulation film GI is formed so as to also cover the gate electrodes GT and the counter electrodes CT. The gate insulation film GI functions as a gate insulation film in a region where the thin film transistor TFT is formed.
[0066] A semiconductor layer AS is formed on the gate insulation film GI so as to overlap with the gate electrode GT, and a drain electrode SD and a source electrode SD are formed on an upper surface of the semiconductor layer AS thus constituting a thin film transistor TFT. A video signal is supplied to one electrode out of the drain electrode SD and the source electrode SD via a drain signal line not shown in the drawing. Further, another electrode out of the drain electrode SD and the source electrode SD extends to the outside of a region where the thin film transistor TFT is formed, and is electrically connected with the pixel electrode PX described later.
[0067] Then, in a region outside the region where the thin film transistor TFT is formed (for example, a region which overlaps with the gate signal line), a stacked body constituted of a semiconductor layer SC and a metal layer ML is formed. The semiconductor layer SC is formed simultaneously with the formation of the semiconductor layer AS, while the metal layer ML is formed simultaneously with the formation of the drain electrode SD and the source electrode SD. The stacked body constituted of the semiconductor layer SC and the metal layer ML forms a spacer pedestal SS together with a protective film PAS described later.
[0068] On a surface of the substrate SUB1, the protective film PAS is formed so as to also cover the thin film transistor TFT and the stacked body constituted of the semiconductor layer SC and the metal layer ML. The protective film PAS is provided for obviating a direct contact between the thin film transistor TFT and the liquid crystal, and is formed of an inorganic insulation film, for example. On a portion of the protective film PAS where the stacked body constituted of the semiconductor layer SC and the metal layer ML is formed, a projecting portion which projects than a periphery thereof is formed, and the projecting portion functions as the spacer pedestal SS.
[0069] A pixel electrode PX which is constituted of a plurality of linear electrodes arranged parallel to each other is formed on an upper surface of the protective film PAS in a region where the pixel electrode PX overlaps with the counter electrode CT. The pixel electrode PX is formed of an ITO (Indium Tin Oxide) film, for example. The pixel electrode PX is electrically connected with another electrode out of the drain electrode SD and the source electrode SD of the thin film transistor TFT via a through hole formed in the protective film PAS at a position not shown in the drawing.
[0070] An alignment film ORI1 made of a photo-decomposition-type material is formed on a liquid-crystal-LC-side surface of the substrate SUB1 so as to also cover the pixel electrodes PX. The film thickness “b” of the alignment film ORI1 on a top surface of the spacer pedestal SS is set smaller than the film thickness “a” of the alignment film ORI1 in a region other than the top surface of the spacer pedestal SS (for example, above the pixel electrode PX), or the film thickness “b” is set to zero. The film thickness “b” of the alignment film ORI1 on the top surface of the spacer pedestal SS is set to a value of not more than 30 nm. Here, the film thickness “a” of the alignment film ORI1 above the pixel electrode PX, for example, is set to 110 nm, for example. A manufacturing method of the alignment film ORI1 is explained in detail later.
[0071] On the other hand, the counter substrate is constituted as follows, for example. First of all, a substrate SUB2 is provided. A black matrix BM and color filters FIL are formed on a liquid-crystal-LC-side surface of the substrate SUB2. The black matrix BM is formed between neighboring pixel regions, and the color filter FIL is formed so as to cover each pixel region.
[0072] On an upper surface of the black matrix BM and upper surfaces of the color filters FIL, an overcoat film OC formed of a resin film, for example, is formed. The overcoat film OC may be omitted in this embodiment.
[0073] Pillar-shaped spacers PS are formed on an upper surface of the overcoat film OC at positions where the pillar-shaped spacers PS face the spacer pedestals SS in an opposed manner. The pillar-shaped spacer PS is formed with a height and an area which are respectively larger than a height and an area of the spacer pedestal SS. The pillar-shaped spacers PS are formed by selectively etching a resin film applied to the upper surface of the overcoat film OC by coating, and the pillar-shaped spacer PS has a flat top surface.
[0074] Then, an alignment film ORI2 is formed on a liquid-crystal-LC-side surface of the substrate SUB2. The film thickness of the alignment film ORI2 on a top surface of the pillar-shaped spacer PS is set smaller than a film thickness “c” of the alignment film ORI2 in a region other than the top surface of the pillar-shaped spacer PS (for example, above the black matrix BM), or the film thickness of the alignment film ORI2 on the top surface of the pillar-shaped spacer PS is set to zero. The reduction of the film thickness of the alignment film ORI2 on the top surface of the pillar-shaped spacer can be realized by applying an alignment film material to liquid-crystal-LC-side surface of the substrate SUB2 and, thereafter, by performing time-prolonged leveling corresponding to viscosity by prolonging a leveling time.
[0075] With respect to the liquid crystal display device having such constitution, materials and film thicknesses of the above-mentioned respective members are described in tables shown in FIG. 2 . The upper table shown in FIG. 2 describes the members on the counter substrate, wherein from a substrate SUB2 side to a liquid crystal layer LC side, sequentially, the black matrix BM (indicated by BM in the table), the color filter FIL (indicated by color pixel layer in the table), the overcoat film OC (indicated by overcoat in the table), the pillar-shaped spacer (indicated by pillar-shaped spacer in the table), and the alignment film ORI2 (indicated by alignment film (film thickness: “c”)) are listed. Here, the film thickness of the alignment film ORI2 indicates a film thickness at a portion where the film thickness is set to the film thickness “c” in FIG. 1 , and a value of the film thickness is described separately (see FIG. 3 ). The lower table shown in FIG. 2 describes the members formed on the electrode substrate, wherein from the liquid crystal layer LC side to the substrate SUB1 side, sequentially, the alignment film ORI1 (indicated by alignment film (film thickness: “a”) in the table), the pixel electrode PX (indicated by pixel electrode in the table), the protective film PAS (indicated by protective film in the table), the source electrode and the drain electrode (indicated by source/drain in the table), the semiconductor device AS (indicated by a-Si in the table), the insulation film GI (indicated by gate insulation film in the table), the gate electrode (indicated by gate in the table), and the counter electrode (indicated by common ITO in the table) are listed. Here, the film thickness of the alignment film ORI1 indicates a film thickness at a portion where the film thickness is set to the film thickness “a” in FIG. 1 . The value of the film thickness is described separately (see FIG. 3 ).
(Manufacturing Method)
[0076] Next, one embodiment of a manufacturing method of the above-mentioned alignment film ORI1 and a manufacturing method of the alignment film ORI2 respectively is described. Although the explanation made hereinafter is directed to the manufacturing method of the alignment film ORI1, the alignment film ORI2 is manufactured substantially in the same manner.
[0077] First of all, an alignment film material is printed on the protective film PAS formed on the electrode substrate by a printer, for example, such that the alignment film material also covers the spacer pedestals SS. The alignment film material is made of a material having a skeleton formed of cyclobutane tetracarboxylic acid-diamine phenyl ether, for example. Here, solution concentration and solution viscosity of the alignment film material are made different corresponding to a plurality of examples. That is, as described in the table shown in FIG. 3 , solution concentration and solution viscosity of the alignment film material are respectively set to 7 wt %, 30 mPa·s (example 1), 7 wt %, 25 mPa·s (example 2), 8 wt %, 20 mPa·s (example 3), and 7 wt %, 35 mPa·s (example 4). Here, in all examples, solution viscosity is set to a value smaller than 35 mPa·s.
[0078] Then, the electrode substrate is heated on a hot plate at a temperature of 80° C. for 3 minutes and, thereafter, is baked at a temperature of 220° C. for 60 minutes. Here, the film thickness of the alignment film material at the portion where the film thickness assumes the film thickness “a”, the portion where the film thickness assumes the film thickness “b” and the portion where the film thickness assumes the film thickness “c” in FIG. 1 is described for the above-mentioned respective examples 1 to 4 in the table shown in FIG. 3 (item: before radiation of light).
[0079] Thereafter, on the hot plate held at a temperature of 200° C., light (polarization light containing ultraviolet rays) generated by a low pressure mercury lamp (integrated illuminance 5 mW/cm2 at 230 to 330 nm) is radiated for 1000 seconds (integrated radiation quantity: 5 J/cm2). Here, the film thickness of the alignment film material at the portion where the film thickness assumes the film thickness “a”, the portion where the film thickness assumes the film thickness “b” and the portion where the film thickness assumes the film thickness “c” in FIG. 1 is described for the above-mentioned respective examples 1 to 4 in the table shown in FIG. 3 (item: after radiation of light). As can be clearly understood from this table, in all embodiments, the film thickness of the alignment film ORI1 on the top surface of the spacer pedestal SS can be set to a value of not more than 30 nm. That is, the film thickness of the alignment film ORI1 on the top surface of the spacer pedestal SS is set to 13 nm in the example 1, 10 nm in the example 2, 8 nm in the example 3 and 30 nm in the example 4. On the other hand, the film thickness of the alignment film ORI1 in other region except for the top surface of the spacer pedestal SS (the region above the pixel electrode PX) is set to 110 nm in the example 1, 100 nm in the example 2, 110 nm in the example 3, and 120 nm in the example 4.
[0080] Further, the film thickness of the alignment film ORI2 on the counter substrate side is set, at a portion in FIG. 1 where the film thickness assumes the film thickness “c”, to 110 nm in the example 1, 100 nm in the example 2, 110 nm in the example 3 and 120 nm in the example 4, while the film thickness of the alignment film ORI2 assumes a value which is substantially zero on the top surface of the pillar-shaped spacer PS although not shown in FIG. 3 .
[0081] In FIG. 3 , for a comparison purpose, comparison examples 1 to 3 are also described. FIG. 3 shows a case where solution concentration and solution viscosity of the alignment film material are respectively set to 6 wt %, 50 mPa·s (comparison example 1), 5 wt %, 45 mPa·s (comparison example 2), and 6 wt %, 40 mPa·s (comparison example 3), wherein solution viscosity is set to a value larger than 35 mPa·s. In the table shown in FIG. 3 , the film thickness of the alignment film before radiation of light and the film thickness of the alignment film after radiation of light are described in association with the above-mentioned examples. Here, it is found that the film thickness of the alignment film ORI1 on the top surface of the spacer pedestal SS becomes larger than 30 nm.
Embodiment 2
(Constitution)
[0082] FIG. 4 shows the constitution of a liquid crystal display device corresponding to the examples 5 to 8, and corresponds to FIG. 1 .
[0083] The constitution which makes the liquid crystal display device shown in FIG. 4 different from the liquid crystal display device shown in FIG. 1 lies in that, first of all, the pillar-shaped spacers PS are formed on an electrode substrate side, and spacer pedestals SS are formed on the counter electrode side. Further, the spacer pedestals SS are formed on an upper surface of an overcoat film OC as a resin layer, for example.
[0084] Also in this case, the film thickness “b” of an alignment film ORI2 on a top surface of the spacer pedestal SS is set smaller than a film thickness “c” of the alignment film ORI2 in a region other than the top surface of the spacer pedestal SS (for example, above a black matrix BM), or the film thickness “b” is set to zero. The film thickness “b” of the alignment film ORI2 on the top surface of the spacer pedestal SS is set to a value of not more than 30 nm. Here, the film thickness “c” of the alignment film ORI2 on the black matrix BM, for example, is set to 110 nm, for example.
[0085] With respect to the liquid crystal display device having such constitution, materials and film thicknesses of the above-mentioned respective members are described in tables shown in FIG. 5 . The upper table shown in FIG. 5 describes the members on the counter substrate, wherein from a substrate SUB2 side to a liquid crystal layer LC side, sequentially, the black matrix BM (indicated by BM in the table), the color filter FIL (indicated by color pixel layer in the table), the overcoat film OC (indicated by overcoat in the table), the spacer pedestal (indicated by pedestal in the table), and the alignment film ORI2 (indicated by alignment film (film thickness: “c”) in the table) are listed. Here, the film thickness of the alignment film ORI2 indicates a film thickness at a portion where the film thickness is set to the film thickness “c” in FIG. 4 . The value of the film thickness is described separately (see FIG. 6 ). The lower table shown in FIG. 5 describes the members formed on the electrode substrate, wherein from the liquid crystal layer LC side to the substrate SUB1 side, sequentially, the alignment film ORI1 (indicated by alignment film (film thickness: “a”) in the table), the pillar-shaped spacer PS (indicated by pillar-shaped spacer in the table), the pixel electrode PX (indicated by pixel electrode in the table), the protective film PAS (indicated by protective film in the table), the source electrode and the drain electrode (indicated by source/drain in the table), the semiconductor device AS (indicated by a-Si in the table), the insulation film GI (indicated by gate insulation film in the table), the gate electrode (indicated by gate in the table), and the counter electrode CT (indicated by common ITO in the table) are listed. Here, the film thickness of the alignment film ORI1 indicates a film thickness at a portion where the film thickness is set to the film thickness “a” in FIG. 1 . The value of the film thickness is described separately (see FIG. 6 ).
(Manufacturing Method)
[0086] The manufacturing method of the alignment film ORI1 and the manufacturing method of the alignment film ORI2 are substantially equal to the corresponding manufacturing methods described in the embodiment 1.
[0087] Solution concentration and solution viscosity of the alignment film material are made different corresponding to a plurality of examples. That is, as described in the table shown in FIG. 6 , solution concentration and solution viscosity of the alignment film material are respectively set to 7 wt %, 30 mPa·s (example 5), 7 wt %, 25 mPa·s (example 6), 8 wt %, 25 mPa·s (example 7), and 7 wt %, 35 mPa·s (example 8). Here, in all examples, solution viscosity is set to a value smaller than 35 mPa·s.
[0088] Here, the film thickness of the alignment film material at the portion where the film thickness assumes the film thickness “a”, the portion where the film thickness assumes the film thickness “b” and the portion where the film thickness assumes the film thickness “c” in FIG. 4 is described for the above-mentioned respective examples 5 to 8 in the table shown in FIG. 4 (item: after radiation of light). As can be clearly understood from this table, in all embodiments, the film thickness of the alignment film ORI1 on the top surface of the spacer pedestal SS can be set to a value of not more than 30 nm. That is, the film thickness of the alignment film ORI1 on the top surface of the spacer pedestal SS is set to 13 nm in the example 5, 10 nm in the example 6, 8 nm in the example 7 and 30 nm in the example 8. On the other hand, the film thickness “c” of the alignment film ORI2 in other region except for the top surface of the spacer pedestal SS (the region above the black matrix BM) is set to 110 nm in the example 5, 100 nm in the example 6, 110 nm in the example 7, and 120 nm in the example 8.
[0089] Further, the film thickness of the alignment film ORI1 on the counter substrate side is set, at a portion in FIG. 4 where the film thickness assumes the film thickness “a”, to 110 nm in the example 5, 100 nm in the example 6, 110 nm in the example 7 and 120 nm in the example 8, while the film thickness of the alignment film ORI1 assumes a value which is approximately zero on the top surface of the pillar-shaped spacer PS although not shown in FIG. 6 .
[0090] In FIG. 6 , for a comparison purpose, comparison examples 4 to 6 are also described. FIG. 6 shows a case where solution concentration and solution viscosity of the alignment film material are respectively set to 6 wt %, 50 mPa·s (comparison example 4), 5 wt %, 45 mPa·s (comparison example 5), and 6 wt %, 40 mPa·s (comparison example 6). In the table shown in FIG. 6 , the film thickness of the alignment film before radiation of light and the film thickness of the alignment film after radiation of light are described in association with the above-mentioned examples. Here, it is found that the film thickness of the alignment film ORI1 on the top surface of the spacer pedestal SS becomes larger than 30 nm.
Embodiment 3
(Constitution)
[0091] FIG. 7 shows the constitution of a liquid crystal display device corresponding to examples 9 to 11 and corresponds to FIG. 1 .
[0092] The constitution which makes this embodiment different from the embodiment shown in FIG. 1 lies in that the spacer pedestal SS shown in FIG. 1 is not particularly necessary in this embodiment and a portion where a thin film transistor TFT is formed to function as a spacer pedestal. It is because that a drain electrode SD and a source electrode SD of the thin film transistor TFT are formed as projecting portions higher than a periphery of these portions and hence, these portions can be also used as a spacer pedestal SS.
[0093] Also in this case, a film thickness “b” of an alignment film ORI1 on an upper surface of the thin film transistor TFT is set smaller than a film thickness “a” of the alignment film ORI1 in a region other than the upper surface of the thin film transistor TFT (for example, above a pixel electrode PX), or the film thickness “b” is set to zero. The film thickness “b” of the alignment film ORI1 on the upper surface of the thin film transistor TFT is set to a value of not more than 30 nm. Here, the film thickness “a” of the alignment film ORI1 on the pixel electrode PX, for example, is set to 110 nm, for example.
[0094] In such constitution, materials and film thicknesses of respective members of the embodiment 2 are substantially equal to the materials and the film thicknesses of the respective corresponding members described in the embodiment 1. That is, materials and film thicknesses of respective members have values substantially equal to values in the table shown in FIG. 2 .
(Manufacturing Method)
[0095] The manufacturing method of the alignment film ORI1 and the manufacturing method of the alignment film ORI2 are substantially equal to the corresponding manufacturing methods described in the embodiment 1.
[0096] Solution concentration and solution viscosity of the alignment film material are made different corresponding to a plurality of examples. That is, as described in the table shown in FIG. 8 , solution concentration and solution viscosity of the alignment film material are respectively set to 7 wt %, 30 mPa·s (example 9), 7 wt %, 25 mPa·s (example 10), and 8 wt %, 25 mPa·s (example 11). Here, in all examples, solution viscosity is set to a value smaller than 35 mPa·s.
[0097] Here, the film thickness of the alignment film material at the portion where the film thickness assumes the film thickness “a”, the portion where the film thickness assumes the film thickness “b” and the portion where the film thickness assumes the film thickness “c” is described for the above-mentioned respective examples 9 to 11 in the table shown in FIG. 8 (item: after radiation of light). As can be clearly understood from this table, in all embodiments, the film thickness of the alignment film ORI1 on the upper surface of the thin film transistor TFT can be set to a value of not more than 30 nm. That is, the film thickness of the alignment film ORI1 on the upper surface of the thin film transistor TFT is set to 21 nm in the example 9, 18 nm in the example 10, and 14 nm in the example 11. On the other hand, the film thickness of the alignment film ORI1 in other region except for the upper surface of the thin film transistor TFT (the region above the pixel electrode PX) is set to 110 nm in the example 9, 100 nm in the example 10, and 110 nm in the example 11.
[0098] Further, the film thickness of the alignment film ORI2 on the counter substrate side is set, at a portion in FIG. 7 where the film thickness assumes the film thickness “c”, to 110 nm in the example 9, 100 nm in the example 10, and 110 nm in the example 11, while the film thickness of the alignment film ORI2 assumes a value which is approximately zero on the top surface of the pillar-shaped spacer PS although not shown in FIG. 8 .
[0099] In FIG. 8 , for a comparison purpose, comparison examples 7 to 9 are also described. FIG. 8 shows a case where solution concentration and solution viscosity of the alignment film material are respectively set to 6 wt %, 50 mPa·s (comparison example 7), 5 wt %, 45 mPa·s (comparison example 8), and 6 wt %, 40 mPa·s (comparison example 9). In the table shown in FIG. 8 , the film thickness of the alignment film before radiation of light and the film thickness of the alignment film after radiation of light are described in association with the above-mentioned examples. Here, it is found that the film thickness of the alignment film ORI1 on the top surface of the spacer pedestal SS becomes larger than 30 nm.
Comparison Example 10
[0100] FIG. 9 shows the constitution in which a spacer pedestal (or a part which replaces the spacer pedestal such as the above-mentioned thin film transistor TFT) is not provided at a position which faces a pillar-shaped spacer PS. That is, FIG. 9 shows a comparison example which facilitates the understanding of advantageous effects of the above-mentioned respective examples in terms of quantity.
[0101] FIG. 9 corresponds to FIG. 1 , and shows the constitution where the pillar-shaped spacer PS on a counter substrate side faces an alignment film ORI1 on an electrode substrate at an intersecting position of a gate signal line GL and a drain signal line DL.
[0102] In this case, a manufacturing method of the alignment film ORI1 is substantially equal to the manufacturing method of the alignment film ORI1 explained in conjunction with the embodiment 1, wherein solution concentration and solution viscosity of an alignment film material are set to 7 wt % and 30 mPa·s, for example, as shown in FIG. 10 . Further, in a table shown in FIG. 10 , a film thickness of the alignment film material at positions where the film thickness is set to a film thickness “a”, a film thickness “b” and a film thickness “c” in FIG. 9 is described with respect to a case before radiation of light and a case after radiation of light respectively. In this case, the film thickness “b” of the alignment film ORI1 which faces the pillar-shaped spacer PS after the radiation of light becomes 100 nm so that the film thickness “b” of the alignment film ORI1 largely exceeds 30 nm.
[0103] That is, on a liquid-crystal-layer-LC-side surface of the electrode substrate which faces the pillar-shaped spacer PS in an opposed manner, the liquid-crystal-layer-LC-side surface of the electrode substrate is only 300 nm which is a film thickness of the gate signal line GL, and the alignment film ORI1 is brought into contact with the top surface over an area larger than an area of the top surface of the pillar-shaped spacer PS and hence, the film thickness “b” of the alignment film ORI1 is largely increased to 100 nm even after the radiation of light.
[0104] FIG. 11 shows a result of inspection of respective bright-spot-generation withstand voltage levels with respect to the examples 1 to 4, the comparison examples 1 to 3, the examples 5 to 8, the comparison examples 4 to 6, examples 9 to 11, and the comparison examples 7 to 10.
[0105] FIG. 11 shows the respective bright-spot-generation withstand voltage levels with respect to the film thickness “b” of the alignment film which faces the pillar-shaped spacer PS after radiation of light in the respective examples and the respective comparison examples.
[0106] Here, the bright-spot-generation withstand voltage level is classified into 7 stages consisting of 0 to 6. As shown in FIG. 12 , the bright-spot-generation withstand voltage level is evaluated based on the presence or the non-presence of the generation of bright spots at the time of completion of the liquid crystal display device, the presence or the non-presence of the abrasion of the surface alignment film at the time of disassembling the liquid crystal display device, the presence or the non-presence of the generation of bright spots after a vibration test (3G), the presence or the non-presence of the abrasion of the surface alignment film after the vibration test (3G), the presence or the non-presence of generation of bright spots after a vibration test (5G), and the presence or the non-presence of the abrasion of the surface alignment film after the vibration test (5G). Here, with respect to the abrasion of the surface alignment film, there exists a possibility that even when the abrasion of the surface alignment film is not found in the observation carried out immediately after the test, an abraded portion which is concealed by a light blocking portion (a black matrix or the like, for example) appears on a display area due to a change with time and hence, such abrasion is also subject to the evaluation.
[0107] FIG. 13 is a graph converted from the table shown in FIG. 11 , wherein an alignment film thickness (nm) is taken on an abscissa, and the bright-spot-generation withstand voltage level is taken on an ordinate. An allowable range is set such that it is sufficient for a liquid crystal display device that no abrasion of the surface alignment film occurs in the vibration test (3G) and a liquid crystal display device whose bright-spot-generation withstand voltage level is up to 2 is rendered acceptable. In this case, it is understood that the film thickness “b” of the alignment film which faces the pillar-shaped spacer PS after the radiation of light is set to a value of not more than 30 nm.
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A liquid crystal display device includes a first substrate, a first alignment film formed over the first substrate, a second substrate, a second alignment film formed over the second substrate, a liquid crystal layer sandwiched between the first alignment film and the second alignment film, and a projecting portion formed over the second substrate. The first alignment film is a photo alignment film, and a thickness “d2” of the second alignment film over the projecting portion and a film thickness “d1” of a portion of the first alignment film facing the projecting portion satisfy formula (1) and (2):
0 nm<d2<30 nm (1);
d2<d1 (2).
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 10/006,009, filed Dec. 4, 2001, pending, which application claims priority under 35 U.S.C. 119(a)-(d) to European Patent Application 00204322.2, filed Dec. 4, 2000 and European Patent Application 01202168.9 filed Jun. 6, 2001, the contents of all of which are incorporated herein by this reference.
TECHNICAL FIELD
[0002] The invention relates to diagnosis of disease and/or determination of functioning of cellular organisms, of multicellular or unicellular nature, including organisms visible to the naked eye and microorganisms.
BACKGROUND
[0003] A diagnostician of disease studying (mal)functioning of cellular organisms can employ a broad range of inroads into the organism to obtain relevant information as to the various aspects of the malfunctioning. These inroads vary widely, examples of which include detecting relative ratios of kidney stones by studying urinary samples obtained from various patients, probing for the presence or absence of intestinal ulcers via endoscopy, scanning for detectable tumors by nuclear magnetic resonance (“NMR”), detecting diabetes by testing for insulin levels and/or glucose concentration in blood plasma, determining cancer proneness by determining transcriptional levels of oncogenes, and so on.
[0004] Currently, the detection of disease or malfunctioning (or vice versa, of health and proper functioning) of higher organisms, such as animals and plants, relies on testing samples obtained from these organisms and studying these samples in a laboratory. Often, when a fruitful method capable of determining, identifying or detecting (aspects of) a disease or malfunctioning of an organism has been found, it is also generally useful in testing or screening of compounds or methods for treatment of (aspects of) the disease or malfunctioning or useful in testing or screening for compounds or methods involved in causing (aspects of) the disease or malfunctioning. By using the same or similar methods used in diagnosis, it is generally possible to assess the usefulness of such candidate compounds or methods in treating and/or causing the disease or malfunctioning in question. Clearly, life science laboratories are always in the need of other inroads into organisms to obtain yet more information relating to disease or malfunctioning and to compounds and methods related to causing and/or treating the disease or malfunctioning.
DISCLOSURE OF THE INVENTION
[0005] The invention provides a method for determining (mal)functioning of a cellular organism comprising determining the relative ratio of an endosymbiont cellular organelle nucleic acid and/or gene product thereof in relation to another nucleic acid or gene product present in a sample obtained from the organism. In terms of the invention, “relative ratio” includes the amount of the first endosymbiont cellular organelle nucleic acid and/or gene product thereof in relation to the amount of the second nucleic acid and/or gene product thereof. The relative ratio may, for instance, be determined by (among other things) dividing the amount of the first nucleic acid or gene product thereof by the amount of the second nucleic acid or gene product thereof, or vice versa. The amount of one or both compounds may also be divided by, or subtracted from, a reference value. By determining functioning of a cellular organism is meant herein determining whether the cellular organism is in its natural healthy state, or whether the organism is somehow affected, for instance, by a disease and/or a (toxic) compound. The disease and/or (toxic) compound may affect the organism to such extent that clinical symptoms are present. Alternatively, the disease or (toxic) compound may have an influence upon the organism while clinical symptoms are not (yet) manifested.
[0006] Endosymbiont cellular organelles include those organelles of a eukaryotic cell that are thought to have been derived of prokaryotic bacteria very early on in the evolution of eukaryotic cells. These bacteria (as it is thought) have engaged in a symbiosis with early eukaryotic cells, and, at present, eukaryotic cells comprising these endosymbiont organelles in general cannot live without them. None of the present eukaryotic cells would function properly without mitochondria, and most plant cells would at least be considered to be malfunctioning when no proplastids, or organelles derived thereof, such as chloroplasts, etioplasts, amyloplasts, elaioplasts or chromoplasts were present. These organelles in general appear to be at least partially self-replicating bodies which, although under some nuclear controls, still possess considerable autonomy.
[0007] In particular, the invention provides a method whereby the relative ratio of an endosymbiont cellular organelle nucleic acid and/or gene product thereof is determined in relation to the amount of essentially nuclear nucleic acid detectable in the sample (be it DNA or RNA), or in relation to gene products (derivable by transcription and/or translation, such as mRNA or (poly)peptides) of the nuclear nucleic acid, (nuclear nucleic acid herein comprises chromosomal DNA and the RNA transcribed therefrom) for example, present in nuclear or cytoplasmatic fractions or parts of the sample. DNA or corresponding mRNA encoding components of small nuclear ribonucleoprotein (SNRNP), or other essentially common nucleic acid derived from chromosomal DNA, is particularly useful to test, because of its ubiquitous presence. In this way, the invention provides a method for studying, for example, endosymbiont cellular organelle-related disease, like mitochondrial and/or proplastid-related disease. By endosymbiont cellular organelle-related disease is meant herein a condition wherein the amount and/or at least one property of nucleic acid of the endosymbiont cellular organelle, and/or gene product thereof, is altered as compared to the natural situation. For instance, expression of the nucleic acid may be reduced. Endosymbiont cellular organelle-related disease, e.g., encoded by defects in the organelle's DNA, manifests in many different syndromes and is often variable in its expression (and thus in general hard to detect by testing for clinical parameters alone) due to heteroplasmy, whereby mutant and wild-type nucleic acid can be found in one cell, whereby its distribution can vary. Endosymbiont cellular organelle-related disease is often aggravated with increasing age of the affected individual. Endosymbiont cellular organelle-related disease can also often be observed after treatment against other disease with various drugs, and then contributes to various side-effects of those drugs that one would like to avoid during treatment. Those side-effects can now be better studied by using a method as provided herein.
[0008] Furthermore, the invention provides a method whereby the relative ratio of a first endosymbiont cellular organelle nucleic acid and/or gene product thereof is determined in relation to the amount of a second (distinct) endosymbiont cellular organelle nucleic acid detectable in the sample (be it DNA or RNA), or in relation to gene products (derivable by transcription and/or translation, such as mRNA or (poly)peptides)) of the endosymbiont cellular organelle nucleic acid. In one aspect of the invention, the method involves determining a ratio between organelle DNA, such as mtDNA, and the corresponding transcriptionally derivable organelle RNA, in the example the related mtRNA, or translated gene product. This way, the level of transcription and/or translation can be determined. An alteration of the level of transcription and/or translation, as compared to the natural level of transcription and/or translation, is indicative for an altered functioning of the organelle. The altered functioning may be malfunctioning of the organelle, because of a disease and/or because of side-effects of a certain treatment. The malfunctioning may, for instance, comprise a decreased level of transcription. Alternatively, the altered functioning may be an improved functioning of the organelle, for instance, during treatment and/or curing of an endosymbiont cellular organelle-related disease.
[0009] The malfunctioning may also comprise an increased level of transcription. A disease, or a treatment of a disease, may involve decrement of the amount of endosymbiont organelle DNA. However, the decrement can at least in part be compensated by an increase in transcription of the DNA, at least in the first stage of the disease. This way, the amount of RNA derived from the endosymbiont organelle DNA may not be decreased at all, or relatively less decreased as compared to the amount of the endosymbiont organelle DNA. Symptomatic side-effects of the disease or treatment may then not be (fully) sensed yet. However, upon further decrement of the amount of the endosymbiont organelle DNA, the amount of RNA derived from the DNA will eventually also drop significantly. Side-effects can then occur. Conventionally, upon manifestation of side-effects, a disease is treated or a treatment is reduced or stopped. However, in this conventional way, a patient already suffers from the side-effect(s). With a method of the invention, however, side-effect(s) involving clinical symptoms can be predicted. For instance, an altered level of transcription and/or translation of an endosymbiont cellular organelle nucleic acid is indicative for altered functioning of a cellular organism, for instance, malfunctioning of the organism involving (future) side-effects. An alteration of the relative ratio of endosymbiont cellular organelle DNA and/or gene product thereof in relation to the amount of nuclear nucleic acid or gene product thereof is also indicative of altered functioning of a cellular organism.
[0010] In yet another aspect of the invention, the ratio between two distinct organelle DNAs or related gene products is determined. In one aspect, a method of the invention is provided wherein the first endosymbiont cellular organelle nucleic acid and the second endosymbiont cellular organelle nucleic acid are obtained from the same kind of organelle. The organelle, for instance, comprises a mitochondrion.
[0011] A method of the invention is particularly suitable for staging of a disease. An organism can already be affected by a disease, while no or little clinical symptoms are essentially present yet. However, although no clinical symptoms are essentially present, the relative ratio of a first endosymbiont cellular organelle nucleic acid and/or gene product thereof in relation to the amount of a second nucleic acid and/or gene product thereof can already be altered. As shown in the examples, the alteration of the relative ratio can be determined before clinical symptoms and/or conventional tests, like determination of the lactate pyruvate ratio, to indicate an altered functioning of an organism. Thus, the relative ratio is very suitable for determining the stage of a certain disease. The invention therefore provides in one aspect a method for determining the staging of a disease, comprising determining the relative ratio of an endosymbiont cellular organelle nucleic acid and/or gene product thereof in a sample obtained from an organism suffering from or at risk of suffering from the disease.
[0012] A method of the invention for staging of a disease can be used for diagnosis. For instance, people can be routinely tested by a method of the invention with certain time intervals. Alternatively, people can be tested at the moment that they have some clinical symptoms. An alteration in the relative ratio is indicative of a certain degree of disease. The kind of the disease need not be diagnosed by a method of the invention.
[0013] Other possible uses of the invention lay in candidate drug testing for beneficial activity and/or side-effects of possible medicaments or pharmaceutical compositions such as candidate anti-parasitic compounds, antibiotic compounds, cytostatic compounds, and so on. For example, the invention provides a method for determining therapeutic activity and/or possible side-effects of a candidate compound, for example, in determining its usefulness for treatment of malfunctioning of a cellular organism, comprising determining the relative ratio of an endosymbiont cellular organelle nucleic acid and/or gene product thereof in a sample obtained from the organism, preferably the organism or an essentially related organism, such as belonging to the same species or genus, having been provided with the compound. If the relative ratio of an endosymbiont cellular organelle nucleic acid, and/or gene product thereof, of a certain organism is altered after the candidate compound is administered to the organism, this indicates therapeutic activity and/or side-effects involved with the compound when administered to the organism. Additionally, this also indicates therapeutic activity and/or side-effects involved with the compound in an essentially related organism. Therefore, for determining therapeutic activity and/or side-effects of a candidate compound for treatment of malfunctioning of a cellular organism, it is not necessary to use exactly the same organism in a method of the invention. An essentially related organism can also be used.
[0014] In another aspect, the invention provides a method for determining therapeutic activity and/or possible side-effects of a medicament comprising determining the relative ratio of an endosymbiont cellular organelle nucleic acid and/or gene product thereof in a sample obtained from an organism, preferably the organism having been provided with the medicament. In terms of the invention, therapeutic activity means the capability of at least in part treating a disease. In one embodiment of the invention, the therapeutic activity comprises a therapeutic activity against an HIV-related disease and/or a tumor-related disease. The medicament may, for instance, comprise a cytostaticum, optionally combined with other antiretroviral therapy. According to the ATHENA-study in the Netherlands, forty percent of the patients undergoing an antiretroviral therapy need to change antiretroviral therapy because of adverse side-effects. Therefore, a method of the invention is very much desired during such therapies, because the method can detect side-effects before (severe) clinical symptoms are essentially present. The therapy can then already be stopped and/or changed before the clinical effects are essentially present. In that case, the clinical symptoms may not, or to a lesser extent, become present. This will prevent a lot of suffering. Thus, in a preferred aspect, a method of the invention is provided wherein the side-effects are not essentially manifested at the moment that the method is performed. In terms of the invention, by “not essentially manifested” is meant that the side-effect is not (yet), or only partly, manifested by clinical symptoms.
[0015] In one aspect, a method of the invention is provided wherein the compound or medicament comprises a cytostaticum. Commonly used cytostatica, for instance, comprise alkylating compounds, antimitotoxic cytostatica, antitumor antibiotica, and topo-isomerase inhibitors. Nonlimiting examples thereof comprise chloorambucil, cyclofosfamide, estramustine, ifosamide, melfalanthiotepabusulfan, treosulfancarmustne, lomustinecisplatine, carboplatine, oxaliplatinedacarbazine, procarbazine, temozolomide vinblastine, vincristine, vindesinedocetaxel, paclitaxeldaunorubicine, doxorubicine, epirubicine, idarubicine, mitoxanthronbleomycine, dactinomycine, mitomycineirinotecan, topotecanetoposide, teniposide amsacrine, asparaginase, cladribine, hydroxycarbamide, pentostatine methotrexate and/or raltitrexed. During antiretroviral treatment, and/or treatment of tumor-related disease, a nucleoside and/or nucleotide analogue is often used. These analogues involve a high risk of side-effects, because they interfere with replication and/or transcription processes in an organism. The amount of endosymbiont cellular organelle nucleic acid is then often altered as well. Therefore, a method of the invention is very suitable when an organism is treated with a medicament involving nucleoside and/or nucleotide analogues.
[0016] In one aspect, the invention provides a method of the invention wherein the compound or medicament comprises a nucleoside and/or nucleotide analogue. Nonlimiting examples of such analogues are fludarabine, mercaptopurine, thioguanine, cytarabine, fluorouracil, and/or gemcytabine. In yet another aspect, a method of the invention is provided wherein the compound or medicament comprises AZT, ddI, ddC, d4T, 3TC and/or tenofofir. In a method of the invention, the organism or an essentially related organism has preferably been provided with the compound or organism.
[0017] Treatment of certain diseases, like, for instance, an HIV-related disease, has to be performed during a long period of time. A method of the invention is particularly suitable during treatment of a disease during a long period of time. During the long period, many side-effects can evolve, and a patient can now be monitored regularly even though no clinical symptoms are present (yet). Therefore, in one aspect, a method of the invention is provided wherein the medicament is used during at least three months, preferably during at least six months, and more preferably during at least twelve months. In one aspect, the medicament is used for treatment of a chronic disease. By a chronic disease is meant herein a disease which cannot be completely cured. Once an individual has acquired the disease, the disease is always present in the individual, albeit the clinical symptoms may vary widely. The symptoms may sometimes even be unnoticed by the individual. A chronic disease, for instance, comprises an HIV-related disease.
[0018] By a side-effect of a compound is meant herein another effect than the purpose of the compound. The side-effect may be an unwanted effect. For instance, a therapeutic compound may counteract a disease and simultaneously reduce the metabolism of an organism. The reduction of the metabolism is then referred to as a (negative) side-effect. Alternatively, a side-effect of a compound may be a beneficial effect, like, for instance, immunity against yet another disease.
[0019] Also, use for (selective) toxin testing of, e.g., herbicides, insecticides, anti-parasitic compounds, and antibiotic compounds is provided herein. The invention provides a method for determining toxic activity of a candidate compound, for example, in determining its usefulness for causing malfunctioning of a cellular organism, e.g., by having a cytostatic or even cytotoxic effect, comprising determining the relative ratio of an endosymbiont cellular organelle nucleic acid and/or gene product thereof in a sample obtained from an organism, preferably the organism or related organism having been provided with the compound.
[0020] In a preferred embodiment, selectivity is also tested, using or applying the method as provided herein (preferably in parallel experiments) on or to a first organism and on or to an essentially unrelated second organism, if desired, belonging to a different family or order, but preferably belonging to at least a different class or phylum, most preferably belonging to a different kingdom of organisms. Selectivity aspects are, for example, tested by testing the compounds in (if desired only in cells of) a first target organism (such as a bacterium or parasite) as well as testing the host or cells thereof, being an essentially unrelated second organism, for example, a mammal or plant, or by testing of a crop plant or cells thereof as well as testing an essentially unrelated weed plant or cells thereof with the compound to determine, for example, selective toxic or selective therapeutic effects. It is also provided to test normal cells derived from an individual in parallel or comparison with aberrant cells, such as tumor cells derived from the same individual, to detect or screen for a tumor-specific or at least selective cytostatic or cytotoxic compound for use in therapy of the individual or others with similar or related disease.
[0021] With a method of the invention, a relative ratio is, for instance, determined by measuring the amount of the nucleic acid(s) and/or gene product(s) present in the sample, usually after at least one processing step, like, for instance, amplification of target nucleic acid. After the amounts have been measured, the relative ratio can be determined by dividing one amount by another.
[0022] Minute amounts of target nucleic acid can be detected and quantified by using enzymatic amplification. Examples of enzymatic amplification techniques are a polymerase chain reaction (PCR), 1 nucleic acid sequence-based amplification (NASBA), 2 SDA, TMA, and others. Specific amplification of a target nucleic acid sequence can be achieved by adding two primer sequences to a reaction. An amplified region can be detected at the end of an amplification reaction by probes that are specific for the amplified region. Alternatively, an amplified region can be detected during generation of the amplified nucleic acid in the amplification reaction. 3 In the latter protocol, a signal of a label attached to a probe can become detectable after the probe has hybridized to a complementary nucleic acid. Examples of such probes that enable real-time homogeneous detection in amplification reactions are TaqMan 3 and Molecular Beacon probes. 4,5
[0023] Quantification of a target nucleic acid sequence is commonly accomplished by adding a competitor molecule, which is amplified using the same primers and which contains sequences that allow discrimination between the competitor and target nucleic acid sequence. 2,6 The ratio between the amplified competitor and target nucleic acid sequence can be used to quantify the target nucleic acid sequence. Detection of the competitor or target nucleic acid sequence can, for instance, be achieved at the end of the amplification reaction by probes that are specific for the amplified region of competitor or target nucleic acid sequence or during generation of the amplified nucleic acid in the amplification reaction. In the latter protocol, a signal of a label attached to a probe can become detectable after the probe has hybridized to a complementary target nucleic acid and when the target has exceeded a threshold level, the time or cycle number to positivity. In other methods for quantification, the time to positivity can be used for quantification without addition of a competitor. 7
[0024] A method of the invention is very suitable for, among others, determining (mal)functioning of a cellular organism, candidate drug testing and selective toxin testing. Many reactions have been carried out using a method of the invention, which has proven to be a useful tool (see Examples). An even more precise result can be obtained using a method of the invention when double spreading in the result is avoided. Generally, double spreading in the result of a method of the invention is obtained due to varieties in conditions in different reaction mixtures. For instance, to be able to detect and quantify specific nucleic acids present in a sample, an amplification step is often necessary. However, the temperature of the reaction mixture of nucleic acid 1 may be slightly higher than the temperature of the reaction mixture of nucleic acid 2. This may result in a higher yield of nucleic acid 1 and, hence, in a higher ratio of the amount of nucleic acid 1 versus nucleic acid 2 than would have been obtained if the temperature of reaction mixture 1 had been exactly the same as the temperature of reaction mixture 2. Because of the temperature difference in the reaction mixtures, the determined ratio is not exactly the same as the real ratio of the two nucleic acids present in the initial sample. Likewise, minute variations in other conditions like, for instance, the amount of enzyme added can lead to variations in the determined amounts of nucleic acids 1 and 2. Thus, the measured amounts of nucleic acids 1 and 2 may vary independently from each other. Independent variations in the determined amounts may result in an even larger variation in the calculated ratio of the measured amounts. This is called double spreading in the result. Thus, by double spreading is meant herein at least one variation in an obtained result, due to a variety of at least one reaction condition in at least two reaction mixtures. For instance, also the total amount of volume may differ slightly between two reaction mixtures.
[0025] In some particular cases, double spreading in a result may exceed the variations of the relative ratio of an endosymbiont cellular organelle nucleic acid and/or gene product thereof in an organism which is due to a certain disease or treatment. For instance, inhibitors of viral polymerase are often used for treatment of HIV. Inhibitors of viral polymerase may also affect mitochondrial polymerase gamma. Thus, the amount of mitochondrial polymerase gamma may be reduced during the treatment of HIV, which may result in a decreased amount of mitochondria per cell. A decrement of, for instance, 50% of the mitochondria may result in side-effects. The ratio of mitochondrial DNA versus nuclear DNA may be diminished by a factor of two. However, a decrement of mitochondrial DNA by a factor of two can, in some cases, lie within the double spreading of the measurement of the ratio because of the mentioned variations in conditions. Therefore, this biologically important difference in the amount of mitochondria may not reliably be detected because of double spreading in the result. Thus, double spreading can, in some cases, reduce the reliability of detection of biologically important differences in a ratio of nucleic acids and/or their gene products. Therefore, one embodiment of the present invention provides a method for determining functioning of a cellular organism, without double spreading in the result, comprising determining the relative ratio of a first endosymbiont cellular organelle nucleic acid and/or gene product thereof in a sample obtained from the organism in relation to the amount of a second nucleic acid and/or gene product thereof. The double spreading can, in a preferred embodiment of the present invention, be prevented by determination of the ratio in the same assay. This means that a processing step and/or a measurement of the amounts of at least two nucleic acids and/or gene products thereof is performed in the same assay. In terms of the invention, an assay typically utilizes one reaction mixture. Preferably, all components of an assay of the invention are mixed randomly in the assay. The reaction mixture may be present in one reaction tube.
[0026] However, a person skilled in the art can think of more methods to prevent double spreading in the result. He/she can, for instance, use a reaction vessel which is divided into different parts by a (semi)permeable membrane. As long as at least one reaction condition varies dependently in the different parts, double spreading is avoided and the obtained result will be more accurate.
[0027] In one embodiment of the current invention, at least two target sequences are amplified in one assay. The two target sequences may be the endosymbiont cellular organelle nucleic acid and the second nucleic acid. Thus, in one embodiment of the current invention, a method of the invention is provided, comprising amplification of the endosymbiont cellular organelle nucleic acid and the second nucleic acid in the same assay. When at least two target sequences are amplified in one assay, varieties in reaction conditions in the assay can influence the obtained amount of each sequence present in the assay dependently. For instance, the obtained amount of each sequence present in the assay will be influenced by the same temperature, the same overall volume, and so on. Detection of the two target sequences can be achieved by using two specific probes during the generation of amplified nucleic acids during an amplification reaction. The two probes may each have a different label allowing discrimination between the two probes and thereby between the two different target sequences. Quantification can be achieved by relating the time to positivity as well as the slope of the relative fluorescence increase of both real time amplification reactions. Preferably, a reference curve is created before. The quantification of the nucleic acid can then be performed by comparing the obtained value(s) with the reference curve. Thus, there is no need for an internal standard like, for instance, a competitor molecule. A method of relative quantification of two targets in one assay has an improved accuracy compared to quantification in two separate assays and requires less handling time and reagents. We found that duplexing of two amplification reactions in the same tube gives an immediate indication of the ratio of the two targets. The conditions of both amplification reactions are the same, ruling out variations of those conditions without the necessity for internal or external calibrators. Hence, double spreading in the result is now avoided. Thus, in one aspect, the invention provides a method, wherein a relative ratio is determined directly by dividing one amount of nucleic acid by another. Preferably, the relative ratio is performed by comparison with a reference curve. In terms of the invention, “determined directly” means that an immediate indication of the ratio of the two targets is possible, for instance, by comparing the intensity of the two different fluorescent labels of the two specific probes. In this embodiment, dividing one amount of nucleic acid by another is performed by dividing the intensity of the corresponding fluorescent label by another. No internal standards are used in a method of the invention wherein the relative ratio is determined directly.
[0028] In one aspect, a method of the invention is provided wherein the cellular organelle nucleic acid, the gene product thereof, the second nucleic acid and/or the gene product thereof is obtained from a peripheral blood mononuclear cell (PBMC) and/or a fibroblast. Especially the use of PBMCs is preferred because then a blood sample from the organism can be used. A blood sample is easy to obtain and relatively large amounts are often available. Therefore, in a preferred embodiment, a method of the invention is provided wherein the sample comprises a blood sample.
[0029] A method of the invention is especially useful to quantify a target nucleic acid and/or gene product thereof with a variable content in relation to a target nucleic acid and/or gene product thereof with a constant content. An example is the quantification of the variable cellular content of mitochondrial DNA to the constant cellular content of the DNA of a nuclear gene (two per diploid cell). Another example comprises the quantification of variably expressed RNA like mitochondrial RNA to constitutively expressed RNA that is essential for cell survival like the SNRP U1A encoding RNA involved in splicing or other essentially common nucleic acids derived from nuclear DNA with a ubiquitous presence. We found that it is possible to determine a relative ratio of a factor 2:3.
[0030] In one aspect, the invention provides a method of the invention wherein the first nucleic acid comprises RNA and the second nucleic acid comprises DNA. A method of the invention is, for instance, particularly suitable for the quantification of the cellular content of mitochondrial RNA to the cellular content of the DNA of a nuclear gene like U1A. This is shown in Example 22.
[0031] Furthermore, the invention provides a diagnostic kit comprising at least one means for performing a method according to the invention the kit of comprising at least one primer or probe set selective for the amplification and detection of a nucleic acid related to or derived from endosymbiont cellular organelles and, when so desired, necessary amplification reagents, such as can be found exemplified in the detailed description herein or which are otherwise known in the art. In particular, the invention provides a diagnostic kit wherein the kit comprises more than one primer or probe set for the amplification of nucleic acid sequences related to cellular organelles, preferably supplemented with a primer or probe set for the amplification of nucleic acid related to the chromosomes, such as an SNRP specific primer or probe. In particular, the invention provides a kit comprising at least one primer or probe from Table 1 for the amplification of nucleic acid sequences related to cellular organelles. It is, of course, preferred that the amplification reagents, when provided with the kit, comprise an enzyme with reverse transcriptase activity, such as required for PCR or NASBA amplification. Of course, a kit comprising a means for the detection of a gene product other than nucleic acid for use in a method according to the invention is herewith also provided.
[0032] The invention furthermore provides the use of a compound obtainable or detectable by a method according to the invention in the preparation of a medicament, a herbicide, insecticide, anti-parasiticum, cytostatic, etc., and a medicament, herbicide, insecticide, anti-parasiticum, etc., obtainable or derivable or identifiable by a method according to the invention.
[0033] The invention is further explained in the detailed description herein, wherein most examples are directed by way of example at testing of mitochondria, being central to the provision and use of energy in a cell; however, it will easily be understood that the same principles apply to tests using other endosymbiont organelles, such as chloroplasts, being central to the provision of carbohydrates to a plant cell.
BRIEF DESCRIPTION OF THE DRAWINGS
[0034] FIG. 1 . Examples of standard curves for DNA and RNA target sequences.
[0035] FIG. 2 . Ratio of mitochondrial DNA and chromosomal DNA in fibroblast cells cultured in the presence of ddC.
[0036] FIG. 3 . Ratio of mitochondrial RNA and chromosome-encoded RNA in fibroblast cells cultured in the presence of ddC.
[0037] FIG. 4 . Ratio of mitochondrial RNA and chromosomal DNA in fibroblast cells cultured in the presence of ddC.
[0038] FIG. 5 . Ratio of mitochondrial RNA and mitochondrial DNA in fibroblast cells cultured in the presence of ddC.
[0039] FIG. 6 . Ratio of chromosome encoded RNA and chromosomal DNA in fibroblast cells cultured in the presence of ddC.
[0040] FIG. 7 . Ratio of mitochondrial DNA and chromosomal DNA in fibroblast cells cultured in the absence of ddC after being cultured with ddC for four weeks.
[0041] FIG. 8 . Ratio of mitochondrial RNA and chromosome-encoded RNA in fibroblast cells cultured in the absence of ddC after being cultured with ddC for four weeks.
[0042] FIG. 9 . Ratio of mitochondrial DNA and chromosomal DNA in PBMCs cultured in the presence of ddC for five days.
[0043] FIG. 10 . Ratio of mitochondrial RNA and chromosome-encoded RNA in PBMCs cultured in the presence of ddC for five days.
[0044] FIG. 11 . Comparison of SNRNP DNA NASBA reactions with and without pretreatment with restriction enzyme Msp I.
[0045] FIG. 12 . Fluorescence in time of the reactions of 1,000 molecules plasmid containing Snrp DNA mixed with 4×10 5 (A), 2×10 5 (B), 10 5 (C), 5×10 4 (D), 2.5×10 4 (E) or 10 4 (F) molecules of plasmid containing mitochondrial DNA. The curve (G) of the ratio of the amount of molecules of amplified mitochondrial DNA to Snrp nuclear DNA plotted against the ratio of the slope of the corresponding fluorescence in time.
[0046] FIG. 13 . Fluorescence in time of the reactions of 1,000 molecules plasmid containing Snrp DNA mixed with 4×10 5 (A), 2×10 5 (B), 10 5 (C), or 5×10 4 (D) molecules of plasmid containing mitochondrial DNA. The standard curve (E) of the ratio of the amount of molecules of amplified plasmid mitochondrial DNA to plasmid Snrp nuclear DNA plotted against ratio of the slope of the corresponding fluorescence in time as derived from the Panels A-D; closed circles indicate data points. The 1:10 (F, H) and 1:100 (G, I) dilutions of PBMC in the absence (F, G) and the presence of 5 μM ddC (H, I). In Panel E, the squares represent the PBMC samples cultured in the absence of ddC and the diamonds represent PBMC samples cultured in the presence of 5 μM ddC.
[0047] FIG. 14 . Mitochondrial DNA copies per chromosomal DNA copy in four blood PBMC samples of an HIV-1 infected patient that died of lactic acidosis. For further explanation of time points see text.
[0048] FIG. 15A . CD4 positive cell numbers and HIV-1 RNA load of an HIV-1 infected individual. Bars labeled with ddC and AZT below the X-axis indicate the time period of treatment with these drugs. The four arrows below the X-axis indicate the time points at which samples of PBMC were analyzed for mitochondrial DNA content and lactate-pyruvate ratio. Approximately one month after time point four, the patient died of lactate acidosis.
[0049] FIG. 15B . The left panel shows the lactate-pyruvate ratios of the PBMC samples numbered 1 to 4. No increase in lactate-pyruvate ratio can be measured in these PBMC. The right panel shows the mitochondrial DNA content of PBMC in samples 1 to 4. In this experiment a clear decrease in mitochondrial DNA content can be observed.
[0050] FIG. 16 . Fluorescence in time of ROX (chromosomal DNA, grey lines) and FAM (mitochondrial DNA, black lines) fluorescent signal using different ratios of mitochondrial DNA to chromosomal DNA as input. In the lower panel the linear relation between the ratio of signal and the ratio of DNAs is shown.
[0051] FIG. 17 . Lactate-pyruvate ratio as measured in fibroblasts cultured in the presence of ddC for the first four weeks, after which the culture was continued both in the presence and absence of ddC.
[0052] FIG. 18 . Fluorescence in time of ROX (chromosomal DNA, grey lines) and FAM (mitochondrial DNA, black lines) fluorescent signal of fibroblasts cultured in the presence of ddC. Panels from top left to top right: culture in the presence of ddC for respectively one, two, three and four weeks. Bottom left two panels: culture continued in the presence of ddC to respectively week seven and week ten. Bottom right two panels: culture continued in the absence of ddC to respectively week seven and week ten.
[0053] FIG. 19 . The bars represent the percent of mitochondria in PBMC during culture in the absence (dotted bars) and presence (striped bars) of ddC. The amount of mitochondrial DNA in the controls (DMSO) is set at 100% at each given time point.
[0054] FIG. 20 . Decrease of mitochondrial DNA content in three patient groups treated with AZT, AZT+ddI and AZT+ddC, respectively. P-values above the bars indicate significant changes in mitochondrial DNA content compared to time point zero, the start of therapy.
[0055] FIG. 21 . The mitochondrial DNA content of three individual patients during treatment with AZT, AZT+ddI and AZT+ddC, respectively.
[0056] FIG. 22 . Fluorescence in time of ROX (chromosomal DNA, grey lines) and FAM (mitochondrial RNA, black lines) fluorescent signal using different ratios of mitochondrial RNA to chromosomal DNA as input. In the lower panel, the linear relation between the ratio of signal and the ratio of RNA and DNAs is shown.
[0057] FIG. 23 . Bars represent the amount of mitochondrial RNA in fibroblasts cultured in the presence of ddC for the first eight weeks, after which the culture was continued both with and without ddC until week 16.
[0058] FIG. 24 . ATHENA-study of patients changing anti-retroviral treatment because of adverse side-effects.
[0059] FIG. 25 . Schematic representation of DNA-NASBA amplification.
[0060] FIG. 26 . Genetic map of the mitochondrial DNA with two regions indicated where part of the amplification primers as shown in Table 1 are located. Other amplification primers shown in Table 1 are located in other regions of the mitochondrial genome and are not indicated in this figure.
DETAILED DESCRIPTION OF THE INVENTION
EXAMPLES
[0000] Used Ingredients and General Methodology
[0061] In Table 1, the primers and probes used in the examples are summarized. Standard NASBA nucleic acid amplification reactions were performed in a 20 μl reaction volume and contained: 40 mM Tris-pH 8.5, 70 mM KCl, 12 mM MgCl 2 , 5 mM dithiothreitol, 1 mM dNTPs (each), 2 mM rNTPs (each), 0.2 μM primer (each), 0.05 μM molecular beacon, 375 mM sorbitol, 0.105 μg/μl bovine serum albumin, 6.4 units AMV RT, 32 units T7 RNA polymerase, 0.08 units RNAse H and input nucleic acid. The complete mixture, except the enzymes, sorbitol and/or bovine serum albumin was, prior to adding the enzyme mixture, heated to 65° C. for two minutes in order to denature any secondary structure in the RNA and to allow the primers to anneal. After cooling the mixture to 41° C., the enzymes were added. The amplification took place at 41° C. for 90 minutes in a fluorimeter (CytoFluor 2000) and the fluorescent signal was measured every minute (using the filter set 530/25 nm and 485/30 nm). For amplification of DNA target sequences, the 65° C. denaturation step was replaced with a 95° C. denaturation step for two to five minutes.
[0062] To achieve quantification, a dilution series of target sequences for a particular primer set was amplified and the time points at which the reactions became positive (the time to positivity, TTP) were plotted against the input amounts of nucleic acid. This way a calibration curve was created that could be used to read TTP values of reactions with unknown amounts of input and deduce the input amount. Examples of typical standard curves for quantification of RNA and DNA are shown in FIG. 1 .
[0063] For some of the target sequences, no dilution series were available with reliable absolute amount of copies determined. Those series were given an arbitrary unit as measurement instead of DNA or RNA copies, e.g., cell-equivalent or ET-unit. As a result, it sometimes seems that there is less RNA than DNA, which is quite the opposite of what is expected.
[0064] Cells (fibroblasts and PBMCs) were cultured under standard conditions in standard media known to persons skilled in the art with the addition of drugs or putative toxic or stimulating compounds as defined in the examples. Nucleic acids were isolated from the cells with the method described by Boom et al. (Boom, R.; Sol, C. J.; Salimans, M. M.; Jansen, C. L.; Wertheim-van Dillen, P. M.; van der Noordaa, J.; 1990, Rapid and simple method for purification of nucleic acids, J. Clin. Microbiol., 28(3):495-503) or with dedicated isolation kits purchased from Qiagen (Qiagen GmbH, Max Volmer Strasse 4, 40724 Hilden, Germany) and used according to the manufacturer's protocols. A small aliquot of the isolated nucleic acid was analyzed on an agarose gel and the remainder stored at −80° C. until further analysis. Usually the nucleic acid was diluted ten times with water, and of the diluted nucleic acid, usually 5 μl was used as input in the NASBA amplification reactions.
Example 1
[0065] In this example it is explained what kind of ratios can be measured with a method according to the invention and the meaning they can have in a diagnostic sense:
[0066] The invention, for example, provides determining the relative ratio of organelle DNA to chromosomal DNA. This ratio, when compared with normal values or determined at at least two points in time, shows the decline or increase of organelles per cell. Also is provided determining the ratio of organelle RNA to chromosome-encoded RNA. This ratio, when compared with normal values or determined at at least two points in time, shows the organelle transcription activity decline or increase per cell, normalized for the active state (i.e., transcription state) of the cell.
[0067] Determining the ratio of organelle RNA to chromosomal DNA is also provided. This ratio, when compared with normal values or determined at at least two points in time, shows the organelle transcription activity decline or increase per cell.
[0068] Determining the ratio of organelle DNA to organelle RNA is also provided. This ratio, when compared with normal values or determined at at least two points in time, shows the decline or increase of transcription in the organelle, indicating regulation at the transcriptional level to achieve a certain mRNA (and therefore protein) level.
[0069] Determining the ratio of organelle DNA to chromosome encoded RNA is also provided. This ratio, when compared with normal values or determined at at least two points in time, shows the decline or increase of transcription in the cell, in relation to chromosomal RNA transcription levels, indicating the activity state of the organelle, which is especially useful when chromosomal RNA is determined that encodes an organelle protein or other component thereof
Example 2
[0070] Fibroblast cells were cultured in vitro in the presence of the antiviral drugs ddC, AZT and D4T at two concentrations each, 3 μM and 30 μM, respectively, for four weeks. As controls, cell cultures with ethidium bromide and without drugs were also performed. Ethidium bromide is known to deplete mitochondrial DNA completely from cells and is a positive control in terms of achieving an effect on the mitochondria content of cells. At one week intervals, part of the cells was harvested and analyzed for an amount of mitochondrial DNA (primers MtD p1 and MtD p2 and probe MtD mb) and chromosomal DNA (primers SnrpD p1 and SnrpD p2 and probe SnrpD mb) in the described NASBA protocol. The cultures with AZT, D4T and without additive showed no measurable change in mitochondrial DNA to chromosomal DNA ratio in the culture period of four weeks. The culture with ethidium bromide showed a decline in mitochondrial DNA content as expected. The results for ddC are shown in FIG. 2 .
[0071] The data in FIG. 2 clearly show a decline in the amount of mitochondrial DNA per cell with more than two logs and therewith the mitochondrial toxicity of the antiviral drug ddC.
Example 3
[0072] Fibroblast cells were cultured in vitro in the presence of the antiviral drugs ddC, AZT and D4T at two concentrations each, 3 μM and 30 μM, respectively, for four weeks. As controls, cell cultures with ethidium bromide and without drugs were also performed. Ethidium bromide is known to deplete mitochondrial DNA completely from cells and is a positive control in terms of achieving an effect on the mitochondria content of cells. At one week intervals, part of the cells was harvested and analyzed for an amount of mitochondrial RNA (primers MtR p1 and MtR p2 and probe MtR mb) and chromosome-encoded RNA (primers SnrpR p1 and SnrpR p2 and probe SnrpR mb) in the described NASBA protocol. The cultures with AZT, D4T and without additive showed no measurable change in mitochondrial RNA to chromosome-encoded RNA ratio in the culture period of four weeks. The culture with ethidium bromide showed a decline in mitochondrial RNA content as expected. The results for ddC are shown in FIG. 3 . The data in FIG. 3 clearly show a decline in the amount of mitochondrial RNA per cell with at least two logs and therewith the mitochondrial toxicity of the antiviral drug ddC. The time point at three weeks has a very low value and presumably this is somewhat of an outlier measurement.
Example 4
[0073] Fibroblast cells were cultured in vitro in the presence of the antiviral drugs ddc, AZT and D4T at two concentrations each, 3 μM and 30 μM, respectively, for four weeks. As controls, cell cultures with ethidium bromide and without drugs were also performed. Ethidium bromide is known to deplete mitochondrial DNA completely from cells and is a positive control in terms of achieving an effect on the mitochondria content of cells. At one week intervals, part of the cells was harvested and analyzed for an amount of mitochondrial RNA (primers MtR p1 and MtR p2 and probe MtR mb) and chromosomal DNA (primers SnrpD p1 and SnrpD p2 and probe SnrpD mb) in the described NASBA protocol.
[0074] The cultures with AZT, D4T and without additive showed no measurable change in mitochondrial RNA to chromosomal DNA ratio in the culture period of four weeks. The culture with ethidium bromide showed a decline in mitochondrial RNA content as expected. The results for ddC are shown in FIG. 4 .
[0075] The data in FIG. 4 clearly show a decline in the amount of mitochondrial RNA per cell with almost three logs and therewith the mitochondrial toxicity of the antiviral drug ddC. The time point at three weeks has a very low value and presumably this is somewhat of an outlier measurement.
Example 5
[0076] Fibroblast cells were cultured in vitro in the presence of the antiviral drugs ddC, AZT and D4T at two concentrations each, 3 μM and 30 μM, respectively, for four weeks. As controls, cell cultures with ethidium bromide and without drugs were also performed. Ethidium bromide is known to deplete mitochondrial DNA completely from cells and is a positive control in terms of achieving an effect on the mitochondria content of cells. At one week intervals, part of the cells was harvested and analyzed for an amount of mitochondrial RNA (primers MtR p1 and MtR p2 and probe MtR mb) and mitochondrial DNA (primers MtD p1 and MtD p2 and probe MtD mb) in the described NASBA protocol.
[0077] The cultures with AZT, D4T and without additive showed no measurable change in mitochondrial RNA to mitochondrial DNA ratio in the culture period of four weeks. The culture with ethidium bromide showed a decline in mitochondrial RNA and DNA content as expected. The results for ddC are shown in FIG. 5 .
[0078] The data in FIG. 5 clearly show that the ratio of mitochondrial DNA to RNA is not significantly changing over the period of four weeks. The time point at three weeks in FIG. 5 has a low value for mitochondrial RNA that shows up; this measurement is presumably somewhat of an outlier measurement.
Example 6
[0079] Fibroblast cells were cultured in vitro in the presence of the antiviral drugs ddC, AZT and D4T at two concentrations each, 3 μM and 30 μM, respectively, for four weeks. As controls, cell cultures with ethidium bromide and without drugs were also performed. Ethidium bromide is known to deplete mitochondrial DNA completely from cells and is a positive control in terms of achieving an effect on the mitochondria content of cells. At one-week intervals, part of the cells was harvested and analyzed for an amount of chromosome-encoded RNA primers SnrpR p1 and SnrpR p2 and probe SnrpR mb) and chromosomal DNA (primers SnrpD p1 and SnrpD p2 and probe SnrpD mb) in the described NASBA protocol.
[0080] The cultures with AZT, D4T, ethidium bromide and without additive showed no measurable change in ratio in the culture period of four weeks. The results for ddC are shown in FIG. 6 .
[0081] The data in FIG. 6 clearly show that the ratio of chromosomal DNA to RNA is not significantly changing over the period of four weeks.
Example 7
[0082] Fibroblast cells were cultured in vitro in the presence of the antiviral drug ddC at a concentration of 30 μM for four weeks. After that period, the cell culture continued but now in the absence of ddC. During this period of culture without ddC, part of the cells was harvested and analyzed for an amount of mitochondrial DNA (primers MtD p1 and MtD p2 and probe MtD mb) and chromosomal DNA (primers SnrpD p1 and SnrpD p2 and probe SnrpD mb) in the described NASBA protocol at two-week intervals for a period of twelve weeks. The results of the analysis are shown in FIG. 7 .
[0083] The results in FIG. 7 clearly show that the amount of mitochondria per cell increases with more than two logs after ddC is removed from the culture. This result shows that the toxic effect of ddC can be reversed if there are still some mitochondria left in the cells to repopulate the new growing cells.
Example 8
[0084] Fibroblast cells were cultured in vitro in the presence of the antiviral drug ddC at a concentration of 30 μM for four weeks. After that period, the cell culture continued but now in the absence of ddC. During this period of culture without ddC, part of the cells was harvested and analyzed for an amount of mitochondrial RNA (primers MtR p1 and MtR p2 and probe MtR mb) and chromosome-encoded RNA (primers SnrpR p1 and SnrpR p2 and probe SnrpR mb) in the described NASBA protocol at two-week intervals for a period of twelve weeks. The results of the analysis are shown in FIG. 8 .
[0085] The results in FIG. 8 clearly show that the amount of mitochondrial RNA per cell increases with more than two logs after ddC is removed from the culture. This results shows that the toxic effect of ddC can be reversed and that the function of the mitochondria comes back as shown by synthesis of RNA and, subsequently, proteins.
Example 9
[0086] Fresh peripheral blood mononuclear cells (PBMCs) from a healthy blood donor were cultured in vitro in the presence of the antiviral drugs ddC, AZT and D4T at two concentrations each, 6 μM and 60 μM, respectively, for five days. As controls, cell cultures with DMSO and without drugs were also performed. DMSO is part of the solvent in which the drugs are solubilized. After five days, the cells were harvested and analyzed for an amount of mitochondrial DNA (primers MtD p1 and MtD p2 and probe MtD mb) and chromosomal DNA (primers SnrpD p1 and SnrpD p2 and probe SnrpD mb) in the described NASBA protocol.
[0087] The cultures with AZT,. D4T, DMSO and without additive showed no measurable change in ratio in the culture period of five days. The results for ddC are shown in FIG. 9 .
[0088] The results in FIG. 9 clearly show the decline in PBMCs of mitochondrial DNA per cell of more than one log during the five-day culture period.
Example 10
[0089] Fresh peripheral blood mononuclear cells (PBMCs) from a healthy blood donor were cultured in vitro in the presence of the antiviral drugs ddC, AZT and D4T at two concentrations each, 6 μM and 60 μM, respectively, for five days. As controls, cell cultures with DMSO and without drugs were also performed. DMSO is part of the solvent in which the drugs are solubilized. After five days, the cells were harvested and analyzed for an amount of mitochondrial RNA (primers MtR p1 and MtR p2 and probe MtR mb) and chromosome-encoded RNA (primers SnrpR p1 and SnrpR p2 and probe SnrpR mb) in the described NASBA protocol.
[0090] The cultures with AZT, D4T, DMSO and without additive showed no measurable change in ratio in the culture period of five days. The results for ddC are shown in FIG. 10 . Interestingly, the results in FIG. 10 do not clearly show a decline in PBMCs of mitochondrial RNA per cell during the five-day culture period at the highest concentration of ddC used. This is in contrast to the mitochondrial DNA as shown in Example 9. Probably the decline in mitochondrial DNA is compensated by an increase in transcription, maintaining the level of mitochondrial RNA. This mechanism delays the decline of mitochondrial RNA.
[0091] Consequently, one can say that the mitochondrial RNA is a reflection of the current status of the functionality of the mitochondria and that mitochondrial DNA is predictive of what will happen in the (near) future with the mitochondrial function and therefore has a more prognostic character.
Example 11
[0092] Using the primers and probes Rubisco-DNA p1, Rubisco-DNA p2, Rubisco-DNA MB, Rubisco-RNA p1, Rubisco-RNA p2 and Rubisco-RNA-MB (Table 1), the chloroplast DNA and RNA of Oryza sativum (rice) can be quantified and the ratio to the chromosomal DNA and RNA can be determined by using primers and probes OryzaDNA p1, OryzaDNA p2, OryzaDNA mb, OryzaRNA p1, OryzaRNA p2, OryzaRNA mb (Table 1). During the application of herbicide (or other) compounds, the conditions of the plants can be assessed by measurement of the chloroplast nucleic acid content of the cells using amplification methods like PCR and NASBA that are known to persons skilled in the art. At the same time, using primer sets suitable for weeds, the deterioration of the unwanted plants can be monitored. It is clear that these molecular tools are very suited in the research for new herbicides that specifically attack one group of plants and not others.
Example 12
[0093] In this example, the NASBA nucleic acid amplification reactions for DNA target sequences were performed in a 20 μl reaction volume and contained: 40 mM Tris-pH 8.5, 70 mM KCl, 12 mM MgCl 2 , 5 mM dithiotreitol, 1 mM dNTPs (each), 2 mM rNTPs (each), 0.2 μM primer (each), 0.05 μM molecular beacon, 1.5 units restriction enzyme Msp I, 375 mM sorbitol, 0.105 μg/μl bovine serum albumin, 6.4 units AMV RT, 32 units T7 RNA polymerase, 0.08 units RNAse H and input nucleic acid. The complete mixture, except the enzymes sorbitol and bovine serum albumin, was, prior to adding the enzyme mixture, incubated at 37° C. for 25 minutes and subsequently heated to 95° C. for two minutes in order to denature the DNA and to allow the primers to anneal. After cooling the mixture to 41° C., the enzyme mixture was added. The amplification took place at 41° C. for 90 minutes in a fluorimeter (CytoFluor 2000) and the fluorescent signal was measured every minute (using the filter set 530/25 nm and 485/30 nm). To achieve quantification, a dilution series of target sequence for a particular primer set was amplified and the time points at which the reactions became positive (the time to positivity, TTP) were plotted against the input amounts of nucleic acid. This way a calibration curve was created that could be used to read TTP values of reactions with unknown amounts of input and deduce the input amount. Fresh peripheral blood mononuclear cells (PBMCs) from a healthy blood donor were cultured in vitro for five days. After five days, the cells were harvested and analyzed for an amount of chromosomal DNA (primers SnrpD p1 and SnrpD2 p2 and probe SnrpD mb) with the described NASBA protocol in the chapter “Used ingredients and general methodology” and compared with the NASBA protocol as described in this example. As can be clearly seen in FIG. 11 , the DNA NASBA reactions with pretreatment of restriction enzyme perform much better than without. The rationale for this observation is the direct extension from the Msp I created 3′ over the T7 promoter part of the p1 primer.
Example 13
[0094] Using the primers and probes tRNA-L-D p1, tRNA-L-D p2, tRNA-L-D MB, petB RNA p1, petB RNA p2 and petB RNA MB (Table 1), the chloroplast DNA and RNA of Oryza Sativum (rice) can be quantified and the ratio to the chromosomal DNA and RNA can be determined by using primers and probes OryzaDNA p1, OryzaDNA p2, OryzaDNA mb, OryzaRNA p1, OryzaRNA p2, OryzaRNA mb (Table 1). During the application of herbicide (or other) compounds, the conditions of the plants can be assessed by measurement of the chloroplast nucleic acid content of the cells using amplification methods like PCR and NASBA that are known to persons skilled in the art. At the same time, using primer sets suitable for weeds, the deterioration of the unwanted plants can be monitored. It is clear that these molecular tools are very suited in the research for new herbicides that specifically attack one group of plants and not others.
Example 14
[0095] A thousand molecules of plasmid containing Snrp DNA were mixed with 4×10 5 , 2×10 5 , 10 5 , 5×10 4 , 2.5×10 4 , or 10 4 molecules of plasmid containing mitochondrial DNA, and the mixture was used as input for the reactions. A reaction mix was prepared similar to that of Example 12, except that primers and beacons differed in order to amplify Snrp-nuclear and mitochondrial DNA in one tube. The reaction mix (duplex-mix) contained two sets of primers and beacon: SnrpD p1 and SnrpD p2, and MtD p1 — 2 and MtD p2 — 2 (each 0.2 μM) with beacons SnrpD mb (ROX-labeled) and MtD mb — 2 (FAM-labeled) (each 0.05 μM). Restriction enzyme digestion, amplification, and detection were performed as in Example 12. Filter sets of the fluorimeter (CytoFluor 2000) were adapted to simultaneously measure the FAM and the ROX-label (485/20 and 530/25 for FAM; 590/20 and 645/40 for ROX). In a duplex reaction with two competing amplifications, the ratio of the slope of the curves of fluorescence in time is proportional to the ratio of the amount of molecules of each amplified species (see FIG. 12 ).
Example 15
[0096] PBMC were cultured in the absence and presence of 5 μM ddC. After five days, PBMC samples were drawn. Nucleic acids were isolated from 10 5 PBMC according to the method described by Boom et al. and dissolved in 50 μl DNAse-free and RNAse-free water. 1:10 and 1:100 dilutions were made, and 5 μl of the dilutions (equivalent to 1,000 or 100 PBMC, respectively) were put in the reaction mix to amplify the specific targets. In parallel, 10 3 molecules of plasmid containing Snrp DNA was mixed with 4×10 5 , 2×10 5 , 10 5 , or 5×10 4 molecules of plasmid containing mitochondrial DNA, and the mixture was used as input for the reactions. A reaction mix was prepared similar to that of Example 12, except that primers and beacons differed in order to amplify Snrp-nuclear and mitochondrial DNA in one tube. The reaction mix (duplex-mix) contained two sets of primers and beacons: SnrpD p1 and SnrpD p2, and MtD p1 — 2 and MtD p2 — 2 (each 0.2 μM) with beacons SnrpD mb (ROX-labeled) and MtD mb — 2 (FAM-labeled) (each 0.05 μM). Restriction enzyme digestion, amplification, and detection were performed as in Example 12. Filter sets of the fluorimeter (CytoFluor 2000) were adapted to simultaneously measure the FAM and the ROX-label (485/20 and 530/25 for FAM; 590/20 and 645/40 for ROX). In a duplex reaction with two competing amplifications, the ratio of the slope of the curves of fluorescence in time is proportional to the ratio of the amount of molecules of each amplified species. The data of the plasmid Snrp/mitochondrial DNA mixtures were used to create a standard curve on which the unknown ratio of mitochondrial to Snrp nuclear DNA of the PBMC samples in the dilutions 1:10 and 1:100 in the absence and presence of 5 μM ddC could be assessed (see FIG. 13 ).
Example 16
[0097] From an HIV-1 infected patient that died as a result of severe lactic acidosis, four blood samples were analyzed for the mitochondrial content of the peripheral blood mononuclear cells (PBMC). Sample 1 was taken one year prior to the moment of death, sample 2 was taken three months before the moment of death, sample 3 was taken 1.5 months before the moment of death and sample 4 was taken just before death. The blood was used to prepare peripheral blood mononuclear cells (PBMC) by Ficoll-Isopaque purification. PBMC were viably frozen in medium plus 5% DMSO and stored in liquid nitrogen until use. Nucleic acids were extracted from 10 5 PBMC using the Boom method. Nucleic acids equivalent of 1,000 PBMC were used as input for the NASBA that measures mitochondrial DNA (primers MtD p1 and MtD p2 and probe MtD mb) and the NASBA that measures chromosomal DNA (primers SnrpD p1 and SnrpD p2 and probe SnrpD mb). See Table 1 for primer and probe sequences. The result of this assay is expressed as the mitochondrial DNA copies per chromosomal DNA copy (see FIG. 14 ).
Example 17
[0098] Different ratios of mitochondrial and chromosomal DNA targets in plasmids were analyzed in this example: 2×10 3 U1a DNA/8×10 3 Mt DNA, 2×10 3 U1a DNA/2×10 4 MtDNA, 2×10 3 U1a DNA/4×10 4 Mt DNA, 2×10 3 U1a DNA/10 5 Mt DNA, 2×10 3 U1a DNA/2×10 5 Mt DNA, 2×10 3 U1a DNA/4×10 5 Mt DNA, and 2×10 3 U1a DNA/8×10 5 Mt DNA molecules were included. A reaction mix was prepared similar to that of Example 12, except that primers and beacons differed in order to amplify chromosomal and mitochondrial DNA in one tube. The reaction mix (duplex-mix) contained two sets of primers and beacons: SnrpD P1 and SnrpD2 P2 (first primer set, each 0.2 μM), and MtD P1 — 2 and MtD P2 — 2 (second primer set, each 0.3 μM) with beacons SnrpD mb — 2 (FAM-labeled) and MtD mb — 3 (ROX-labeled) (each 0.04 μM). See Table 1 for primer and, probe sequences. Restriction enzyme digestion, amplification, and detection were performed as in Example 12. Filter sets of the fluorimeter (CytoFluor 2000 or EasyQ analyzer) were adapted to simultaneously measure the FAM and the ROX-label (485/20 and 530/25 for FAM; 590/20 and 645/40 for ROX). In a duplex reaction with two competing amplifications, the ratio of the slope of the curves of fluorescence in time is proportional to the ratio of the amount of molecules of each amplified species. The results are shown in FIG. 16 . The relation between the ratio of the slopes of FAM and ROX signal is linear to the ratio of mitochondrial DNA and chromosomal DNA in the input. This result can be used to generate a calibration curve and the number of mitochondrial DNA copies per cell can be calculated from this standard calibration curve.
Example 18
[0099] Fibroblasts were cultured in the presence of the anti-retroviral drug ddC. (30 μM) for four weeks. After that period, the cell culture continued in the presence, but also in the absence, of ddC for another six weeks. During this period of culture, part of the cells were harvested and analyzed for the ratio of lactate-pyruvate using standard methods known by persons skilled in the art. The results of the lactate-pyruvate ratio measurements are shown in FIG. 17 .
[0100] The data in FIG. 17 clearly show that in the presence of ddC, the lactate pyruvate ratio increases, but significant increase can only be observed after four weeks of culture. During continued culture in the presence of ddC, the lactate-pyruvate ratio remains high; however, in continued culture after week four in the absence of ddC, the lactate-pyruvate ratio drops to normal levels.
[0101] Furthermore, the same samples were used to determine the ratio of mitochondrial DNA and chromosomal DNA as described in Example 17. The results are shown in FIG. 18 .
[0102] The data in FIG. 18 clearly show that in the presence of ddC, the fibroblasts lose their mitochondrial DNA (decline of the black line in top panels). A significant decrease in the mitochondrial DNA content can already be observed after two weeks and hardly any mitochondrial DNA can be observed after three weeks of culture in the presence of ddC. These data are in contrast to the traditional lactate-pyruvate measurements where a significant change could only be observed after four weeks. These results clearly show the predictive value of measurement of mitochondrial DNA content for effects on functionality in time.
[0103] In the continued culture in the presence of ddC, the amount of mitochondrial DNA remains very low (bottom left two panels). Continued culture in the absence of ddC shows a clear rebound in the amount of mitochondrial DNA in the fibroblasts (bottom right two panels).
Example 19
[0104] PBMCs were cultured in the presence of the anti-retroviral drug ddC (5 μM) and with a corresponding concentration of the solvent (DMSO) of the drug as a control for eleven days. During this period of culture, every two days, part of the cells were harvested and analyzed for the ratio of mitochondrial DNA and U1a DNA as described in Example 17. The results are shown in FIG. 19 .
[0105] The data of this experiment clearly show that the mitochondrial DNA content of PBMC in culture in the presence of ddC rapidly declines. At day two, the mitochondrial DNA content of PBMC cultured in the presence of ddC has decreased to 20%, compared to control cultures. The number or mitochondrial DNA copies in PBMC further declines to undetectable levels at day eleven of the culture in the presence of ddC.
Example 20
[0106] Forty-eight HIV-1 infected patients were randomized for antiviral therapy with either AZT, AZT+ddI, or AZT+ddC. Blood was drawn at week 0, 4, 24, and 48 after the start of therapy. The blood was used to prepare peripheral blood mononuclear cells (PBMC) by Ficoll-Isopaque purification. PBMC were viably frozen in medium plus 5% DMSO and stored in liquid nitrogen until use.
[0107] Nucleic acids were extracted from 10 5 PBMC using the Boom method. Nucleic acids equivalent of 1,000 PBMC were used as input for the one-tube real-time duplex-NASBA that measures both mitochondrial and chromosomal DNA as described in Example 17. The result of this assay is expressed as the mitochondrial DNA content per cell (i.e., PBMC) of the patient sample. The results are summarized in Table 2.
[0108] The mtDNA content of the PBMC of the patients at start of therapy was compared to the mtDNA content at week 4, 24, and 48 and analyzed for statistically significant changes (see Table 3 and FIGS. 20 and 21 ). The data clearly show that patients undergoing therapy containing AZT+ddI or ddC experience a significant decline in the mitochondrial DNA content of their PBMC.
Example 21
[0109] Different ratios of mitochondrial RNA target and chromosomal DNA target in a plasmid were analyzed in this example: 2×10 3 U1a DNA/5×10 4 Mt RNA, 2×10 3 U1a DNA/2.5×10 5 Mt RNA, 2×10 3 U1a DNA/5×10 5 Mt RNA, 2×10 3 U1a DNA/2.5×10 6 Mt RNA, 2×10 3 U1a DNA/5×10 6 Mt RNA, 2×10 3 U1a DNA/10 7 Mt RNA, 2×10 3 U1a DNA/2.5×10 7 Mt RNA molecules were included. A reaction mix was prepared similar to that of Example 12, except that primers and beacons differed in order to amplify chromosomal DNA and mitochondrial RNA in one tube. The reaction mix (duplex-mix) contained two sets of primers and beacons: SnrpD P1 and SnrpD2 P2 (first primer set, each 0.1 μM) and MtR P1 — 2 and MtR P2 — 2 (first primer set, each 0.4 μM) with beacons SnrpD mb (ROX-labeled) and MtR mb (FAM-labeled) (each 0.04 μM). See Table 1 for primer and probe sequences. Restriction enzyme digestion, amplification, and detection were performed as in Example 12. Filter sets of the fluorimeter (CytoFluor 2000 or EasyQ) were adapted to simultaneously measure the FAM and the ROX-label (485/20 and 530/25 for FAM; 590/20 and 645/40 for ROX). In a duplex reaction with two competing amplifications, the ratio of the slope of the curves of fluorescence in time is proportional to the ratio of the amount of molecules of each amplified species. The results are shown in FIG. 22 . The relation between the ratio of the slopes of FAM and ROX signal is linear to the ratio of mitochondrial RNA and chromosomal DNA in the input. This result can be used to generate a calibration curve and the number of mitochondrial RNA copies per cell can be calculated from this standard calibration curve.
Example 22
[0110] Fibroblasts were cultured in the presence of the anti-retroviral drug ddC (30 μM) for eight weeks. After that period, the cell culture continued in the presence, but also in the absence, of ddC for another eight weeks. During this period of culture, part of the cells were harvested at different time points and analyzed for the ratio of mitochondrial RNA and chromosomal DNA as described in Example 21. The results are shown in FIG. 23 .
[0111] The data in FIG. 23 clearly show that in the presence of ddC, the fibroblasts lose their mitochondrial RNA. In the continued culture in the presence of ddC, the amount of mitochondrial RNA remains very low. Continued culture in the absence of ddC shows a clear rebound in the amount of mitochondrial RNA in the fibroblasts (week 10, 12, 14 and 16 time points).
Example 23
[0112] Two HIV-1 infected patients (patients 1 and 2) treated with antiviral therapy (AZT+ddI) were analyzed for the mitochondrial RNA content in their PBMC. Blood was drawn at week 0, 4, 24, and 48 after the start of therapy. The blood was used to prepare peripheral blood mononuclear cells (PBMC) by Ficoll-Isopaque purification. PBMC were viably frozen in medium plus 5% DMSO and stored in liquid nitrogen until use.
[0113] Nucleic acids were extracted from 10 5 PBMC using the Boom method. Nucleic acids equivalent of 1,000 PBMC were used as input for the one-tube real-time duplex-NASBA that measures both mitochondrial RNA and chromosomal DNA as described in Example 21. The result of this assay is expressed as the mitochondrial RNA content per cell (i.e., PBMC) of the patient sample. The results are summarized in Table 4.
[0114] The mitochondrial RNA content of the PBMC of the patients 1 and 2 does not seem to vary significantly in the time of this study and with the therapies (drugs and doses) applied. The current study will be expanded to encompass more individuals and different therapies to get an even better assessment of the changes in mitochondrial RNA caused by therapies encompassing nucleoside analogues.
Table 1 Sequences of primers and probes used in the examples. Name Sequence 1 Sequence ID No. MtD p1 5′ AATTCTAATACGACTCACTATAGGG AGAAGAGCCGT (SEQ ID NO:1) TGAGTTGTGGTA 3′ MtD p2 5′TCTCCATCTATTGATGAGGGTCTTA 3′ (SEQ ID NO:2) MtD mb 5′ GCATGC CCCTCCTAGCCTTACTACTAAT GCATGC (SEQ ID NO:3) MtD p1_2 AAT TCT AAT ACG ACT CAC TAT AGG G AA GAA CCG (SEQ ID NO:4) GGC TCT GCC ATC TTA A MtD p2_2 GTA ATC CAG GTC GGT TTC TA (SEQ ID NO:5) MtD mb_2 GGA CCC CCC ACA CCC ACC CAA GAA GAG GGT CC (SEQ ID NO:6) SnrpD p1 5′ AATTCTAATACGACTCACTATAGGG AGAGGCCCGGC (SEQ ID NO:7) ATGTGGTGCATAA 3′ SnrpD p2 5′TTCCTTACATCTCTCACCCGCTA 3′ (SEQ ID NO:8) SnrpD mb 5′GCATGCTGTAACCACGCACTCTCCTCGCATGC 3′ (SEQ ID NO:9) SnrpD2 p2 5′TGCGCCTCTTTCTGGGTGTT 3′ (SEQ ID NO:10) MtR p1 5′ AATTCTAATACGACTCACTATAGGG AGGAGAAGATG (SEQ ID NO:11) GTTAGCTCTAC 3′ MtR p2 5′CGATATGGCGTTCCCCCGCATAAA 3′ (SEQ ID NO:12) MtR mb 5′GCTCCG AAGCTTCTGACTCTTACCTCCC CGGAGC 3′ (SEQ ID NO:13) MtR p1_2 AAT TCT AAT ACG ACT CAC TAT AGG G AG AGG AGA (SEQ ID NO:14) CAC CTG CTA GGT GT MtR pl_3 AAT TCT AAT ACG ACT CAC TAT AGG G AG AAG GGT (SEQ ID NO:15) AGA CTG TTC AAC CTG TT MtR p2_2 GGT GCC CCC GAT ATG GCG TTC C (SEQ ID NO:16) MtR p2_3 GTA ATA ATC TTC TTC ATA GTA A (SEQ ID NO:17) SnrpR p1 5′AATTCTAATACGACTCACTATAGGGAGAGGCCCG (SEQ ID NO:18) GCATGTGGTGCATAA 3′ SnrpR p2 5′CAGTATGCCAAGACCGACTCAGA 3′ (SEQ ID NO:19) SnrpR mb 5′ CGTACG AGAAGAGGAAGCCCAAGAGCCA CGTACG 3′ (SEQ ID NO:20) SnrpR p1_2 AAT TCT AAT ACG ACT CAC TAT AGG G A GAA GAA (SEQ ID NO:21) GAT GAC AAA GGC CTG GCC SnrnpR p1_3 AAT TCT AAT ACG ACT CAC TAT AGG G A GAA AAA (SEQ ID NO:22) GGC CTG GCC CCT CAT CTT SnrnpR p2_2 TCC ATG GCA GTT CCC GAG A (SEQ ID NO:23) SnrnpR p2_3 CAC TAT TTA TAT CAA CAA CC (SEQ ID NO:24) SnrnpR p2_4 TCA ATG AGA AGA TCA AGA A (SEQ ID NO:25) SnrnpR mb_2 CGA TCG AGT CCC TGT ACG CCA TCT TC CGA TCG (SEQ ID NO:26) Rubisco-DNA p1 5′ AATTCTAATACGACTCACTATAGGGG GATAATTTCAT (SEQ ID NO:27) TACCTTCACGAG 3′ Rubisco-DNA p2 5′GGAGTCCTGAACTAGCCGCAG 3′ (SEQ ID NO:28) Rubisco-DNA MB 5′ GCATGC GGTAGATAAACTAGATAGCTAG GCATGC 3′ (SEQ ID NO:29) Rubisco-RNA p1 5′ AATTCTAATACGACTCACTATAGGG GAGTTGTTGTTA (SEQ ID NO:30) TTGTAAGTC 3′ Rubisco-RNA p2 5′CAAGTCTTATGAATTCCTATAG 3′ (SEQ ID NO:31) Rubisco-RNA-MB 5′GCTAGCACACAGGGTGTACCCATTATGCTAGC 3′ (SEQ ID NO:32) OryzaDNA p1 5′ AATTCTAATACGACTCACTATAGGG GGATCTTAATTA (SEQ ID NO:33) CATGCCGTTCA 3′ OryzaDNA p2 5′AAAGGTGCCGGTTCTCACTA 3′ (SEQ ID NO:34) OryzaDNA mb 5′ GCTAGC CTCTGCAAGCTTCATCAGTAATAG GCTA (SEQ ID NO:35) GC 3′ OryzaRNA p1 5′ AATTCTAATACGACTCACTATAGGG GCTAATGCCCTT (SEQ ID NO:36) TTCTTTTCTTCCTC 3′ OryzaRNA p2 5′CATATTGGCT TTCGAAGATT 3′ (SEQ ID NO:37) OryzaRNA mb 5′ GCTAGC CTTCAGCCATTATTCAAGAT (SEQ ID NO:38) GGTG GCTAGC 3′ tRNA-L-D p1 5′AATTCTAATACGACTCACTATAGGGGGGTTCTAGTTC (SEQ ID NO:39) GAGAACCGCTTG 3′ tRNA-L-D p2 5′GCGAAATCGGTAGACGCTACG 3′ (SEQ ID NO:40) tRNA-L-D MB 5′ GCTAGC CAACTTCCAAATTCAGAGAA GCTAGC 3′ (SEQ ID NO:41) petB RNA p1 5′AATTCTAATACGACTCACTATAGGGAAACCGGTA (SEQ ID NO:42) GCAACTTGTACTAG 3′ petB RNA p2 5′GGTTTCGGTATCTCTGGAATATGAG 3′ (SEQ ID NO:43) petB RNA MB 5′ GCTAGC GAGGAACGTCTTGAGATTCA GCTAGC 3′ (SEQ ID NO:44) SnrnpD mb_2 CGCATGC TGTAACCACGCACTCTCCTC GCATGCG (SEQ ID NO:45) MtD mb_3 CGTACG TGATATCATCTCAACTTAGTAT CGTACG (SEQ ID NO:46) 1 The T7 promoter part of primer p1 sequences is shown in italics, the stem sequences of the molecular beacon probes are shown in bold . The molecular beacon sequences were labeled at the 3′end with DABCYL (the quencher) and at the 5′end with 6-FAM (the fluorescent label).
[0115]
TABLE 2
Mitochondrial DNA content in PBMC of patients undergoing
different therapy regimens during 48 week follow up.
Week
Median
Interquartiles range;
AZT
0
196
111-252
4
157
103-191
24
182
123-224
48
155
110-224
AZT/ddI
0
174
150-243
4
126
89-235
24
93
42-200
48
112
66-170
AZT/ddC
0
132
83-200
4
48
36-76
24
68
29-107
48
74
51-83
[0116]
TABLE 3
Analysis of significant changes in mitochondrial DNA content
of PBMC of patients undergoing different regimens of therapy
Antiviral drugs
Week
% decrease
p-value
AZT
4
11%
0.22
24
1%
0.80
48
5%
0.55
AZT + ddI
4
13%
0.04
24
24%
0.09
48
16%
0.02
AZT + ddC
4
22%
0.002
24
22%
0.06
48
25%
0.04
[0117]
TABLE 4
Mitochondrial RNA content in PBMC of patients undergoing
different therapy regimens during 48 week follow up.
Week
Patient 1
Patient 2
0
632
680
4
1482
605
24
516
1106
48
448
not valid
[0118]
TABLE 5
Mitochondrial toxicities of nucleoside and nucleotide analogue HIV-1 RT-inhibitors.
From: A. Carr, DA Cooper, Lancet 2000; 356: 1423-1430.
Affected
Laboratory
organ
Clinical features
features
Rate (%)
Drug(s)
Muscle
Fatigue, myalgia,
Creatine
17
AZT
proximal weakness,
kinase ↑
wasting
Heart
Dilated cardio-myopathy
Rare
AZT
Nerve
Distal pain, numbness,
10-30
ddC = d4T >
paraesthesia, reduced,
ddI > 3TC
reflexes/power
Liver
Hepatomegaly, nausea,
Lactic acidosis
<1
All except,
ascites, oedema, dyspnea,
Serum lactate ↑
3TC, ABC
encephalopathy
Liver enzymes ↑
Anion gap ↓
Bicarbonate ↑
Pancreas
Abdominal pain
Amylase
<1-6
ddI > 3TC/ddC
Fat
Peripheral atrophy
50
d4T > others
Lipodystrophy
REFERENCES
[0119] 1. Saiki, R. K.; Gelfand, D. H.; Stoffel, S.; Scharf, S. J.; Higuchi, R.; Horn, G. T.; Mullis, K. B.; Erlich, H. A.: Primer-directed enzymatic amplification of DNA with a thermostable DNA polymerase. Science 239:487-491, 1988.
[0120] 2. Van Gemen, B.; van Beuningen, R.; Nabbe, A.; Van Strijp, D.; Jurriaans, S.; Lens, P.; Kievits, T.: A one-tube quantitative HIV-1 RNA NASBA nucleic acid amplification assay using electrochemiluminescent (ECL) labeled probes. J. Virol. Methods 49:157-167, 1994.
[0121] 3. Heid, C. A.; Stevens, J.; Livak, K. J.; Williams, P. M.: Real time quantitative PCR. Genome Res. 6:986-994, 1996.
[0122] 4. Tyagi, S.; Kramer, F. R.: Molecular beacons: probes that fluoresce upon hybridization. Nat. Biotechnol. 14:303-308, 1996.
[0123] 5. Leone, G.; van Schijndel, H.; Van Gemen, B.; Kramer, F. R.; Schoen, C. D.: Molecular beacon probes combined with amplification by NASBA enable homogeneous, real-time detection of RNA. Nucleic Acids Res. 26:2150-2155, 1998.
[0124] 6. Piatak, M.; Luk, K. C.; Williams, B.; Lifson, J. D.: Quantitative competitive polymerase chain reaction for accurate quantitation of HIV DNA and RNA species. Biotechniques 14:70-81, 1993.
[0125] 7 . De Baar, M. P.; van Dooren, M. W.; de Rooij, E.; Bakker, M.; Van Gemen, B.; Goudsmit, J.; and de Ronde, A.: Single rapid real-time monitored isothermal RNA amplification assay for quantification of HIV-1 isolates from group M, N, and O. J. Clin. Microbiol. 39(4):1378-1384, 2001.
[0126] 8. Boom, R.; Sol, C. J.; Salimans, M. M.; Jansen, C. L.; Wertheim-van Dillen, P. M.; van der, N. J.: Rapid and simple method for purification of nucleic acids. J. Clin. Microbiol. 28:495-503, 1990.
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The invention relates to the diagnosis of disease or the determination of functioning of cellular organisms, being of multi-cellular or unicellular nature, being visible by the naked eye or being a microorganism. The invention provides a method for determining functioning of a cellular organism comprising determining the relative ratio of a first endosymbiont cellular organelle nucleic acid and/or gene product thereof in a sample obtained from the organism in relation to the amount of a second nucleic acid and/or gene product thereof.
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FIELD OF THE INVENTION
[0001] This present invention relates to a new and improved reductive amination process for the preparation of 3-azabicyclo[3.1.0]hexane derivatives and pharmaceutical compositions comprising such derivatives. The invention particularly relates to using such derivatives to treat certain disorders and conditions, including, for example, irritable bowel syndrome, drug addiction or dependency, alcohol addiction or dependency, depression, and eating disorders.
BACKGROUND OF THE INVENTION
[0002] Compounds that bind to opiate receptors (e.g. mu, kappa and delta opioid receptors) are likely to be useful in the treatment of diseases modulated by opiate receptors, for example irritable bowel syndrome; constipation; nausea; vomiting; and pruritic dermatoses, such as allergic dermatitis and atopy in animals and humans. Compounds that bind to opiate receptors have also been indicated in the treatment of eating disorders, opiate overdoses, depression, smoking and alcohol addiction and dependence, sexual dysfunction, shock, stroke, spinal damage and head trauma.
[0003] It is furthermore beneficial to obtain drugs that bind to opioid receptors which are not substrates of the enzyme CYP2D6. The presence of CYP2D6 enzyme among the human population is variable, and therefore it is easier to develop dosage schemes for a drug that are more generally applicable to a human population if the drug is not metabolized by CYP2D6.
[0004] Certain 4-arylpiperidine-based compounds are disclosed in European patent applications EP 287339, EP 506468 and EP 506478 as opioid antagonists. In addition, International Patent Application WO 95/15327 discloses azabicycloalkane derivatives useful as neuroleptic agents. 3-Azabicyclo[3.1.0] hexane derivatives useful as opioid receptor antagonists are also disclosed in WO 00/39089.
[0005] The synthesis, composition, and methods of use of certain 3-azabicyclo[3.1.0] hexane derivatives are disclosed in U.S. Pat. No. 6,313,312 and U.S. patent application No. 2003/0087898. The present invention provides an alternative route to these compounds with improved yield.
[0006] The aforementioned patents and patent applications are incorporated herein by reference therein in their entirety.
SUMMARY OF THE INVENTION
[0007] According to the invention there is provided a process for the preparation of 3-azabicyclo[3.1.0.]hexane derivatives having the formula:
wherein X is halogen, —OH, —CN, -C 1 to C 4 alkyl substituted with one to three halogen atom, —NH 2 , —NH(C 1 -C 4 alkyl), —N(C 1 -C 4 alkyl) (C 1 -C 4 alkyl), —C(═O)NH 2 , —C(═O)NH(C 1 -C 4 alkyl), —C(═O)N(C 1 -C 4 alkyl) (C 1 -C 4 alkyl), —NHS(═O) 2 H, or —NHS(═O) 2 R 4 ;
[0008] R 1 and R 2 are, with the carbon to which they are attached, connected to form a C 3 -C 7 cycloalkyl or a 4-7 membered heterocycloalkyl comprising from one to three hetero moities selected from O, S, —C(═O), and N; and wherein said cycloalkyl or heterocycloalkyl optionally contains one or two double bonds; and wherein said cycloalkyl or heterocycloalkyl is optionally fused or attached to a C 6 -C 14 aryl or 5-14 membered heteroaryl group;
[0009] R 3 is C 1 -C 4 alkyl which may optionally contain one or two unsaturated bonds, —OH, —CN, —NO 2 , —OC 1 -C 4 alkyl, —NH 2 amide or alkyl substituted amide and n is one or zero;
[0010] R 4 is selected from C 1 -C 4 alkyl, -(C 1 -C 4 alkylene)—O-(C 1 -C 4 alkyl), 4-(1-methylimidazole), -(C 1 -C 4 alkylene)—NH 2 , -(C 1 -C 4 alkylene)—NH(C 1 -C 4 alkyl), -(C 1 -C 4 alkylene)—N(C 1 -C 4 alkyl)(C 1 -C 4 alkyl);
comprising reacting a compound of formula
with a compound of formula
in the presence of a reducing agent and an organic solvent; wherein R 1 , R 2 , R 3 , and n are as defined above.
[0011] In a preferred embodiment of the present invention R 1 and R 2 are, with the carbon to which they are attached, connected to form a C 5 cycloalkyl group. In another preferred embodiment n is zero and R 3 is —OH.
[0012] In one embodiment of the present invention, the compound of formula III is the addition product (adduct) of aqueous sodium bisulfite and an organic aldehyde of formula IV wherein the adduct exists in a solution equilibrium with sodium bisulfite and the aldehyde.
[0013] In another embodiment of the present invention, the aldehyde-bisulfite adduct in the presence of a base is substantially dissociated into sodium bisulfite and the corresponding aldehyde IV.
[0014] In another embodiment the solvent is 2-methyl-tetrahydrofuran and the base is aqueous sodium hydroxide in sufficient amount to elevate the pH of the reaction mixture to a pH of at least 9.0.
[0015] In yet another embodiment of the present invention the reducing agent is sodium triacetoxyborohydride.
[0016] In another embodiment the organic solvent is a mixture of N-methylpyrrolidone (NMP) and a C 5 -C 10 hydrocarbon, preferably cyclohexane.
[0017] In another embodiment the compound of formula III is selected from the group consisting of:
[0018] Hydroxy-(2-hydroxyindan-2-ylymethanesulfonic acid, sodium salt;
[0019] Hydroxy-[cis-1-hydroxy-3-(4-methoxy-phenyl)-cyclobutyl]-methanesulfonic acid, sodium salt;
[0020] Hydroxy-[cis-1-hydroxy-3-phenyl-cyclobutyl]-methanesulfonic acid, sodium salt;
[0021] Hydroxy-[cis-1-hydroxy-3-(4-fluoro-phenyl)-cyclobutyl]-methanesulfonic acid, sodium salt; and
[0022] Hydroxy-[cis-1-hydroxy-3-(4-bromo-phenyl)-cyclobutyl]-methanesulfonic acid, sodium salt;
[0023] In another embodiment the compound of formula I is selected from the group consisting of:
[0024] Exo-N-{3-[6-ethyl-3-(2-hydroxy-indan-2-ylmethyl)-3-aza-bicyclo[3.1.0]hex-6-yl]-phenyl}-methanesulfonamide;
[0025] Exo-{3-[6-ethyl-3-(cis-1-hydroxy-3-phenyl-cyclobutylmethyl)-3-aza-bicyclo[3.1.0]hex-6-yl]-phenyl}-propanesulfonamide;
[0026] Exo-N-{3-[6-ethyl-3-(2-hydroxy-indan-2-ylmethyl)-3-aza-bicyclo[3.1.0]hex-6-yl]-phenyl}-propanesulfonamide;
[0027] Exo-{3-[6-ethyl-3-(cis-1-hydroxy-3-(4-bromo-phenyl)-cyclobutylmethyl)-3-aza-bicyclo[3.1.0]hex-6-yl]-phenyl}-methanesulfonamide;
[0028] Exo-N-{3-[6-ethyl-3-(2-hydroxy-indan-2-ylmethyl)-3-aza-bicyclo[3.1.0]hex-6-yl]-phenyl}-(2-methoxyethane)sulfonamide;
[0029] Thiophene-2-carboxylic acid (3-fluoro-4-morpholin-4-yl-phenyl)-[Exo-3-(2-hydroxy-indan-2-ylmethyl)-3-aza-bicyclo[3.1.0]hex-6-ylmethyl]-amide; and
[0030] Exo-N-{3-[6-ethyl-3-(2-hydroxy-indan-2-ylmethyl)-3-aza-bicyclo[3.1.0]hex-6-yl]-phenyl}-ethanesulfonamide
[0031] and their pharmaceutically acceptable salts and prodrugs.
[0032] In another embodiment the compounds of formula I are used in the treatment of irritable bowel syndrome, drug addiction, alcohol addiction, depression and eating disorders.
DETAILED DESCRIPTION OF THE INVENTION
[0033] The present invention provides a new process for the preparation of selected 3-azabicyclo [3.1.0] hexane derivatives (formula I) by the reductive amination of aldehyde-bisulfite adducts of formula III with the corresponding heterocyclic amine of formula II. The synthesis of compounds of formula II is disclosed in U.S. Pat. No. 6,313,312.
[0034] In accordance with the present invention, compounds of formula I above may be prepared by the reductive amination illustrated below:
wherein X, n and R 1 through R 3 are as defined above.
[0035] As illustrated above, treatment of an amino compound of formula II with the sodium bisulfite adduct of an appropriately substituted aldehyde of formula III and a reducing agent in an organic solvent produces the corresponding compound of formula I.
[0036] Reductive aminations are discussed generally in a “Advanced Organic Chemistry”, 3 rd Ed., J. March, pp. 798-800, John Wiley & Sons, 1985, New York.
[0037] The present invention provides an alternative route to compounds of formula I in high purity and yield. Prior attempts to prepare compounds of formula I as disclosed in U.S. patent application No. 2003/0087898, utilized the free aldehyde (IV) in the reductive amination reaction described above.
[0038] In the present invention, the aldehyde-bisulfite adducts III are expected to give increased product yield by providing the aldehyde in a more stable form which is less prone to side-reactions such as, for example, dimer formation. For purposes of the present invention the term adduct refers to a compound which is the addition product of an aldehyde and sodium bisulfite.
[0039] In a preferred embodiment of the present invention, the reducing agent is sodium triacetoxyborohydride, and the organic solvent is 2-methyltetrahydrofuran or a mixture of N-methylpyrrolidone and cyclohexane.
[0040] Compounds of formula III are addition products (adducts) resulting from the reaction of aqueous sodium bisulfite and the corresponding aldehyde (IV) as illustrated below:
[0041] The adducts of formula III are isolated prior to treatment with compounds of formula II.
[0042] In one embodiment, the amine II may be treated with the adduct (III) in the form of an equilibrium mixture of aldehyde IV and sodium bisulfite. Alternatively, the amine II is treated with the adduct in the presence of a base resulting in substantial dissociation of the adduct into the aldehyde and sodium bisulfite.
[0043] The present inventors have discovered that the use of aldehyde-bisulfite adducts in the reductive-amination reaction leading to compounds of formula I provides significantly higher yield as compared to the unmodified aldehyde. For example, when the ∝ carbon contains a hydroxyl group (R 3 is —OH and n is zero), the corresponding aldehyde is unstable and highly reactive tending to form unwanted dimers and oligomers. The present invention overcomes this problem by providing a derivative of the aldehyde in the form of the bisulfite adduct which exhibits highly selective reactivity and is less prone to undergo undesirable side reactions.
[0044] Compounds of formula I are useful in treating mammals, including a human, in need thereof a disorder or condition selected from irritable bowel syndrome; constipation; nausea; vomiting; pruritic dermatoses, including allergic dermatitis and contact dermatitis; psoriasis; eczema; an insect bite; an eating disorder, including anorexia, bulimia, and obesity; depression, smoking addiction; drug addiction, including alcohol addiction, amphetamine addiction, cocaine addiction and addiction to an opiate, for example morphine, opium, or heroine; an opiate overdose; a sexual dysfunction, including erectile dysfunction and impotence; stroke; head trauma; traumatic brain injury; spinal damage; Parkinson's disease; Alzheimer's disease, age-related cognitive decline; and Attention Deficit and Hyperactivity Disorder; which composition comprises an amount of a compound of formula I effective in treating said disorder or condition and a pharmaceutically acceptable carrier.
[0045] The terms “treatment”, “treating”, and the like, refers to reversing, alleviating, or inhibiting the progress of the disorder or condition to which such term applies, or one or more symptoms of such disorder or condition. As used herein, these terms also encompass, depending on the condition of the patient, preventing the onset of a disorder or condition, or of symptoms associated with a disorder or condition, including reducing the severity of a disorder or condition or symptoms associated therewith prior to affliction with said disorder or condition. Thus, “treatment”, as used herein, can refer to administration of a compound of the invention to a subject that is not at the time of administration afflicted with the disorder or condition. “Treating” thus also encompasses preventing the recurrence of a disorder or condition or of symptoms associated therewith.
[0046] “Mammal”, as used herein, and unless otherwise indicated, means any mammal. The term “mammal” includes, for example and without limitation, dogs, cats, and humans.
[0047] References herein to disorders and conditions “mediated by an opioid receptor or receptors” indicate disorders or conditions that are caused at least in part by binding of the endogenous ligands to an opioid receptor, for example endogenous ligand binding to a mu, kappa, and/or delta opioid receptor. Examples of disorders and conditions that are mediated by an opioid receptor or receptors include, but are not limited to, irritable bowel syndrome, eating disorders, sexual dysfunction, depression, smoking and drug addictions, as well as the other specific disorders and conditions recited above.
[0048] The stereochemistry of compounds of formula I synthesized according to the methods described above can be determined using standard spectroscopic methods. Isolation of the exo diastereomer of a compound of formula I from an exo/endo mixture can be accomplished using standard separation methods know to those of ordinary skill in the art, for example crystallization or chromatographic methods.
[0049] Pharmaceutically acceptable salts of a compound of formula I can be prepared in a conventional manner by treating a solution or suspension of the corresponding free base or acid with one chemical equivalent of a pharmaceutically acceptable acid or base. Conventional concentration or crystallization techniques can be employed to isolate the salts. Illustrative of suitable acids are acetic, lactic, succinic, maleic, tartaric, citric, gluconic, ascorbic, benzoic, cinnamic, fumaric, sulfuric, phosphoric, hydrochloric, hydrobromic, hydroiodic, sulfamic, sulfonic acids such as methanesulfonic, benzene sulfonic, p-toluenesulfonic, and related acids. Illustrative bases are sodium, potassium, and calcium.
[0050] A compound of this invention may be administered alone or in combination with pharmaceutically acceptable carriers, in either single or multiple doses. Suitable pharmaceutical carriers include inert solid diluents or fillers, sterile aqueous solutions and various organic solvents. The pharmaceutical compositions formed by combining a compound of formula I or a pharmaceutically acceptable salt thereof can then be readily administered in a variety of dosage forms such as tablets, powders, lozenges, syrups, injectable solutions and the like. These pharmaceutical compositions can, if desired, contain additional ingredients such as flavorings, binders, excipients and the like. Thus, for purposes of oral administration, tablets containing various excipients such as sodium citrate, calcium carbonate and calcium phosphate may be employed along with various disintegrants such as starch, methylcellulose, alginic acid and certain complex silicates, together with binding agents such as polyvinylpyrrolidone, sucrose, gelatin and acacia. Additionally, lubricating agents such as magnesium stearate, sodium lauryl sulfate and talc are often useful for tabletting purposes. Solid compositions of a similar type may also be employed as fillers in soft and hard filled gelatin capsules. Preferred materials for this include lactose or milk sugar and high molecular weight polyethylene glycols. When aqueous suspensions or elixirs are desired for oral administration, the essential active ingredient therein may be combined with various sweetening or flavoring agents, coloring matter or dyes and, if desired, emulsifying or suspending agents, together with diluents such as water, ethanol, propylene glycol, glycerin and combinations thereof.
[0051] For parenteral administration, solutions containing a compound of this invention or a pharmaceutically acceptable salt thereof in sesame or peanut oil, aqueous propylene glycol, or in sterile aqueous solution may be employed. Such aqueous solutions should be suitably buffered if necessary and the liquid diluent first rendered isotonic with sufficient saline or glucose. These particular aqueous solutions are especially suitable for intravenous, intramuscular, subcutaneous and intraperitoneal administration. The sterile aqueous media employed are all readily available by standard techniques known to those skilled in the art.
[0052] A compound of formula I or a pharmaceutically acceptable salt thereof can be administered orally, transdermally (e.g., through the use of a patch), parenterally (e.g. intravenously), rectally, topically, or by inhalation. In general, the daily dosage for treating a disorder or condition as described herein using a compound of formula I will be about from about 0.01 to about 100 mg per kg, preferably from about 0.1 to about 10 mg per kg, of the body weight of the animal to be treated. As an example, a compound of the formula I, or a pharmaceutically acceptable salt thereof, can be administered for treatment to an adult human of average weight (about 70 kg) in a dose ranging from about 0.5 mg up to about 10 g per day, preferably from about 10 mg to about 1 g per day, in single or divided (i.e., multiple) portions. Variations based on the aforementioned dosage ranges may be made by a physician of ordinary skill taking into account known considerations such as the weight, age, and condition of the animal being treated, the severity of the affliction, and the particular route of administration chosen.
[0053] Affinity of a compound for the delta opioid receptor can be assessed using binding of the delta opioid receptor ligand [3H]-naltrindole to NG108-15 neuroblastoma-glioma cells according to modification of the protocol described in Law et al. (Law, P. Y., Koehler, J. E. and Loh, H. H., “Comparison of Opiate Inhibition of Adenylate Cyclase Activity in Neuroblastoma N18TG2 and Neuroblastoma X Glioma NG108-15 Hybrid Cell Lines”, Molecular Pharmacology, 21: 483-491 (1982)). Law et al. is incorporated herein in its entirety by reference. Affinity of a compound for the kappa opioid receptor can be assessed using binding of [ 3 H]-bremazocine to kappa receptors as described in Robson, L. E., et al., “Opioid Binding Sites of the Kappa-type in Guinea-pig Cerebellum”, Neuroscience ( Oxford ), 12(2): 621-627 (1984). Robson et al. is incorporated herein it its entirey by reference. For assessment of a compound for mu opioid receptor activity, the mu receptor ligand [ 3 H]-DAMGO (Perkin Elmer Life Sciences, Boston, Mass.; specific activity 55 Ci/mmol, 1.5 nM) is used with rat forebrain tissue. Briefly, the binding is initiated with the addition of a crude membrane preparation of rat forebrain tissue to 96-well polypropylene plates containing the radioligand [ 3 H]-DAMGO and test compound, and are incubated for about 90 minutes at about 25° C. The assay is terminated by rapid filtration with 50 mM Tris HCl pH 7.4 onto Wallac Filtermat B and counted on a Betaplate reader (Wallac).
[0054] The data generated can be analyzed using IC 50 analysis software in Graphpad Prism. Ki values can be calculated using Graphpad Prism according to the following formula:
Ki=IC 50 /1+[ 3 H ligand]/K o
[0055] where IC 50 is the concentration at which 50% of the 3 H ligand is displaced by the test compound and K D is the dissociation constant for the 3 H ligand at the receptor site.
EXAMPLE 1
[0056]
[0057] Reductive amination, General Method A: Exo-N-{3-[6-ethyl-3-(2-hydroxy-indan-2-ylmethyl)-3-aza-bicyclo[3.1.0]hex-6-yl]-phenyl}-methanesulfonamide.
[0058] Exo-N-{3-[6-ethyl-3-aza-bicyclo[3.1.0]hex-6-yl]-phenyl}-methanesulfonamide (5.00 g, 12.7 mmol) and hydroxy-(2-hydroxyindan-2-yl)-methanesulfonic acid, sodium salt (7.43 g, 50% by weight with NaHSO 3 , 14.0 mmol) were combined in 50 mL N-methylpyrrolidone. Cyclohexane (25 mL) was added, and the slurry heated in a 110° C. oil bath. The mixture was distilled through a short path condenser to remove the water-cyclohexane azeotrope, collecting ca. 20 mL. The resulting solution was maintained at 105° C. for 20 min, then cooled to room temperature. Sodium triacetoxyborohydre (4.03 g, 19.0 mmol) was then added in a single portion. After 20 min, LC/MS analysis indicated complete conversion to the desired product. The reaction was quenched by careful addition of 10 mL water, diluted with 10% aq Na 2 CO 3 and brine, then extracted with two 50 mL portions of EtOAc. The organic extracts were combined and concentrated to provide 5.3 g of product (free base) as a brown oil. Addition of methanesulfonic acid in 2:1 EtOAc-EtOH provided the mesylate salt in 54% overall yield (3.58 g).
EXAMPLE 2
[0059] Reductive amination, General Method B: Exo-N-{3-[6-ethyl-3-(2-hydroxy-indan-2-ylmethyl)-3-aza-bicyclo[3.1.0]hex-6-yl]-phenyl}-methanesulfonamide.
[0060] Exo-N-{3-[6-ethyl-3-aza-bicyclo[3.1.0]hex-6-yl]-phenyl}-methanesulfonamide (12.0 g, 30.4 mmol) and (2-hydroxyindan-2-yl)-carboxaldehyde (10.8 g, 66.7 mmol, as a solution in 150 mL 2-Me-THF)** were combined. The solution was heated to distill off water as its azeotrope with 2-Me-THF, collecting ca. 100 mL of distillate. The solution was cooled to room temperature, then treated portionwise with 12.9 g Na(OAc) 3 BH (12.9 g, 61 mmol) and stirred overnight. The reaction was quenched by addition of 100 mL 20% Na 2 CO 3 (aq), and the phases separated. The aqueous phase was washed with water, then concentrated to an oil. Ethyl acetate (65 mL) and ethanol (32 mL) were added, and methanesulfonic acid (2.0 mL, 31 mmol) was added dropwise over 5 min. The resulting solids were stirred overnight, then cooled to 0° C. for 30 min. Filtration, rinsing with cold ethyl acetate, provided 11.3 g pale yellow solids (71% yield).
[0061] **Bisulfite adduct break: The bisulfite adduct (hydroxy-(2-hydroxyindan-2-yl)-methanesulfonic acid, sodium salt) is partitioned between 8 volumes (mL/g) water and 10 volumes 2-Me-THF. Three volumes of 1 N NaOH are then slowly added, to provide an aqueous pH of 9-10. The phases are separated, and the organic phase washed with two 5 volume portions of 20% Na 2 CO 3 (aq). The 2-Me-THF solution is used directly in the above process (an aliquot is concentrated to provide the concentration of aldehyde).
EXAMPLE 3
[0062]
[0063] Exo-{3-[6-ethyl-3-(cis-1-hydroxy-3-phenyl-cyclobutylmethyl)-3-aza-bicyclo[3.1.0]hex-6-yl]-phenyl}-propanesulfonamide:
[0064] Following general Method B, Exo-{3-[6-ethyll-3-aza-bicyclo[3.1.0]hex-6-yl]-phenyl}-propanesulfonamide hydrochloride I (50 mg, 0.16 mmol) and hydroxy-[cis-1-hydroxy-3-phenyl-cyclobutyl]-methanesulfonic acid, sodium salt (100 mg, 0.32 mmol) were coupled to provide the title compound.
EXAMPLE 4
[0065]
[0066] Exo-N-{3-[6-ethyl-3-(2-hydroxy-indan-2-ylmethyl)-3-aza-bicyclo[3.1.0]hex-6-yl]-phenyl}-propanesulfonamide:
[0067] Following General Method B, Exo-N-{3-[6-ethyl-3-aza-bicyclo[3.1.0]hex-6-yl]-phenyl}-propanesulfonamide hydrochloride (215 mg, 0.32 mmol) and hydroxy-(2-hydroxyindan-2-yl)-methanesulfonic acid, sodium salt (215 mg, 0.80 mmol) were coupled to provide the title compound.
EXAMPLE 5
[0068]
[0069] Exo-{3-[6-ethyl-3-(cis-1-hydroxy-3-(4-bromo-phenyl)-cyclobutylmethyl)-3-aza-bicyclo[3.1.0]hex-6-yl]-phenyl}-methanesulfonamide:
[0070] Following General Method B, Exo-{3-[6-ethyl-3-aza-bicyclo[3.1.0]hex-6-yl]-phenyl}-methanesulfonamide trifluoroacetate (100 mg, 0.25 mmol) and hydroxy-[cis-1-hydroxy-3-(4-bromo-phenyl)-cyclobutyl]-methanesulfonic acid, sodium salt (183 mg, 0.51 mmol) were coupled to provide the title compound.
EXAMPLE 6
[0071]
[0072] Exo-N-{3-[6-ethyl-3-(2-hydroxy-indan-2-ylmethyl)-3-aza-bicyclo[3.1.0]hex-6-yl]-phenyl}-(2-methoxyethane)sulfonamide:
[0073] Following General Method B, Exo-N-{3-[6-ethyl-3-aza-bicyclo[3.1.0]hex-6-yl]-phenyl}-(2-methoxyethane)sulfonamide trifluoroacetate (5.4 g, 12 mmol) and hydroxy-(2-hydroxyindan-2-yl)-methanesulfonic acid, sodium salt (8.2 g, 31 mmol) were coupled to provide the title compound.
EXAMPLE 7
[0074]
[0075] Thiophene-2-carboxylic acid (3-fluoro-4-morpholin-4-yl-phenyl)-[Exo-3-(2-hydroxy-indan-2-ylmethyl)-3-aza-bicyclo[3.1.0]hex-6-ylmethyl]-amide:
[0076] Following General Method B, Thiophene-2-carboxylic acid (3-fluoro-4-morpholin-4-yl-phenyl)-[Exo-3-aza-bicyclo[3.1.0]hex-6-ylmethyl]-amide (100 mg, 0.25 mmol) and hydroxy-(2-hydroxyindan-2-yl)-methanesulfonic acid, sodium salt (166 mg, 0.62 mmol) were coupled to provide the title compound.
EXAMPLE 8
[0077]
[0078] Exo-N-{3-[6-ethyl-3-(2-hydroxy-indan-2-ylmethyl)-3-aza-bicyclo[3.1.0]hex-6-yl]-phenyl}-ethanesulfonamide:
[0079] Following General Method B, Exo-N-{3-[6-ethyl-3-aza-bicyclo[3.1.0]hex-6-yl]-phenyl}-ethanesulfonamide (400 mg, 1.36 mmol) and hydroxy-(2-hydroxyindan-2-yl)-methanesulfonic acid, sodium salt (907 mg, 3.40 mmol) were coupled to provide the title compound.
EXAMPLE 9
[0080]
[0081] Bisulfite Adduct Formation, General Method C: Sodium hydroxy-(2-hydroxyindan-2-yl)-methanesulfonate
[0082] (The following representative procedure is taken from Ragan et al., Org. Process Res. Dev. 2003, 7, 155-160). 2-Vinyl-indan-2-ol (15.0 g, 93.6 mmol) was dissolved in 150 mL MeOH, cooled to −78° C., and treated with a stream of ozone generated from O 2 . The dark solution became lighter in color after ca. 15 min, and HPLC analysis indicated consumption of starting material. Oxygen was bubbled through the solution for 5 min, then a stream of nitrogen was bubbled through for 30 min. A slurry of NaHSO 3 (19.5 g, 187 mmol) in 15 mL water was then added, and the mixture was allowed to gradually warm to room temperature. After 30 min, a starch-Kl strip tested negative for peroxides. The slurry was then heated to 60° C. for 30 min to complete formation of the bisulfite adduct. After cooling to room temperature and stirring for 2 h, the resulting solids were collected and rinsed with methanol (2×30 mL), to provide the desired product as a while powder (16.2 g, 61% yield from 2-indanone). Combustion analysis of this material indicated 56% purity (Anal. Calcd for C 10 H 11 SO 5 Na: C, 45.1; H, 4.2. Found: C, 25.2; H, 2.6). Recrystallization from 10 volumes of water provided analytically pure material in 47% recovery (8.01 g recrystallized from 80 mL water, isolated 3.75 g analytically pure 2):
EXAMPLE 10
[0083]
[0084] Hydroxy-[cis-1-hydroxy-3-(4-methoxy-phenyl)-cyclobutyl]-methanesulfonic acid, sodium salt:
[0085] Following General Procedure C, cis-3-(4-methoxy-phenyl)-1-vinyl-cyclobutanol was converted into the title compound.
EXAMPLE 11
[0086]
[0087] Hydroxy-[cis-1-hydroxy-3-phenyl-cyclobutyl]-methanesulfonic acid, sodium salt:
[0088] Following General Procedure C, cis-3-phenyl-1-vinyl-cyclobutanol was converted into the title compound.
EXAMPLE 12
[0089]
[0090] Hydroxy-[cis-1-hydroxy-3-(4-fluoro-phenyl)-cyclobutyl]-methanesulfonic acid, sodium salt:
[0091] Following General Procedure C, cis-3-(4-fluoro-phenyl)-1-vinyl-cyclobutanol was converted into the title compound.
EXAMPLE 13
[0092]
[0093] Hydroxy-[cis-1-hydroxy-3-(4-bromo-phenyl)-cyclobutyl]-methanesulfonic acid, sodium salt:
[0094] Following General Procedure C, cis-3-(4-bromo-phenyl)-1-vinyl-cyclobutanol was converted into the title compound.
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This present invention relates to a new and improved reductive amination process for the preparation of 3-azabicyclo[3.1.0]hexane derivatives and pharmaceutical compositions comprising such derivatives. The invention particularly relates to using such derivatives to treat certain disorders and conditions, including, for example, irritable bowel syndrome, drug addiction or dependency, alcohol addiction or dependency, depression, and eating disorders.
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BACKGROUND OF THE INVENTION
This invention relates to aluminum and more particularly, it relates to heating and melting aluminum with very high efficiency and with remarkably low melt loss or skim generation.
Aluminum is melted either continuously, that is, continuous recirculation or in static furnaces using natural gas. In natural gas fired reverberatory continuous melting furnaces, aluminum is recirculated using a molten metal pump, from the furnace, through a side bay or aluminum charging bay to a molten metal treatment bay and then back to the furnace. Aluminum metal to be melted is submerged in the charging bay. The skim or dross and other impurities resulting from the melting are removed in the melt treatment bay. Heat usually generated using natural gas is applied in the furnace.
In static furnaces, aluminum metal is charged directly to the furnace or through an open charge bay. Metal treatment may be provided using a side bay.
This method melting has the problem that it is very inefficient. That is, these furnaces operate at a 22-30% thermal efficiency because heat transfer to the melt in the furnace is effected by radiation from overhead natural gas burners to the melt. In this method of heating, large quantities of heated gases are lost as they are exhausted up the stack, creating environmental problems. This method of heating has the disadvantage that the surface temperature of the melt increases dramatically, resulting in significant skim generation and in melt loss due to oxidation of the molten aluminum. The problem is aggravated as a layer of aluminum oxide or skim forms on the surface of the melt. That is, the layer of aluminum oxide formed on the surface operates as a thermal barrier or insulator to the natural gas fire flames impinging on the surface. Aluminum oxide has a characteristically low thermal conductivity and therefore greatly inhibits heat transfer to the molten aluminum. Thus, not only is this method of heating thermal inefficient, as noted, but this method results in very high levels of melt loss due to the high surface temperature and conversion of aluminum to aluminum oxide. That is, melt loss is a significant problem encountered in this method of heating, generally averaging 2 to 5%. The high levels of skim generated in melting requires intensive molten metal treatment downstream to remove entrained skim particles.
As an alternative to reverberatory furnaces, induction melting, which can be either channel or coreless, has been used. However, coreless induction furnaces only have a thermal efficiency of about 60 to 70%, have to use a water cooled inductor surrounding the crucible and have to use a complex power supply to maintain a power factor of near unity for efficiency purposes. The power supplies are large, involve a reactor and capacitor and also must use water cooling.
Induction heating also has the problem that it stirs or agitates the melt. This constantly exposes new surface air which oxidizes the metal to form aluminum oxide.
The oxides along with other impurities are mixed into the melting, resulting in serious metal quality problems. This requires intensive metal treatment with gases and/or salts downstream. This results in environmental problems from disposing of the salts. Also, it adds greatly to the expense of producing high quality metal.
Thus, it will be seen that there is a great need in the aluminum industry for a highly efficient melting system where a large portion of the heat applied is not wasted and which greatly minimizes skim or dross generation and its attendant problems of removing and treating in an environmentally responsible manner.
The present invention provides such a heating and melting system.
SUMMARY OF THE INVENTION
It is an object of this invention to provide an improved method and system for heating and/or melting aluminum.
It is a further object of this invention to provide a highly efficient system for heating and/or melting aluminum.
It is yet a further object of this invention to provide a system for heating and/or melting aluminum having greatly reduced skim or dross generation.
Yet, it is a further object of this invention to provide a recirculating system for heating and/or melting aluminum wherein the heat utilization is near 100% because of less containment losses.
And still it is a further object of this invention to provide a system for heating and melting aluminum having significantly reduced melt loss, e.g., less than 4% and typically less than 2%, resulting from oxidation of the melt.
Still yet, it is another object of this invention to provide a substantially closed system having minimal access to air to thereby minimize oxidation of molten aluminum.
And still yet, it is another object of this invention to provide a portable heat generating means such as a turbo alternator for electric power generation and utilization of exhaust heat to heat or condition solid charge to be melted.
These and other objects will become apparent from a reading of the specification and claims appended hereto.
In accordance with these objects, there is provided a method and system of heating a body of molten aluminum, for example, contained in a heating bay, the method comprising providing a body of molten aluminum; projecting an electric powered heater into the body of molten aluminum; passing electric current through the element and adding heat to the body of molten aluminum. The heater is comprised of a sleeve suitable for immersing in the molten aluminum. The sleeve may have a closed end and is comprised of a composite material comprised of an inner layer of metal such as titanium or titanium alloy having an outside surface having a refractory coating thereon exposed to the molten aluminum, the refractory coating resistant to attack by the molten aluminum. An electric heating element is located in the sleeve in heat transfer relationship therewith for adding heat to the molten aluminum.
BRIEF DESCRIPTION OF DRAWINGS
FIG. 1 is a schematic of a system for heating and/or melting aluminum in accordance with the invention.
FIG. 2 is a schematic of an electric heater for use in a heating bay or channel, for example, for supplying heat for heating and/or melting aluminum in accordance with the invention.
FIG. 3 is a cross-sectional view of an electric heater assembly showing a heating element wire insulated by a contact medium from a protective sleeve.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, there is shown a schematic of a recirculating system for heating and/or melting metal such as aluminum. In the system, a molten aluminum reservoir 200 is provided and molten aluminum is recirculated along line 202 to a pumping bay 204 which operates to pump molten metal from reservoir 200 and through subsequent steps. Molten aluminum is removed from reservoir 200 along line 206 for casting, for example. Any type of molten aluminum pump may be used which efficiently recirculates molten aluminum through the subsequent treatment stages. Such pumps or impellers are disclosed in U.S. Pat. Nos. 3,997,336 and 4,128,415, for example, incorporated herein by reference.
After the pumping stage, the molten aluminum is removed or conveyed along line 206 to heating bay or stage 208. In bay 208, heat is added for purposes of melting solid aluminum charged in a subsequent bay. Typically, the melt is heated to a temperature in the range of about 1200° to 1500° F. in heat bay 208. Heating bay 208 is accomplished by either electric powered immersion heaters or by electric powered radiation heaters (described hereinafter) mounted close to the surface of the molten metal, e.g., 1/2 to 18 inches from the surface of the molten aluminum. When radiation heat is used, it is preferred that heating bay 208 is covered with an insulating cover to capture radiant heat and direct it towards the melt.
After heating, molten aluminum is then directed along line 210 to a charging bay 212 where aluminum metal is added for purposes of melting. It should be understood that pumping and melting may be performed in the same bay. For purposes of melting the solid aluminum, the charge may be forcibly submerged along with fluxing salts by any suitable means to accelerate the melting process, such as disclosed in U.S. Pat. Nos. 3,997,336; 4,128,415 and 4,286,985, incorporated herein by reference. After ingesting the solid aluminum, the melt is conveyed along line 214 to metal treatment bay 216 wherein the metal can be treated for purposes of removing impurities such as dissolved gases, e.g., hydrogen, fluxing salts, and undissolved solid particles such as metal oxides. The metal treatment in bay 216 can comprise treatment with a fluxing gas to remove the impurities to the surface of the melt to form a skim layer which can be removed. Fluxing may be achieved by any fluxing means, for example, using a unidirectional impeller but is preferably carried out by the process and apparatus using a bi-directional impeller disclosed in U.S. Pat. Nos. 5,364,450; 5,462,580; 5,462,581; 5,616,167; and 5,630,863, incorporated herein by reference as if specifically set forth.
After the melt has been treated in metal treatment bay 216, it is recirculated back into molten metal reservoir 200 from where the molten metal is withdrawn along line 206, as needed.
The theoretical amount of heat required to be added in heating bay 208 and the cost thereof can be calculated as follows: ##EQU1## Q=heat addition rate, BTU/hr W Al =charge rage of aluminum, lb/hr
Cp=heat capacity of aluminum alloy
T 1 -T 2 =metal entry and exit temperatures dT
dT=temperature
H m =heat of melting example:
W Al =20,000 lb/hr (rate of solid aluminum)
T 1 =temperature of solid charge aluminum, 100° F.
T 2 =melt temperature, 1350° F. Q=20,000 0.225(1350-100)+168!=8.99×10 6 BTU/hr (heating rate)
This is the next heat inputrate required for conditions as specified.
Using natural gas heat at 26% thermal efficiency: ##EQU2##
At a typical commercial price for natural gas of $4.50/MCF, the cost to melt aluminum at 20,000 lb/hr is $148.19/hr.
If electric induction melting is used at 63% thermal efficiency: ##EQU3##
At a typical commercial price for electricity of $0.015/KW-H, the cost is $62.72/hr.
For melting in accordance with the invention, the cost is: ##EQU4## This is exclusive of melt loss,
For a typical ingot plant using solid charge with a monthly throughput of 100 million lb/month, the savings using the process of the invention are about $2 million/month, taking melt loss into consideration. For some companies, this can be a savings of $100 million per year.
While the process or system is shown utilizing heating bay 208, it should be understood that bay 208 is used for illustration purposes. That is, heat can be applied in line or channel 202 or in line or channel 206 utilizing the heating means of the present invention. Further, heat may be applied to the melt just prior to it being withdrawn from reservoir 200 at 202A. It will be appreciated that heat can be applied anywhere in reservoir 200; however, by applying heat at location 202A, hotter molten metal can be recirculated. Or, heat can be applied at several locations when the heat is supplied in accordance with the present invention.
The present invention has the advantage that it greatly reduces melt loss.
Melt loss is the amount of molten aluminum that is lost in the heating and/or melting process to the formation of aluminum oxide and the metallic aluminum that becomes entrained therein. This combination is often referred to as skim or dross and may have other materials such as fluxing salts entrained or entrapped therein. The skim or dross requires intensive processing to recover free metallic aluminum therefrom and presents an environmental disposal problem because of the salt content. The amount of aluminum lost to skim is quite large and is only one of the considerable detriments of the conventional melting and heating systems. Melt loss due to conventional heating and/or melting can be as high as 5%. Thus, for every million pounds of aluminum heated or melted, 50,000 pounds are lost to skim or dross. The direct cost in terms of melt loss is extremely high. Indirect costs are incurred in terms of skim treatments for environmental reasons and recovery of entrained metal. However, the cost in terms of inefficient heating, for example, 25% efficiency, is also extremely high because the inefficient heating applies to the total pounds of aluminum heated or melted. Because of inefficient heating, the size of furnaces utilized is very large, often being five times larger than required, also adding greatly to construction costs and heating costs to maintain temperature in such conventional furnaces.
The heating system in accordance with the present invention employs high watt density immersion heaters capable of watt densities of 25 to 375 watts/in 2 of heater surface for applying heat to the melt beneath the surface of the melt where substantially all the heat generated is applied to the melt with only minimal heat losses. That is, compared to conventional heating of 25% efficiency, the present invention results in a heating efficiency of greater than 90% and typically greater than 95% efficiency, with only minimal melt loss, typically 1 to 2%, depending to some extent on the heating and/or melting operation and cleanliness of the solid metal being melted.
Referring to FIG. 2, there is shown a schematic of an electric heater assembly 10 for use in the heating and/or melting system of the invention. The electric heater assembly is comprised of a protective sleeve 12 and an electric heating element 14. A lead 18 extends from electric heating element 14 and terminates in a plug 20 suitable for plugging into a power source. A suitable element 14 is available from International Heat Exchange, Inc., Yorba Linda, Calif. 92687 under the designation Maxi-Zone, or Ogden Manufacturing Co., Arlington Heights, Ill. 60005.
Preferably, protective sleeve 12 is comprised of titanium tube 30 having an end 32 which preferably is closed. While the protective sleeve is illustrated as a tube, it will be appreciated that any configuration that protects or envelops electric heating element 14 may be employed. Thus, reference to tube or sleeve herein is meant to include such configurations. A refractory coating 34 is employed which is resistant to attack by the environment in which the electric heater assembly is used. A bond coating may be employed between the refractory coating 34 and titanium tube 30. Electric heating element 14 is seated or secured in tube 30 by any convenient means. For example, swaglock nuts and ferrules may be employed or the end of the tube may be crimped or swaged shut to provide a secure fit between the electric heating element and tube 30. Alternatively, welding can be used. In the invention, any of these methods of holding the electric heating element in tube 30 may be employed. It should be understood that tube 30 does not always have to be sealed. In one embodiment, electric heating element 14 is encapsulated in a metal tube 15, e.g., steel or Inconel tube, which is then inserted into tube 30 to provide an interference or friction fit. The present invention contemplates and prefers a heating element 14 without a metal tube 15. It is preferred that electric heating element 14, when it utilizes a metal tube 15, has the outside surface of tube 15 in contact with the inside surface of tube 30 to promote heat transfer through tube 30 into the molten metal. Thus, air gaps between the surface of metal tube 15 of electric heating element 14 and inside surface of tube 30 should be minimized.
If electric heating element 14 is inserted in tube 30 with a friction fit, the fit gets tighter with heat because electric heating element 14 expands more than tube 30, particularly when tube 30 is formed from titanium.
While it is preferred to fabricate tube 30 out of a titanium base alloy, tube 10 may be fabricated from any metal or metalloid material suitable for contacting molten metal and which material is resistant to dissolution or has controlled dissolution or erosion by the molten metal. Other materials that may be used to fabricate tube 30 include niobium, chromium, molybdenum, combinations of NiFe (364 NiFe) and NiTiC (40 Ni 60TiC), particularly when such materials have low thermal expansion, all referred to herein as metals. Other metals suitable for tube 30 include: 400 series stainless steel including 410, 416 and 422 stainless steel; Greek ascoloy; precipitation hardness stainless steels, e.g., 15-7 PH, 174-PH and AM350; Inconel; nickel based alloys, e.g., Unitemp 1753; Kovar, Invar, Super Nivar, Elinvar, Fernico, Fernichrome; metal having composition 30-68 wt. % Ni, 0.02-0.2 wt. % Si, 0.01-0.4 wt. % Mn, 48-60 wt. % Co, 9-10 wt. % Cr, the balance Fe. For protection purposes, it is preferred that the metal or metalloid be coated with a material such as a refractory resistant to attack by molten metal and suitable for use as a protective sleeve. Alternatively, cast iron tubes may be employed, for example, for molten aluminum without a protective refractory coating. However, cast iron tubes have a dissolution rate in molten aluminum in the range of 0.0033 to 0.167 in 2 of area loss/in 2 of original area/hr.
Further, the material or metal of construction for tube 30 may have a thermal conductivity of less than 30 BTU/ft hr °F., and less than 15 BTU/ft hr °F., with material having a thermal conductivity of less than 10 BTU/ft hr °F. being useful. Another important feature of a desirable material for tube 30 is thermal expansion. Thus, a suitable material should have a thermal expansion coefficient of less than 15×10 -6 in/in/°F., with a preferred thermal expansion coefficient being less than 10×10 -6 in/in/°F., and the most preferred being less than 7.5×10 -6 in/in/°F. and typically less than 5×10 -6 in/in/°F. The material or metal useful in the present invention can have a controlled chilling power. Chilling power is defined as the product of heat capacity, thermal conductivity and density. Thus, the metal in accordance with the invention may have a chilling power of less than 5000 BTU 2 /ft 4 hr °F., preferably less than 2000 BTU 2 /ft 4 hr °F., and typically in the range of 100 to 750 BTU 2 /ft 4 hr °F.
As noted, the preferred material for fabricating into tubes 30 is a titanium base material or alloy having a thermal conductivity of less than 30 BTU/ft hr °F., preferably less than 15 BTU/ft hr °F., and typically less than 10 BTU/ft hr °F., and having a thermal expansion coefficient less than 15×10 -6 in/in/°F., preferably less than 10×10 -6 in/in/°F., and typically less than 5×10 -6 in/in/°F. The titanium material or alloy should have a chilling power as noted, and for titanium, the chilling power can be less than 500, and preferably less than 400, and typically in the range of 100 to 300 BTU/ft 2 hr °F.
When the electric heater assembly is being used in molten metal such as lead, for example, the titanium base alloy need not be coated to protect it from dissolution. For other metals, such as aluminum, copper, steel, zinc and magnesium, refractory-type coatings should be provided to protect against dissolution of the metal or metalloid tube by the molten metal. By the use of titanium herein in meant to include titanium and titanium alloys.
For most molten metals, the titanium alloy that should be used is one that preferably meets the thermal conductivity requirements, the chilling power and, more importantly, the thermal expansion coefficient noted herein. Further, typically, the titanium alloy should have a yield strength of 30 ksi or greater at room temperature, preferably 70 ksi, and typical 100 ksi. The titanium alloys included herein and useful in the present invention include CP (commercial purity) grade titanium, or alpha and beta titanium alloys or near alpha titanium alloys, or alpha-beta titanium alloys. The alpha or near-alpha alloys can comprise, by wt. %, 2 to 9 Al, 0 to 12 Sn, 0 to 4 Mo, 0 to 6 Zr, 0 to 2 V and 0 to 2 Ta, and 2.5 max. each of Ni, Nb and Si, the remainder titanium and incidental elements and impurities.
Specific alpha and near-alpha titanium alloys contain, by wt. %, about:
(a) 5 Al, 2.5 Sn, the remainder Ti and impurities.
(b) 8 Al, 1 Mo, 1 V, the remainder Ti and impurities.
(c) 6 Al, 2 Sn, 4 Zr, 2 Mo, the remainder Ti and impurities.
(d) 6 Al, 2 Nb, 1 Ta, 0.8 Mo, the remainder Ti and impurities.
(e) 2.25 Al, 11 Sn, 5 Zr, 1 Mo, the remainder Ti and impurities.
(f) 5 Al, 5 Sn, 2 Zr, 2 Mo, the remainder Ti and impurities.
The alpha-beta titanium alloys comprise, by wt. %, 2 to 10 Al, 0 to 5 Mo, 0 to 5 Sn, 0 to 5 Zr, 0 to 11 V, 0 to 5 Cr, 0 to 3 Fe, with 1 Cu max., 9 Mn max., 1 Si max., the remainder titanium, incidental elements and impurities.
Specific alpha-beta alloys contain, by wt. %, about:
(a) 6 Al, 4 V, the remainder Ti and impurities.
(b) 6 Al, 6 V, 2 Sn, the remainder Ti and impurities.
(c) 8 Mn, the remainder Ti and impurities.
(d) 7 Al, 4 Mo, the remainder Ti and impurities.
(e) 6 Al, 2 Sn, 4 Zr, 6 Mo, the remainder Ti and impurities.
(f) 5 Al, 2 Sn, 2 Zr, 4 Mo, 4 Cr, the remainder Ti and impurities.
(g) 6 Al, 2 Sn, 2 Zn, 2 Mo, 2 Cr, the remainder Ti and impurities.
(h) 10 V, 2 Fe, 3 Al, the remainder Ti and impurities.
(i) 3 Al, 2.5 V, the remainder Ti and impurities.
The beta titanium alloys comprise, by wt. %, 0 to 14 V, 0 to 12 Cr, 0 to 4 Al, 0 to 12 Mo, 0 to 6 Zr and 0 to 3 Fe, the remainder titanium and impurities.
Specific beta titanium alloys contain, by wt. %, about:
(a) 13 V, 11 Cr, 3 Al, the remainder Ti and impurities.
(b) 8 Mo, 8 V, 2 Fe, 3 Al, the remainder Ti and impurities.
(c) 3 Al, 8 V, 6 Cr, 4 Mo, 4 Zr, the remainder Ti and impurities.
(d) 11.5 Mo, 6 Zr, 4.5 Sn, the remainder Ti and impurities.
When it is necessary to provide a coating to protect tube 30 of metal or metalloid from dissolution or attack by molten metal, a refractory coating 34 is applied to the outside surface of tube 30. The coating should be applied above the level to which the electric heater assembly is immersed in the molten metal. The refractory coating can be any refractory material which provides the tube with a molten metal resistant coating. The refractory coating can vary, depending on the molten metal. Thus, a novel composite material is provided permitting use of metals or metalloids having the required thermal conductivity and thermal expansion for use with molten metal which heretofore was not deemed possible.
Because titanium or titanium alloy readily forms titanium oxide, it is important in the present invention to avoid or minimize the formation of titanium oxide on the surface of titanium tube 30 to be coated with a refractory layer. That is, if oxygen permeates the refractory coating, it can form titanium oxide and eventually cause spalling of the refractory coating and failure of the heater. To minimize or prevent oxygen reacting with the titanium, a layer of titanium nitride is formed on the titanium surface. The titanium nitride is substantially impermeable to oxygen and can be less than about 1 μn thick. The titanium nitride layer can be formed by reacting the titanium surface with a source of nitrogen, such as ammonia, to provide the titanium nitride layer.
When the electric heater assembly is to be used for heating molten metal such as aluminum, magnesium, zinc, or copper, etc., a refractory coating may comprise at least one of alumina, zirconia, yittria stabilized zirconia, magnesia, magnesium titanite, or mullite or a combination of alumina and titania. While the refractory coating can be used on the metal or metalloid comprising the tube, a bond coating can be applied between the base metal and the refractory coating. The bond coating can provide for adjustments between the thermal expansion coefficient of the base metal alloy, e.g., titanium, and the refractory coating when necessary. The bond coating thus aids in minimizing cracking or spalling of the refractory coat when the tube is immersed in the molten metal or brought to operating temperature. When the electric beater assembly is cycled between molten metal temperature and room temperature, for example, the bond coat can be advantageous in preventing cracking, particularly if there is a considerable difference between the thermal expansion of the metal or metalloid and the refractory.
Typical bond coatings comprise Cr--Ni--Al alloys and Cr--Ni alloys, with or without precious metals. Bond coatings suitable in the present invention are available from Metco Inc., Cleveland, Ohio, under the designation 460 and 1465. In the present invention, the refractory coating should have a thermal expansion that is plus or minus five times that of the base material. Thus, the ratio of the coefficient of expansion of the base material can range from 5:1 to 1:5, preferably 1:3 to 1:1.5. The bond coating aids in compensating for differences between the base material and the refractory coating.
The bond coating has a thickness of 0.1 to 5 mils with a typical thickness being about 0.5 mil. The bond coating can be applied by sputtering, plasma or flame spraying, chemical vapor deposition, spraying, dipping or mechanical bonding by rolling, for example.
After the bond coating has been applied, the refractory coating is applied. The refractory coating may be applied by any technique that provides a uniform coating over the bond coating. The refractory coating can be applied by aerosol, sputtering, plasma or flame spraying, for example. Preferably, the refractory coating has a thickness in the range of 0.3 to 42 mils, preferably 5 to 15 mils, with a suitable thickness being about 10 mils. The refractory coating may be used without a bond coating.
In another aspect of the invention, boron nitride may be applied as a thin coating on top of the refractory coating. The boron nitride may be applied as a dry coating, or a dispersion of boron nitride and water may be formed and the dispersion applied as a spray. The boron nitride coating is not normally more than about 2 or 3 mils, and typically it is less than 2 mils.
The heater assembly of the invention can operate at watt densities of 25 to 250 watts/in 2 and typically 40 to 175 watts/in 2 .
The heater assembly for use in the heating and melting system has the advantage of a metallic-composite sheath for strength and improved thermal conductivity. The strength is important because it provides resistance to mechanical abuse and permits an ultimate contact with the internal element. When a metal tube 15 is used, intimate contact between heating element metal tube 15 and sheath I.D. provides for substantial elimination of an annular air gap between heating element and sheath. In prior heaters, the annular air gap resulted in radiation heat transfer and also back radiation to the element from inside the sheath wall which limits maximum heat flux. By contrast, the heater of the invention employs an interference fit that results in essentially only conduction.
In conventional heaters, heating element tube 15 is not in intimate contact with the protection tube resulting in an annular air gas or space therebetween. Thus, the element is operated at a temperature independent of the tube. Heat from the element is not efficiently removed or extracted by the tube, greatly limiting the efficiency of the heaters. Thus, in conventional heaters, the element has to be operated below a certain fixed temperature to avoid overheating the element, greatly limiting the heat flux.
The heater assembly very efficiently extracts heat from the heating element and is capable of operating close to molten metal, e.g., aluminum temperature. The heater assembly is capable of operating at watt densities of 40 to 175 watts/in 2 . The low coefficient of expansion of the composite sheath, which is lower than heating element tube 15, provides for intimate contact of the heating element with the composite sheath.
For better heat conduction from the heating element 42 (FIG. 3) to protective sleeve 12, a contact medium such as a low melting point, low vapor pressure metal alloy may be placed in the heating element receptacle in the baffle. The low melting metal alloy can comprise lead-bismuth eutectic having the characteristic low melting point, low vapor pressure and low oxidation and good heat transfer characteristics. Magnesium or bismuth may also be used. The heater can be protected, if necessary, with a sheath of stainless steel; or a chromium plated surface can be used. After a molten metal contact medium is used, powdered carbon may be applied to the annular gap to minimize oxidation.
Alternatively, a powdered material 40 may be placed in the heating element receptacle. When the contact medium is a powdered material, it can be selected from silica carbide, magnesium oxide, carbon or graphite, for example. When a powdered material is used, the particle size should have a median particle size in the range from about 0.03 mm to about 0.3 mm or equivalent U.S. Standard sieve series. This range of particle size greatly improves the packing density of the powder and hence the heat transfer from electric element wire 42 (FIG. 3) to protective sleeve 12. For example, if mono-size material is used, this results in a one-third void fraction. The range of particle size reduces the void fraction below one-third significantly and improves heat transfer. Also, packing the range of particle size tightly improves heat transfer.
When baffles are used, the shape of the opening, straightness and surface topography present in the baffle also determine the intimacy of fit between the heater and baffle material. Commercial refractory casting techniques do not always assure that the most desirable conditions (i.e., circular cross section, straightness, and smooth interior surface of the holes to provide a close fit diameter) for heat transfer are obtained.
To overcome these limitations, tubes of machined graphite or carbon, or suitable metals, such as titanium, titanium alloys, Kovar, Invar, and Nilo may be used as inserts. Such inserts would be installed in the mold used to cast the baffle prior to introducing the refractory material to be cast. The tubes not only finction as cores to form the holes during casting, but to provide improved heat transfer by creating more optimum conditions.
Heating elements that are suitable for use in the present invention are available from Ogden Manufacturing Co., Arlington Heights, Ill. 60005, or International Heat Exchange Inc., Yorba Linda, Calif. 92687. These heating elements are often encased in steel or Inconel tubes and use ICA or nichrome elements.
In another feature of the invention, a thermocouple (not shown) may be inserted between sleeve 12 and heating element 14 or heating element wire 42. The thermocouple may be used for purposes of control of the heating element to ensure against overheating of the element in the event that heat is not transferred away sufficiently fast from the heating assembly. Further, the thermocouple can be used for sensing the temperature of the molten metal. That is, sleeve 12 may extend below or beyond the end of the heating element to provide a space and the sensing tip of the thermocouple can be located in the space.
In the present invention, it is important to use a heater control. That is, for efficiency purposes, it is important to operate heaters at highest watt density while not exceeding the maximum allowable element temperature, as noted earlier. The thermocouple placed in the heater senses the temperature of the heater element. The thermocouple can be connected to a controller such as a cascade logic controller to integrate the heater element temperature into the control loop. Such cascade logic controllers are available from Watlow Controls, Winona, Minn., designated Series 988.
Heating element wire or member 42 of the present invention is preferably comprised of titanium or a titanium alloy. The titanium or titanium alloy useful for heating element member 42 can be selected from the above list of titanium alloys. Titanium or titanium alloy is particularly suitable because of its high melting point which is 3137°F. for high purity titanium. That is, a titanium element can be operated at a higher heater internal temperature compared to conventional elements, e.g., Nichrome which melts at 2650°F. Thus, a titanium based element 42 can provide higher watt densities without melting the element. Further, electrical characteristics for titanium remain more constant at higher temperatures. Titanium or titanium alloy forms a titanium oxide coating or titania layer (a coherent oxide layer) which protects the heating element wire. In a preferred embodiment of the present invention, an oxidant material is added or provided within the sleeve of the heater assembly to provide a source of oxygen for purposes of forming or repairing the coherent titanium oxide layer. The oxidant may be any material that forms or repairs the titanium oxide layer. The source of oxygen can include manganese dioxide or potassium permanganate which may be added with the powdered contact medium.
The oxidant, such as manganese dioxide or potassium permanganate, can be added to conventional heaters employing a powder contact medium to provide a source of oxygen for conventional heating wire such as ICA elements. This permits conventional heating elements to be sealed.
In another aspect of the invention, it has been found that intimate contact or fit can be obtained by swaging metal tube 30 about or onto heating element 14. It will be appreciated that element 14 is circular in cross section and, therefore, tube 30 can be swaged tightly onto element 14, thereby substantially eliminating air gaps. Swaging includes the operation of working and partially reshaping metal tube 30, particularly the inside diameter, placing in compression, the tube contents, and more exactly fitting the outside diameter of element 14 to eliminate air gaps between element 14 and tube 30. It will be appreciated that intermediate tubes may be placed between the heating element of the heater assembly and tube 30. Further, the invention contemplates a preferred heating element wire 42 (FIG. 3) surrounded by an electrical insulating material such as a powder which has good heat conduction, e.g., magnesium oxide, contained by tube 30 only without any intermediate tubes such as steel tubes.
Intimate contact and dense fill of the MgO powder is essential to proper heater operation, one means of providing improved fill density is to form a slurry comprising fluid or liquid vehicle, i.e., water or alcohol, and the dispersoid powder, i.e., MgO. Once a heater tube is filled with the slurry, entrapped air can be removed by vibration and/or vacuum.
A chemical binder may be employed that incorporates a chemical reaction to consume the vehicle, or progressive volitalization can be used to properly evaporate the vehicle. Progressive volitalization is a process that heats the tube from the closed end towards the open end in a progressive manner. Suitable heating means include induction, radiation and microwave/radio frequency. The heating means is moved from the closed to open end of the tube, thus assuring vapor phase vehicle to freely pass through the remaining liquid slurry.
When tube 30 is swaged on heater element 14, the refractory coating is applied after swaging. Whether the heater assembly is made by inserting heating element 14 into tube 30 or by swaging, as noted, it can be beneficial to use a contact medium for better heat conduction between heating element 14 and tube 30. The contact medium can be a powdered material located between the heating element and the tube. The powdered material can be selected from silicon carbide, magnesium oxide and carbon or graphite if the heating element is contained in an intermediate tube. If no intermediate tube is used, the contact medium must provide electrical insulation as well as good heat conduction. The powdered material should have a median particle size ranging from about 0.03 to 0.3 mm. The powdered material has the effect of filling any voids between the heating element and the tube. The range of size for the powdered material improves heat conduction by minimizing void fraction. Swaging is very beneficial with the powdered material because the swaging effectively packs the powder tighter for improved heat conduction.
The inside of tube 30 may be treated to provide a roughening effect or controlled RMS for improved packing of powder against the inside wall of tube 30. That is, having a range of particle size and a roughened inside wall provides a higher level of contact by said powdered contact medium and therefore a greater level of heat conduction to the wall. In addition, providing the element with a roughened surface improves heat conduction to the powdered contact medium. If an intermediate metal tube, e.g., a steel tube, is used, then it is also important to provide it with a roughened surface for heat transfer.
Another contact medium that may be used includes high temperature pastes such as anti-seize compounds having a nickel or copper base.
It will be appreciated that heating and/or melting in accordance with process steps of this invention, greatly reduces melt loss or greatly reduces the amount of skim generated. To further minimize skim, the molten aluminum reservoir can be provided with an inert gas atmosphere (inert to aluminum). Alternatively, the surface of molten aluminum exposed to the atmosphere can be minimized by design of the lid or top of the molten metal reservoir because there is now no need for a large surface area to be contacted with impinging gas fired flames. That is, the molten reservoir can be designed on a volumetric basis rather than a surface area heated by overhead burners.
Efficiency of heating the heating and/or melting system in accordance with the invention can use novel electric power generation means including turbine engines coupled to an electric power generator. Economic fuel sources can be selected for the turbine for power generation and scrap to be melted, e.g., beverage container scrap, can be delaquered and preheated using exhaust gases from the turbine which can have temperatures in the range of 800° to 1000° F. Similarly, oily milling chips can be pretreated with turbine exhaust gases to remove impurities prior to melting. The turbine generator provides a source of power which is portable. That is, because of the high efficiency of this melting system, smaller molten metal reservoirs can be utilized, greatly improving efficiency and economics of the heating and/or melting process.
While the invention has been described in terms of preferred embodiments, the claims appended hereto are intended to encompass other embodiments which fall within the spirit of the invention.
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A method and system of heating a body of molten aluminum, for example, contained in a heating bay, the method comprising providing a body of molten aluminum; projecting an electric powered heater into the body of molten aluminum; passing electric current through the element and adding heat to the body of molten aluminum. The heater is comprised of a sleeve suitable for immersing in the molten aluminum. The sleeve may have a closed end and is comprised of a composite material comprised of an inner layer of titanium or titanium alloy having an outside surface having a refractory coating thereon exposed to the molten aluminum, the refractory coating resistant to attack by the molten aluminum. An electric heating element is located in the sleeve in heat transfer relationship therewith for adding heat to the molten aluminum.
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BACKGROUND OF THE INVENTION
This invention relates to differential pressure filtration devices and, in particular, to a differential filtration device having an improved design which permits manufacturing with straight-pull molds and without mold mismatch flaws which arise from side action molds and can cause leakage.
Filtration devices employing differential pressure have been previously described in many patents. See, for example, Farr U.S. Pat. No. 3,481,477; Grover U.S. Pat. No. 3,693,804; Farr U.S. Pat. No. 3,969,250; Ahlstrand et al. U.S. Pat. No. 3,970,565; and Jaffe U.S. Pat. No. 4,035,150.
A typical prior art device (FIGS. 1 and 2) includes an outer container (a) which slidably receives a hollow plunger (b). A filter (c) is disposed near the end of the hollow plunger (b) and is retained there by a retainer ring (d) ultrasonically welded to the inside of the hollow plunger (b). Typically, an O-ring (e) is disposed in an annular groove (f) circumscribing the hollow plunger (b). The annular groove (f) is bounded and defined by shoulder portions (g) and (h) of increased diameter which prevent the O-ring (e) from moving with respect to the hollow plunger (b).
A major drawback of filtration devices of this type is the inability to manufacture them on straight-pull molds due to the annular groove (f) which makes it impossible to remove this part from a straight-pull mold. Consequently, previously known filtration devices have been manufactured in side action or two-part mold cavities divided longitudinally in half. As a result of two-part molds, mismatches known as parting lines (s) are inevitable along the seam joining the two halves. Even though mismatch flaws may only be on the order of a few thousandths of an inch, this can be enough to cause the O-ring (e) to seat improperly in the annular groove (f) and cause a leak. While flaws of this magnitude generally will not permit liquids to pass, they often will permit air to pass, causing a poor seal. A poor air seal compromises the pressurization of trapped air essential to good sample filtrate delivery in differential filtration devices.
In addition, heat generated by the ultrasonic welding of the retaining ring (d) to the end of the hollow plunger (b) can often damage the filter (c) which is adjacent thereto. Moreover, the pressure with which the ring (d) compresses the filter (c) cannot be adequately controlled. Insufficient or non-uniform pressure permits bypass leaks, while excessive pressure can damage the filter.
SUMMARY OF THE INVENTION
The present invention overcomes these disadvantages of the prior art filtration devices by providing a sample filtration device manufactured on straight-pull molds to avoid mismatch flaws associated with the prior art devices. The invention also overcomes the disadvantages of ultrasonic welding by providing friction means for retaining the filter media within the core of the hollow plunger.
In one aspect, the present invention comprises an improved differential pressure sample filtration apparatus. An outer container, closed at one end for holding a fluid sample for filtering. slidably receives a hollow plunger. The hollow plunger comprises two pieces: a first piece or collector portion having an annular shoulder thereon; and a second piece or retaining portion having a first annular ring. The retaining portion is affixed to the collector portion such that the annular shoulder of the collector portion and the first annular ring of the retaining portion cooperate to form the sides of an annular groove which retains a sealing means. The sealing means may comprise any structure capable of achieving a fluid seal between the outer container and the hollow plunger, for example, an O-ring or flat washer. A filtering means is disposed near one end of the plunger for filtering fluid from the outer container into an inner collecting means in the hollow plunger, as the plunger is inserted into the outer container.
Preferably, the retaining portion also includes a plurality of legs connecting the first annular ring to a second annular ring which is smaller in diameter and axially spaced from the first annular ring. The second annular ring is dimensioned to fit inside the hollow portion of the plunger to retain the filter media in place. Ideally, the retaining portion is affixed to the collector portion by means of friction fit or "snap fit" between the second annular ring and the interior of the hollow plunger.
In another aspect, the invention comprises a method for forming and assembling the components of the filtration device using straight pull molds, which method eliminates leaking due to parting line mismatch flaws. According to the method of the invention, a collector portion of the plunger and a retaining portion of the plunger are formed separately, each from a distinctly configured straight pull mold, and are assembled so that an annular shoulder on the collector portion cooperates with an annular face on the retaining portion to form the annular groove in which the sealing means is disposed. Preferably, the retaining portion and the collector portion remain engaged due to friction between a second annular ring dimensioned to frictionally engage the interior of the collector portion.
BRIEF DESCRIPTION OF THE DRAWINGS
A better understanding of the invention can be had by reference to the following detailed description of a preferred embodiment when read in conjunction with the accompanying drawings in which like reference numerals refer to like parts throughout the several views and in which:
FIG. 1 is a longitudinal cross-section of a filtration device known in the prior art;
FIG. 2 is an exploded perspective view of the plunger portion of the filtration device of FIG. 1;
FIG. 3 is a longitudinal cross-sectional view of the filtration device of the present invention;
FIG. 4 is an exploded perspective view of the plunger portion of the invention;
FIG. 5 is a cross sectional view taken substantially along line 5--5 of FIG. 3;
FIG. 6 is a bottom plan view of the retaining portion of the plunger; and
FIG. 7 is a diagrammatic representation of a straight-pull mold employed in the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 3, the filtration device 10 is depicted in longitudinal cross-section and comprises a cylindrical outer container 12 into which is slidably received a cylindrical, hollow plunger. The hollow plunger comprises a first piece or collecting portion 14, the upper end of which (as viewed in FIGS. 3 and 4) is closed by a cap 16. A second piece of the plunger, a retaining portion 18 (somewhat resembling and herein referred to as a "crown"), is shown at the opposite end of the collector portion 14.
As shown in FIGS. 3 and 5, the outer container 12 comprises a cylindrical tube having inner and outer walls. The container 12 is open at a top end and closed at a bottom end. A section of the container 12 near the bottom end preferably includes a radially reduced portion 19 and the interior face of the bottom end includes a raised bump 20 for a reason to be subsequently discussed. Circumferentially spaced in the interior wall of the container 12, just above the reduced portion 19, are formed a plurality of raised nubs 21 which serve a purpose to be described below.
The collector portion 14 (FIGS. 3, 4 and 5) similarly comprises a cylindrical tube but is open at both ends to form a hollow passageway or collecting chamber in the interior of the plunger. The exterior of the lower or inserted end (as viewed in FIGS. 3 and 4) of the collector piece 14 also has a reduced diameter portion 22 forming an annular shoulder 23. The interior lower end of the collector portion 14 houses filter media 24 and may or may not have a correspondingly reduced portion.
The filter media 24 may be single or multiple layer and comprises any known filtering media including, but not limited to, paper, glass fiber, cellulose, and nitrocellulose. Depth filters are generally preferred over membrane filters due to their ability to remove greater quantities of particulate matter without becoming occluded. Especially preferred for most applications is fiberglass combined with polypropylene, however, different media may be preferred, depending on the application.
The filter media 24 is held in place from above by an annular ledge 26 formed in the interior walls of the collector portion 14 and, optionally, by cross bars 28 extending diametrically across the opening formed by the annular ledge 26. The annular ledge 26 and, if necessary, the cross bars 28 support the filter media 24 against the pressurized sample which must be filtered as the plunger is inserted into the outer container 12.
From below, the filter media 24 is supported by the retaining portion or crown 18. As best shown in FIGS. 4 and 6, the crown 18 comprises a first annular ring 30 and a second annular ring 32 which are joined together by a plurality of longitudinal legs 34. The first annular ring 30 is larger in diameter and is dimensioned to fit snugly over the reduced diameter portion 22 of the collector piece 14. Conversely, the second annular ring 32 is smaller in diameter and is dimensioned to fit snugly inside the interior wall of the reduced portion 22 of the collector piece 14. Accordingly, the legs 34 are somewhat L-shaped. As best seen in FIGS. 3 and 4, the legs 34 axially space the second annular ring 32 from the first annular ring 30 which gives the crown 18 its characteristic appearance. Furthermore, the second annular ring 32 includes a portion that extends axially upward from the foot of the leg 34 so that it can be inserted into the hollow interior of the reduced diameter portion 22 of the collector portion 14 to retain the filter media 24 in position. Preferably, circumferentially spaced raised nubs 33 are disposed on either the outside of the second annular ring 32 (see FIG. 4) or the inside of the reduced portion 22 below the annular ledge 26 (not shown). The other component (ring 32 or inside of portion 22) has depressions (not shown) corresponding to the nubs 33 to securely lock one to the other.
As best seen in FIG. 3, the legs 34 have a length slightly less than the axial length of the reduced diameter portion 22 which leaves a gap between the top axial face 36 of the first annular ring 30 and the annular shoulder 23 formed by the reduced portion 22 of the collector piece 14. The gap defines an annular groove about the periphery of the plunger into which an O-ring 40 is securely seated. In this manner, the O-ring 40 slides with the plunger as it is inserted into the outer container 12 so that a fixed quantity of air is trapped in the outer container 12 and forces the sample through the filter media 24.
While the preferred embodiment of the crown 18 has been described, the invention also contemplates other straight-pull molded retaining portions secured to a collector portion 14 by suitable means and having an annular face axially spaced from the annular shoulder 23 to form an annular groove. A second ring, distinct or continuous with the retaining portion, can optionally form the filter retaining means.
It will be apparent to those skilled in the art that the gap between the annular shoulder 23 and the top axial face 36 is equivalent in function to the annular groove (f) of the prior art defined by the raised portions (g) and (h) as shown in FIGS. 1 and 2. However, by forming the cap from two components (ie. the collector portion 14 and the crown portion 18 of the plunger), it is possible to achieve the filtration device 10 which can be molded from straight-pull molds to eliminate mismatch flaws or parting lines inherent in two-piece or side action molds. By eliminating these mismatch flaws, it is possible to decrease the chances that a particular plunger will have an air leak past the O-ring 40.
Each of the major components of the device 10, namely the outer container 12, the collector piece 14 and the crown 18, is made of a relatively rigid substance such as plastic, polypropylene or polyethylene. These components may all be made of the same material. An especially preferred substance is polypropylene because it is easily molded by injection molding techniques and relatively inert to the assay. Ideally, the material is flexible enough and the dimensions small enough to permit the nubs 21 to be formed in spite of the shear action of the mold.
A typical mold (FIG. 7) for forming the collector portion 14 of the plunger comprises a cavity 50 cut into a block 52. The cavity 50 is dimensioned to correspond to the outer wall of the collector portion and is open at the top. The bottom of the cavity 50 can be formed by the block 52, but more conveniently is formed by a pin 53 inserted into the cavity 50 to a predetermined position. The block 52 also has a port or gate 54 opening between the cavity 50 and a source 56 of molten plastic to permit injection molding of the component. A core 58 is inserted into the center of the cavity 50 and is dimensioned to correspond with the interior dimensions of the collector portion 14. The core 58 is centered within the cavity 50 by means of spacers 60 which also can be used to remove the formed collector piece 14 from the central core 58 by sharp downward pressure. The pin 53 is centered by a spacer plate or collar 62, which may be integral with the block 52 or separate.
The crown 18 can be formed similarly from a straight-pull mold having a cavity and central core slightly different than those of FIG. 7 but which can easily be determined by one skilled in the art. The retaining portion or crown 18 is then slid over the reduced diameter portion 22 of the collector portion 14 and locked into place by frictional engagement of the nubs 33. The retainer portion forms part of the annular groove for the O-ring 40 and, simultaneously, holds the filter media 24 in place.
In use, a liquid sample to be filtered is placed in the bottom of the reduced diameter portion 20 of the outer container 12. The plunger is inserted filter end first into the open end of the outer container 12 and the O-ring 40 sealingly engages the inner wall to form an air-tight seal between the outer container 12 and the plunger 14. As the plunger is depressed further into the outer container 12, air is forced through the filter media 24 and escapes through the loosely fitting cap 16.
Once the plunger reaches the surface of the sample fluid to be filtered, a fixed quantity of air is trapped between the O-ring 40 and the fluid level and, upon further depression of the plunger this trapped air is compressed. The pressurized air in turn forces the fluid sample through the filter media 24 and into the collecting chamber in the interior of the hollow plunger. As the reduced diameter portion 22 of the plunger is pushed into the reduced diameter portion 20 of the outer container 12, the trapped quantity of air is forced into a smaller volume which multiplies its compressive effect on the fluid to deliver as much sample as possible through the filtering media 24. This arrangement increases the efficiency of filtration which is important for small volume samples.
The bump 20 at the bottom end of the outer container 12, by occupying space inside the second annular ring 32, also serves to decrease the available space for trapped air, thereby to deliver as much sample filtrate as possible.
Filtration is complete when the plunger hits the bottom end of the outer container 12. Simultaneously, the O-ring 40 snaps past the nubs 21 formed in the inner wall of container 12 to lock the two components together. This feature permits thick and thin samples alike to be filtered without the need for holding the components together manually. This is advantageous since some samples take longer than others to completely filter.
When filtration is complete, the filtrate can be poured from the open end of the hollow plunger upon removal of the cap 16. Alternatively, additional reagents can be added to the filtered sample in the inner collector portion to further process the sample prior to pouring. Filtered sample can then be poured into any desired assay format without including undesired particulate matter present in the original sample.
The foregoing description of the preferred embodiment has been given for purposes of illustration only and no unnecessary limitations should be understood therefrom. Rather, the invention is intended to be limited only by the following claims:
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The present invention relates to a sample filtration device of the type employing differential pressure. An outer container filled with a sample to be filtered slidably receives a hollow plunger having filter media disposed near one end and sealing means disposed in an annular groove about the periphery of the plunger. The annular groove of the plunger is formed by two components: an annular shoulder on a collector portion and the axial face of an annular ring formed in a retainer portion. The two portions are frictionally engaged to retain the filter in place and form the annular groove for the sealing means. This construction permits straight-pull molding of the component parts which eliminates mold mismatch flaws.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to energy absorbing seat belt systems, such as automotive seat belt webbing.
2. Description of the Prior Art
Heretofore, various concepts and designs have been proposed to provide or improve upon the energy absorbing capability of seat belt webbing, such as webbing utlized in a vehicle restraint system. Such webbing typically is formed from nylon or polyester fabric and usually is stored in a rolled up configuration on a seat belt retractor. Although the seat belt webbing per se is somewhat extensible and hence is capable to a limited degree of absorbing energy resulting from movement of the wearer against the seat belt such as occurs in a collision, in some cases increased energy absorption is desirable. For example, in smaller vehicles it would be especially desirable to utilize an energy absorbing system due to the compactness of the vehicle interior. Among the various devices which have been proposed for providing an energy absorbing characteristic to the seat belt assembly are those described in U.S. Pat. Nos. 3,550,957, 3,409,327 and 3,446,533 all to Radke, et al. However, such designs either involve relatively expensive equipment or are bulky and hence are difficult to wind up, or both. It would be desirable if a simplified, relatively inexpensive and non-bulky energy absorbing seat belt webbing system were provided.
SUMMARY OF THE INVENTION
In accordance with this invention there is provided an energy absorbing seat belt restraint comprising a thin, flexible elongated element having a length substantially greater than its width and adapted for securing a wearer in a vehicle, the element being provided with at least one integral discontinuity along its length, whereby said element is capable of absorbing kinetic energy imparted thereto by movement of the wearer thereagainst. It has been found that by providing at least one such discontinuity in the seat belt element, the energy absorbing capability of the element is vastly increased. Such discontinuity may be in various forms, such as slits, perforations or other configurations provided in seat belt webbing, for example, and located at the edges or in the central portion of the webbing. The discontinuities may extend in longitudinal, transverse or angular directions, or combinations thereof, and may be formed in the element itself or may be formed in a similar element which is affixed to the restraining element in the manner of a patch, for instance. More specific details of the present invention are described hereinbelow.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a view of one embodiment of the seat belt restraint of this invention wherein the discontinuities are provided on the element itself.
FIG. 2 is a view of another embodiment of the device of this invention wherein the discontinuities are provided on a member secured to the flexible element.
FIG. 3 is a graph of force versus extension of a typical device of this invention when tested under load.
FIG. 4 is a partial view of an inflatable seat belt restraint.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In accordance with this invention, a flexible seat belt restraint element, preferably in the form of conventional seat belt webbing, is provided with at least one integral discontinuity along its length so as to provide a kinetic energy absorbing structure. With reference to FIG. 1, a portion of a flexible seat belt restraint element 10 is depicted in the form of seat belt webbing. As is conventional, the webbing is formed from a plurality of warp yarns 14 and weft yarns 16, which yarns may be formed from any suitable fiber, such as polyester, nylon and the like. Provided along each edge of webbing 10 is an integral discontinuity 12 shown in the form of slits extending through webbing 10 from the edge towards the center of the webbing. Such slits provide integral discontinuities in some of the warp yarns 14. By the term "integral" discontinuities, it is meant that the discontinuous structure is imparted in some manner to the length of the webbing as opposed to the natural interstices formed as a result of the weaving or other textile process, the size of which depends upon the compactness of the weave.
Slits 12 may be provided in any suitable manner in webbing 10, such as by any cutting, punching or similar operation. Preferably, in order to eliminate frayed ends, the slits are formed in a manner which fuses the yarn or fiber ends. For example, a hot knife employed in cutting seat belt webbing to desired lengths may be used to form the slits or other discontinuities. Although discontinuities 12 are depicted in FIG. 1 as being in the form of slits, they may be provided in the webbing in any suitable form such as oval shape, circular shape, etc. Furthermore, the discontinuities, which are shown in FIG. 1 as extending in the transverse direction from the edge, may be provided in any suitable location along the length and width of the webbing, such as for example, in the central portion of the webbing as shown in FIG. 2. Also, the discontinuities may extend in any direction with respect to the width of the webbing, such as, for example, parallel, perpendicular or at an intermediate angle thereto. What is necessary for purposes of this invention is that such discontinuities extend along at least a portion of the length of the webbing. In addition, only a single discontinuity may be provided or edge discontinuities may be provided on the same or opposite edges or central discontinuities may be provided.
As indicated above, the discontinuities may be provided in the integral element itself or on a separate element which is attached thereto. The latter embodiment is shown in FIG. 2 wherein a restraint system 20 comprises seat belt webbing 22 which is provided with a section of another flexible element 24, such as in the form of a patch of seat belt webbing, which is secured to the restraint member in any suitable manner such as by means of stitching 26 as depicted. The patch 24 is provided with a discontinuity shown in the form of a central slit 28. Preferably, the patch and the restraint element are seamed together to provide a slightly bowed portion in one of the elements for greater energy absorption. The total system, however, is relatively compact and is suitable for storage on conventional seat belt retractors.
It will be appreciated by those skilled in the art that the location, extent and number of discontinuities are dependent upon the desired energy absorbing characteristics which are required for restraint of a specific seat belt assembly system. That is to say, depending upon the configuration of the system and vehicle interior, various design criteria are fixed which define the extent of webbing elongation is permissible over a maximum amount of energy imparted to the webbing. For example, in a compact or subcompact vehicle, extensions of seat belt webbing in the order of, for example, about 4 to 8 inches may be desired at a minimum force of, for example, 1500 to 2500 pounds. Seat belt webbing in accordance with this invention have been capable of meeting such criteria by, for example, providing slits of about one-half inch in width in a conventional 2 inch wide polyester seat belt webbing with the slits extending from opposite edges of the webbing and spaced apart along the extent of the webbing at distances ranging from about 1 to 8 inches, for example. Obviously, other design criteria can be achieved by varying the location, direction, size and shape of the discontinuities.
The restraint element of this invention may be utilized in any desired seat belt system. Preferably, the energy absorbing feature is provided on a shoulder harness since that portion of an occupant restraint system usually is under the most stress in a collision. Alternatively, the energy absorber may be provided in the lap belt or in both the lap and shoulder belts. The specific location of the energy absorber along the extent of the webbing is likewise a design feature dependent upon the specific restraint system. For example, the energy absorber may be located on the shoulder belt behind the plane of the wearer and preferably adjacent to an anchor point or a pivoting member such as a D-ring. Also, the present invention may be employed with various occupant restraint systems, such as those of the inflatable band type as is shown, for example, in U.S. Pat. No. 3,841,654 to Lewis. An inflatable belt 11 is shown in FIG. 4.
With respect to FIG. 3, this graph illustrates a typical force-extension curve of the energy absorbing webbing of this invention. Such a curve, which represents extension of webbing in the direction of the arrow of FIG. 1, is made on an Instron testing machine wherein two jaws secure the webbing and extend the webbing in opposite directions. In this figure, conventional polyester seat belt webbing of 2 inch width was utilized with two slits extending across the width of the webbing for about one-half inches each and from opposite edges of the webbing. The slits were spaced approximately 4 inches apart along the length of the webbing and were formed by a hot knife. The jaws were separated at a speed of 5 inches per minute and the chart speed was synchronized to the separation speed. As can be seen, the webbing of this invention provided an extension of about 2 to 5 inches at 2000 pounds of force or absorbed about 300 to 800 foot-pounds of energy.
It is to be understood that variations and modifications of the present invention may be made without departing from the scope of the invention. It is also to be understood that the scope of the invention is not to be interpreted as limited to the specific embodiment disclosed herein, but only in accordance with the appended claims when read in light of the foregoing disclosure.
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Energy absorbing seat belt restraint comprising a thin, flexible elongated element having a length substantially greater than its width and adapted for securing a wearer in a vehicle, the element being provided with at least one integral discontinuity along its length, whereby said element is capable of absorbing kinetic energy imparted thereto by movement of the wearer thereagainst.
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FIELD OF THE INVENTION
[0001] The invention concerns an installation for hardening tubular concrete workpieces in chambers which are open at the top, can be closed with cover plates, can be filled with vapour and which can be charged with the aid of an overhead travelling crane bearing the load of the workpieces.
DESCRIPTION OF THE PRIOR ART
[0002] After tubular, concrete workpieces such as concrete pipes, tubbing rings or well casings have been removed from the mold, these workpieces must be placed into an interim storage facility to allow the concrete to harden. This is done with consideration being given to the fact that the concrete is yet to harden and can only be subjected to minimal load in an upright position. Overhead travelling cranes with a hoisting device (AT 405 395 B) are used to transport the tubular workpieces which include an encompassing, metallic bottom ring for setting them down. Said cranes consist of a supporting frame which runs above the workpieces to be picked up and brackets which encircle the exterior of the workpiece. Said brackets reach under a flange located in the metallic bottom ring by means of adjustable dogs which are perpendicular to the axis of the workpiece and which lift it. With the aid of such overhead travelling cranes, the workpieces can be stored in an appropriate storage area and allowed to harden after they have been removed from the mold and can then be transported from this storage area after hardening.
[0003] If the tubular workpieces are subjected to vaporisation to facilitate more effective hardening, the workpieces must be placed in chambers for hardening which are closed for vaporisation. To achieve this, chambers are known which are open at the top and which are closed by means of cover plates. To load and unload the chambers the cover plates must be opened before the workpieces can be inserted or removed. Due to the size of the relatively heavy cover plates, their opening and closing requires measures involving significant effort which must not hinder the movement of the workpieces either. In order to avoid having to allocate a special opening and closing device for each cover plate, in known installations the cover plates share a common lifting device which is driven along the row of chambers, with attention needing to be paid to the transportation routes of the overhead travelling crane employed for workpiece charging in order to avoid mutual interference. In order for charging and discharging to occur, the individual workpieces do not only have to be lowered into and lifted out of the single chambers which are open at the top, but must also be transported away from the chambers at a distance above them.
SUMMARY OF THE INVENTION
[0004] The aim of the invention is to provide an installation for hardening tubular concrete workpieces of the type described at the outset such that the construction for opening and closing the cover plates can be significantly simplified.
[0005] The invention fulfils this aim by incorporating a holding device for the cover plates into the overhead travelling crane used for the workpieces.
[0006] As the overhead travelling crane used for the workpieces includes a holding device for cover plates, there is no longer any need for a separate lifting device for the cover plates, which are now lifted off the chambers and replaced onto them by the overhead crane used for the workpieces before and after the workpieces have been transported. One must only ensure that the weight of a cover plate does not exceed the permissible load rating of the overhead crane. In order to suffice with an overhead crane designed to work with the weight of the workpieces, the chamber cover plates can be divided into removable cover plate segments of less weight accordingly.
[0007] In order to set down the cover plates removed from the chambers, a stackable storage facility for the cover plates can be located at the end of the row of chambers which are oriented in the direction of travel of the overhead crane so that the workpieces can be transported without interference after the cover plates have been stacked. A particularly simple construction constellation results in this case if the stackable storage facility for the cover plates is arranged in the area near the discharging station of a feeder conveyor for the workpieces to be hardened and/or in the area near the charging station of a discharge conveyor for the hardened workpieces as in this case a workpiece requiring hardening can be picked up and transported into the opened chamber after the cover plate has been set down without the overhead crane having to make an additional empty run. Similarly, no further conveyer travel is required for the overhead crane to convey a stockpiled cover plate to the open chamber after a hardened workpiece has been removed from it.
[0008] Although the overhead crane for the workpieces can be provided with a holding device designed specifically for each cover plate's dimensions, a particularly simple construction constellation results if the hoist for the workpieces is insertable. Preferably, this hoist shall consist of a supporting frame which runs above the standing workpieces to be picked up and of brackets which are arranged on the supporting frame and which encompass the workpieces externally and which have dogs which are adjustable along an axis lying at right angles to the axis of the workpiece and grip under a flange located on the bottom ring of the workpieces. In this case the chamber cover plates only need to have pick-up recesses which have been modified to accommodate the bracket arrangement for the dogs, which are located on the brackets of the hoisting device, to then be able to be inserted into the pick-up recesses when adjusted accordingly, connecting each cover plate to the bracket of the hoist.
[0009] An especially advantageous way of handling the cover plates to be opened and closed during charging of the chambers can be achieved if the opened chambers are not closed with a cover plate from the stackable storage facility, but with the cover plate from the chamber opened immediately beforehand which is then to be loaded. This means that after a chamber cover plate has been stacked in the storage facility, the chamber concerned shall not be closed with the stacked cover plate any longer, but preferably with the cover plate of the neighbouring chamber which has been opened to remove the fully hardened workpieces and to receive workpieces requiring hardening, while the cover plate stacked in the storage facility is to be used to close the final chamber opened.
BRIEF DESCRIPTION OF THE DRAWING
[0010] The drawing shows one embodiment of the invention.
[0011] [0011]FIG. 1 shows an installation in accordance with the invention for hardening concrete tubular workpieces in schematic view from above;
[0012] [0012]FIG. 2 shows this installation in a simplified, magnified cross-section for II-II indicated in FIG. 1 illustrating a section of the cover plate lifted by the overhead crane;
[0013] [0013]FIG. 3 shows the section corresponding to FIG. 2 illustrating a workpiece being held by the overhead crane;
[0014] [0014]FIG. 4 shows a magnified, partial lateral view of the bottom ring of a workpiece gripped from below by a dog attached to the hoist;
[0015] [0015]FIG. 5 shows a magnified, partial, lateral view of a section of a cover plate in the area of a recess for a dog attached to the hoist.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] The installation for hardening tubular workpieces 1 features numerous adjacent chambers 2 which are open at the top and can be closed with cover plates 3 in order to be able to subject the workpieces 1 located in the chambers 2 to a vaporising process to achieve more effective hardening. In accordance with this design embodiment, each of the cover plates 3 of the individual chambers 2 are subdivided into three cover plate segments 4 , each of which can be individually removed from the chambers 2 . Due to the resultant reduction in the weight and the reduced dimensions of the cover plate segments 4 , this subdivision of the cover plates 3 results in the facilitation of the handling of the cover plates 3 when the chambers 2 are opened and closed.
[0017] Laterally adjacent to the chambers 2 positioned next to one another provision is made for tracks 5 for an overhead travelling crane 6 , along the bridge 7 of which a crab 8 with a lifting and a lowering hoist 9 for the workpieces 1 can be slid. This hoist 9 consists of a supporting frame 10 which travels above the workpieces 1 to be hoisted and on which the brackets 11 for encompassing the exterior of the workpieces are arranged, as can be seen in FIG.3. At the lower ends of the brackets 11 provision is made for dogs 12 which can be positioned perpendicular to the vertical axis of the tubular workpiece 1 and in accordance with FIG. 4 grip under a flange 13 of the metallic bottom ring 14 on which the workpiece 1 is positioned and by means of which it can be elevated, encompassing the tubular workpiece 1 . The dogs 12 can be adjusted into a position at right angles to the axis of the workpiece 1 by moving the brackets 11 laterally, by actuating the dogs 12 at right angles to the brackets 11 , or by rotating the brackets 11 upon their axis as provided for in this embodiment of the arrangement.
[0018] In order that not only the workpieces 1 , but also the cover plate segments 4 can be lifted by the overhead travelling crane 6 , the overhead travelling crane 6 must be provided with the necessary holding devices for the cover plate segments 4 . Although special holding devices for this purpose are conceivable, a particularly simple construction constellation results when the hoist 9 for the workpieces 1 can be utilised. For this purpose and in accordance with FIG. 5 the cover plate segments 4 have pick-up recesses 15 for the dogs 12 on the brackets 11 , with the recesses designed to accommodate the bracket arrangement. Therefore, if the hoist 9 in the embodiment provided for is lowered in relation to a cover plate segment 4 , the dogs 12 on the lower ends of the brackets 11 enter the area in which the recesses 15 are located, so that the pick-up recesses 15 are gripped from beneath by the dogs 12 after the brackets 11 have been rotated as shown in FIG. 5. In this manner, the cover plate segments 4 coupled to the hoist 9 for the workpieces 1 can be lifted from the chamber 2 involved by means of the overhead travelling crane 6 as shown in FIG. 2. The cover plate segment 4 which has been lifted off can be placed in a stackable storage facility 16 which in accordance with FIG. 1 is located directly adjacent to the rows of chambers 2 in the direction of travel of the overhead travelling crane 6 . The stackable storage facility 16 is located advantageously between the discharge station 17 of the feeder conveyor 18 for the workpieces 1 requiring hardening and the charging station 19 of the discharge conveyor 20 for the hardened workpieces 1 . This spatial arrangement of the feeder conveyor 18 and the discharge conveyor 20 in relation to the stackable storage facility 16 for the cover plate segments 4 means that any empty runs which may have been necessary for the overhead travelling crane 6 between picking up the cover plate segments 4 and the workpieces 1 are avoided in an advantageous manner.
[0019] However, it is not at all necessary to always convey the cover plate segments 4 removed from the chambers 2 to the stackable storage facility 16 in order to remove them from the stackable storage facility 16 to close the chambers 2 . The loading circumstances can be made much more advantageous if, for instance in accordance with FIG. 1, the chamber section to be closed, ‘a’, is not closed using a cover plate segment 4 from the stackable storage facility 16 , but by using the cover plate segment 4 a from the neighbouring chamber 2 , which is to be charged with new workpieces 1 . Therefore, the cover plate segment 4 a only needs to be moved the distance of one chamber 2 in order to close the previously open chamber 2 in area ‘a’ on the one hand and to open a section of a chamber 2 to be recharged on the other. Then the already treated and fully hardened workpieces 1 can be removed from the open chamber using the overhead travelling crane 6 and replaced with workpieces to be treated which are conveyed by the feeder conveyor 18 , while the hardened workpieces 1 are removed from the installation by the discharge Conveyor 20 . This charging and discharging procedure of the chambers 2 is repeated chamber after chamber until the final chamber in the sequence of chambers has been opened and the cover plate segment 4 required to close this chamber must be taken from the stackable storage facility 16 . The cover plate segments 4 stored in the stackable storage facility 16 are those from the first chamber 2 opened in the charging sequence.
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An installation is described for hardening tubular concrete workpieces ( 1 ) in chambers ( 2 ) which are open at the top, can be closed with cover plates ( 3 ) and can be subjected to vapor and which can be charged with the aid of an overhead travelling crane ( 6 ) bearing a hoist ( 9 ) for workpieces ( 1 ). In order to achieve an advantageous construction constellation it is recommended that the overhead travelling crane ( 6 ) for the workpieces ( 1 ) has a gripping device for the cover plates ( 3 ) of the chambers ( 2 ).
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This is a continuation of U.S. application Ser. No. 08/366,832, filed Dec. 30, 1994, now U.S. Pat. No. 5,486,127.
BACKGROUND OF THE INVENTION
This invention relates to an improvement on a snap connector, namely a single point axial connector with a formed configuration or key like portion to prevent rotational movement about its axis and/or for the selective attachment of components of toy assemblages, educational models, hobby constructions, component attachments or the like.
While there are many examples of patents of snap together connectors, this invention is directed to a single point axial connector with a key component molded thereto or configured in such a fashion to prevent axial rotation of the component part by virtue of the key feature or configured end of the male connector not being able to axially rotate within the corresponding female opening.
There are many instances where there is a need for a compact axial snap together connector, and also a need to prevent rotation about the axis of the components connected and or to have selective attachment. One example of the use of these connectors is a skeletal model, where each consecutive bone segment would be connected only in a single position, without rotation, so that the correct positioning in the configuration of the model or toy is maintained. In the past, skeletal models have been wired together which is complicated and time consuming, Once wired together, these skeletal models are not meant to be disassembled and reassembled. In U.S. Pat. No. 2,995,833 by Bezark and U.S. Pat. No. 4,200,995 by Trella, ball in socket connectors are used, however they do not describe any keying or shaping of the connector to prevent rotation about the connectors axis, and therefore do not address positioning and maintaining each component in their proper position. The skeletal model is an example where a keyed selective connection is desired, so that the parts could also be assembled in such a way as to maintain the correct order of placement of the constituent components.
Since many skeletal model sets are assembled by wiring the bones together, most younger students do not have the dexterity, the patience, nor the time during one school period to accomplish such a construction. Such constructions, using this invention may be easily assembled, increasing the recreational, educational or functional value of the construction by requiring less dexterity and time in assembling the objects. There is also an educational value from assembling such constructions due to the participation and experience one obtains from building the construction itself.
In patents such as U.S. Pat. No. 2,662,335 by Calverley, ball and socket snap together connectors are employed, however there is no intention nor desire to restrain the rotation of the component parts. The same is true of U.S. Pat. No. 3,822,499 by DeVos.
There are several component systems which employ ball and socket configurations with axially attached components and also prevent rotation of the components which are being attached together, however several ball and socket sets are required on each component face in order to achieve this condition. In U.S. Pat. No. 4,947,527 by Hennig, however, two sets of ball and sockets must be employed specifically to prevent rotation and maintain alignment.
U.S. Pat. No. 2,397,801 by Mitchell, and one embodiment of U.S. Pat. No. 3,461,514 by Morris are strips which employ several ball and socket connectors, which when connected, prevents rotation of the attached component. However this connection is also one of ball and sockets along a lateral face rather than a single axial one. Prior to the present invention, the problem of making a single point, compact, nonrotational connector has not been addressed.
SUMMARY OF THE INVENTION
It is the object of this invention to provide a coupling means which permits components to be snap connected together (or disengaged) in a single point axial rigid connection, and likewise be unsnapped if desired with a pre-determined amount of physical force, with the additional configuration of shape or a key, formed as part of the connector to prevent rotation about its axis and/or limit the selectivity of the components being joined. Some examples include again skeletal models, educational, toy construction sets as well as other component attachments.
This invention is especially useful in situations where components that are to be connected are especially small, where rotational restraint is required, and so a single point attachment is more conducive as a connector than one that requires multiple connectors.
The object is achieved by including a configured area or one or more keys to a male button head connector so that it will engage a female opening only in a certain selective position or positions wherein any rotational movement is prevented or restricted. Another object that can be achieved is that only a certain connector, because of its configuration or keying, will only engage its like female counterpart.
Another beneficial feature of this connector is that it can be entirely concealed within the components to be connected.
There are many uses of this invention, including snap together toy construction sets, construction models, instruction kits such as skeletal kits as shown in FIG. 1, or any of a number of uses to connect components together in this fashion.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of several units of a skeletal assembly.
FIG. 2 is a cross sectional view of the connectors, integral with the component parts of FIG. 1.
FIG. 3 is an axiometric view of one example of an integral male connector.
FIG. 4 is an axiometric view of a multiple key male connector.
FIG. 5 is an axiometric view of an amorphically configured male connector.
FIG. 6 A-F are elevation views of some different female coupling configurations.
FIG. 7 is a section view of an example of an connector with flexure.
FIG. 8 is a sectional view of connector inserted within component parts.
FIG. 9 is a sectional view of single sided connectors inserted into component parts.
DETAILED DESCRIPTION OF THE INVENTION
The present invention provides a system for coupling components in which a male connector is engaged with a female connector and rotational movement about the axis of the male and female connectors is restricted. The male connector and female connector can be in separate pieces or both male and female connectors may be molded into a single piece.
The male connector is a first component part from which projects a button head connector. The button head connector has a shaft which may have a ball end having a larger diameter than the shaft or may have a configured end which has a larger diameter than the shaft. If the button head connector has a ball end, then there will be at least one key adjoining the button head connector.
The female connector is a second component part which has a female receptor integrally formed in the second component part. The female receptor is surrounded by scalloped edges to receive and hold the configured end or the ball end and adjoining key of the male connector. The female connector may also have one or more integrally formed slots in the second component part to enable multiple positioning of the male connector when the button head connector has a ball end and an adjoining key. The slot may be wider than the key of the male connector to provide a controlled amount of displacement about the axis of the male and female connectors. If desired, more than one slot may be wider than the key of the male connector. When the button head connector of the male connector has a configured end, then, instead of slots, the female connector will have at least one opening integrally formed in the second component part for either singular or multiple positioning of the male connector. As when slots are used, the opening may be wider than the configured end of the male connector to provide a controlled amount of displacement about the axis of the male and female connectors and more than one opening may be wider.
The male and female connectors can be made of flexible material to allow tortional flexure when the male connector is engaged with the female connector. The component parts of the male and female connectors can be shaped to allow flexure of the component parts when the male connector is engaged with the female connector.
One embodiment of the use of the present invention is the coupling together of components such as the skeletal construction set shown in FIG. 1, where a set of components can be snapped together in a particular fashion and in predetermined positions to form a larger object and likewise be unsnapped apart again into its constituent pieces. The connectors can be molded together with the component pieces and are preferably made of plastic or metal or other formed type of material.
Each component piece 1 has either a male connector 2 or a female receptor 3 or both, but may also have a plurality of each. FIG. 2 shows a cross section of components with integral male and female connector parts. The male connector 2 comprises a button head connector having a neck or shaft 4 integrally attached to the component part 1, with a ball or configured head 5 which is of a larger diameter than the attaching neck portion, and which also has a key like formation 6 adjoining the button head connector or can have multiple key formations as in FIG. 4.
In FIG. 5 is shown a connector which is amorphically configured or shaped. The male connector may have an amorphically configured end, which because of its non cylindrical shape constrains rotation about its axis.
Amorphic is defined here as a non defined shape unlike defined geometrical shapes such as a sphere, cylinder, cube or combination of defined geometric shapes.
All the connectors are preferably, compact with rounded edged male heads without sharp edges for ease of insertion and removal and limiting snagging and broken edges.
The female connector 3 in FIG. 2 is an opening integrally formed in the component piece which receives the male connector 2. The female connector comprises an opening or female receptor 7 in which the head of the male connector passes through and snaps in place. The female receptor has scalloped edges 8 which have a certain amount of flexibility in order for the male connector which has a slightly larger head 5 to pass through using a certain amount of physical pressure into a void molded within the component. Once the head of the male connector passes through the opening, the scalloped edges 8 of the female receptor 3 resumes their original position entrapping the ball like end 5 of the male connector 2 thus securing the components together.
Because the shape of the male connector along with its adjoining key or configuration, would be restrained from rotating in its corresponding female receptor, then the components are similarly restrained about the axis of the connector. It is also an embodiment of this invention that the male connector and its adjoining key or keys be together as a single compact mass and to prevent rotation about the axis of the connector in that its inherent shape is not simply a ball or cylindrical shape.
It is intended that the connection may be either designed that the components 1 may then be either unsnapped with a predesigned amount of force, or left in a rigid connection. A male connector which would be appropriate for a connector which is not designed to be unsnapped is shown as element 5b in FIG. 7.
In FIG. 6 the scalloped edges 8 of the female receptor 3 are designed with a formed key slot or slots 9 and a closed down or narrowed portion 10 so that the key portion 6 of the male connector may pass through the formed key slot or slots 9 in only that position that is intended for the component piece to align and not through the closed down or narrowed portion 10 where the connector key is not intended to pass through. The amount of force required to achieve connection would be determined by the size of the head of the male connector in relation to the constriction and the flexibility of the scalloped areas of the female connector opening.
FIGS. 6A-6D shows elevations of several different possible configurations of the female connector opening showing some possible alignments which may be achieved. A single position alignment is shown in FIG. 6A where a single keyed connector of similar shape would be able to pass through and be fixed and restrained from rotation in one position only. For instance the shape of the male connector in FIG. 3 would fit into the female connector opening in FIG. 6A but not a male connector such as illustrated in FIG. 4 which has a double keyed male connector. In FIG. 6B shows a two way female alignment position for a single key, or a single position for a similar multiple key slot. A multiple key and slot arrangement would be conducive for the selective attachment of components. FIG. 6C is yet another combination of possible connection positions, and many further combinations, configurations and shapes are possible and are included within the framework of this invention. FIG. 6D shows a widened key connector slot at top which, being wider than the key on the male connector side, would permit an intended amount of twist or displacement about the axis of the connector.
FIG. 6E shows a female receptor without a separate formed key slot but which is keyed alone by the similar configured or formed shape and size as the male connector, (for example the male connector in FIG. 5) the connection holding the component parts in a singular orientation, and limiting rotation about the axis of the connection. FIG. 6F shows a female receptor without separate formed key slots but which accepts a similar shaped and sized male connector (for example the male connector in FIG. 5) in more than one designated and intended orientation.
It is intended that the configuration of key formations or the configured shape of the male connector, or the shape or number of scallops at the opening edge of the female receptor may vary within this invention.
If in some cases, where it is desirous by design, that the components are intended to rotate about the axis of the connection in the same construction, then those connectors may be designed without a positioning or restraining key type element as described for this invention.
Another embodiment of this invention comprises the aspect where the components, which are being connected together, are shaped in such a way as to allow a designed amount of flexure of the component parts perpendicular to the axis of the connector as shown in FIG. 7. The relative limit of flexure is created by the extent of the splay of the mating surfaces of the connector faces 11 perpendicular to the axis of the connector and is shown by the angle φ in FIG. 7. The flexure can be created in one or more directions about the axis of the connector face 11 or limited by design. The flexure of the components can be designed so as to remain in a reformed position, or to return to its original shape or position.
The connector elements can also be made of a flexible type of material which would permit a certain amount of torsion or twist to the configuration.
Another use for this connector would be for providing the connection of other existing elements, for instance natural bone. In FIG. 8 is shown a molded keyed connector 12 inserted into existing component 13, in this case natural bone vertebra, in which the connector can be glued, frictionally form fit or attached in other various ways into a pre-existing cavity or similarly anchored into a bored hole. In this embodiment in FIG. 8, both the male and the female connector are molded into a single piece, but it may be also configured in separate pieces. The connector 12 as shown has a flange area 14 representing cartilage section between the natural bone segments.
In FIG. 9 a split keyed connector is shown where the male keyed connector 15 is inserted into a bored hole 18 of an existing component 16, again in this case a natural bone. A keyed connector female insert 17 is anchored into a drilled or existing hole in the natural bone. The connector 15 can be a direct concealed connection, or have a visable portion such as a disc of emulated cartilage as shown.
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A system for coupling components of toy assemblages, educational models, hobby constructions, component attachments, or the like together using a compact single point snap together axial connector, which is configured or formed with a key like portion included as part of the male connector part, and a corresponding female connector configured to prevent rotational movement about the connectors axis, and/or to limit the selective attachment of the components.
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This application is a 35 U.S.C. 371 of PCT/GB95/01987 filed Aug. 21, 1995.
The present invention relates to methods of nucleotide sequencing, and more particularly to methods for rapidly determining the identity of several single bases at given locations simultaneously within one or more target nucleotide base sequences within a sample comprising one or more polynucleotide chains.
BACKGROUND OF THE INVENTION
The ability to determine the identity of a nucleotide within a characterised sequence of DNA has many applications in the fields of medical and forensic science. For instance, changes in one or more individual, ie. single, bases in genomic DNA have been shown to be associated with a number of human hereditary diseases including muscular dystrophy and cystic fibrosis. The identification of such mutations at the prenatal and postnatal stages can be a valuable diagnostic tool. Similarly, the identity of single bases at several polymorphic sites in human DNA can provide an accurate method for matching forensic samples with genetic material taken from known subjects.
Methods for the detection of characterised sequences or variations are known in which the region of DNA containing the variation is first amplified by the Polymerase Chain Reaction (PCR) and the sample is then tested using immobilised oligonucleotide probes which correspond to the possible variations in the region (Saiki et al. 1989; Proc Natl Acad Sci U.S.A. 86: 6230-6234). Such methods are cumbersome because a probe is required for each possible variation, and a separate reaction must be carried out for each probe.
Methods are also known for detecting a single base variation in which first a segment of DNA is amplified by PCR using two primers, one of which has been conjugated to biotin. The resulting biotin-DNA is immobilised and used as a template for a single detection-step primer which anneals to the DNA immediately upstream of the site of the variation. The variation is then investigated using a pair of radiolabelled nucleoside triphosphates corresponding to two possible base variations. These are added to the immobilised DNA/primer mixture in the presence of a suitable polymerase.
The identity of the base variation can then be ascertained by using a scintillation counter to measure the radioactivity incorporated into the eluted detection primer. Alternatively a digoxigenin label can be used which can be detected by spectrophotometery. This method has the disadvantage that a separate incorporation experiment must be carried out for each possible variation in each variable region. By using two distinguishable radiolabels, the number of experiments can be reduced slightly. However, each variable region must still be analysed separately which makes it laborious when analysing several polymorphic sites, for instance when compiling stringent forensic data or screening for several different inherited diseases. The present inventors have now provided a method that addresses some, and in preferred forms all, of these problems.
According to a first aspect of the present invention there is provided a method for determining the identity of at least two discrete single nucleotide bases each adjacent to a predetermined target nucleotide base sequence in a target sample comprising one or more types of polynucleotide chain, the method comprising mixing the target sample with (i) nucleotide primers which are complementary to the predetermined base sequences such that they anneal thereto at positions adjacent to the bases to be identified, (ii) at least two types of chain terminator each type labelled with a characteristic fluorescent group, and (iii) a nucleotide chain extending enzyme such that terminators complementary to the bases to be identified are incorporated into the nucleotide primers; separating the types of extended nucleotide primer on basis of size and/or charge and identifying the terminators incorporated into each type of nucleotide primer by reference to its fluorescent characteristics. Using the preferred embodiments the present invention provides a method for rapidly determining several discrete bases simultaneously.
Preferably the chain terminators are dideoxynucleoside triphosphates (ddNTPs); however other terminators such as might occur to the skilled addressee eg. nucleotide analogs or arabinoside triphosphates, are also encompassed by the present invention.
Preferably the polynucleotide is DNA, however the invention could also be applied to RNA were suitable enzymes to become available. The primary requirement for the method to operate is that each of the unknown bases is adjacent to a nucleotide base sequence which is sufficiently elucidated to allow the design of a working primer i.e one which can initiate accurate template-mediated polymerisation. The term `adjacent` in this context means one base upstream of the unknown base i.e in the 3' direction with respect to the template strand of the target DNA.
As is known, ddNTPs differ from conventional deoxynucleoside triphosphates (dNTPs) in that they lack a hydroxyl group at the 3' position of the sugar component. This prevents chain extension of incorporated ddNTPs, and thus leads to termination. Although the use of ddNTPs in conjunction with dNTPS for the sequencing of DNA chains by the Sanger-Coulson method is well documented, in the present invention ddNTPs are used without dNTPS; hence chain extension by the chain extending enzyme terminates after the addition of only one base which is complementary to the base being determined.
Each of the ddNTPs used in the present invention is labelled with a distinguishable fluorescent group, thereby allowing all possible base identities to be ascertained in a single operation. Any distinctive fluorescent label which does not interfere with the incorporation of the ddNTP into a nucleotide chain may be suitable. Dye labels having these characteristics are discussed by Lee et al. 1992; Nucleic Acids Research Vol. 20 10: 2471-2483. The fluorescently labelled nucleotides generated by the methods of the current invention can be conveniently scanned using conventional laboratory equipment, for instance the Applied Biosystems Inc. Model 373 DNA Sequencing system.
Preferably the target DNA in the sample to be investigated is first amplified by means of the Polymerase Chain Reaction (PCR) technique well known to those skilled in the art. Enriching the target DNA used in the method can provide a quicker, more accurate. template-directed synthesis by the nucleotide chain extending enzyme. Since target DNA used in the method can consist of several different regions or chains of DNA, these can potentially be generated in a single PCR step by using several different primer pairs. The invention can be carried out without any need to separate the target chains.
Preferably the target nucleotide sequence in the sample, or a corresponding nucleotide sequence derived from it (eg. by PCR) is purified before mixing with agents (i) to (iii) by incorporating a capture group into it and immobilising it through that group. By carrying out PCR with primers which have been conjugated to a capture group, a population of target DNA can be generated which can be readily immobilised onto an insoluble, solid-phase substrate adapted to complement the capture group. Alternatively the capture group can be annealed to the target DNA directly. Any pair of chemical species which bind strongly, and one of which can be annealed to nucleotide chains, can be used. Suitably the biotin/avidin pair can be employed, with the biotin being annealed to the target DNA and the avidin being attached to a solid substrate eg. latex or polystyrene coated magnetic beads.
Immobilisation greatly facilitates the efficient removal of unincorporated primers and labelled ddNTPs, which will in turn improve the analysis of the extended primers to see which ddNTPs have been incorporated into them. This is particularly important when the invention is being applied to identify a large number of nucleotide bases in a single operation and hence where there will be many extended primer products to separate and analyse.
The number of types ddNTP which are used in the method will depend on the number of possible identities which the bases to be determined could possess. Thus, for instance, if none of the bases to be determined is likely to be an adenosine residue, then ddTTP can be omitted from the reaction mixture. In most cases, however, it will be preferable to have four ddNTP species present, so as to be able to accurately detect all possible combinations.
The nucleotide chain extending enzyme is preferably a DNA polymerase, or viable fragment thereof (such as the Klenow fragment). Most preferably the DNA polymerase is a thermostable polymerase, such as that from Thermus aquaticus (`Taq polymerase`).
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a schematic diagram of the method described in the example;
FIG. 2 shows flow chart of the steps carried out in the method described in the example; and
FIG. 3 shows the results obtained on a primer-extension product mix provided by carrying out the method of the example.
DETAILED DESCRIPTION OF THE INVENTION
After the incorporation of the ddNTPs, the extended nucleotide primers are preferably separated by gel electrophoresis. This facilitates the identification of the incorporated ddNTPs since the bands on the gel can be conveniently scanned with a fluorimeter set to suitable excitation/emission wavelengths. Alternatively, the primers can be separated by column chromatography such as gel filtration, and the fluorescence characteristics can be assessed by analysis of the eluent.
The nucleotide primers, which form a further aspect of this invention, should be selected such that they do not inhibit each other when used simultaneously. Preferably each primer has a length that ensures its extension product's mobility (eg. on PAGE) is distinct from other primer products. In order to facilitate separation of the extended nucleotide primers, it may be preferable to adapt the size of the nucleotide primers used in the reaction i.e. to engineer them such that they are separable by the chosen method. This is especially important when using a large number of primers to investigate several sites simultaneously. Any means which alters the size, and hence mobility, of the primer without interfering with its binding and chain initiating properties would be suitable.
Most preferably, however, the mobility is adapted by means of a polynucleotide tail attached to the 5' end of the nucleotide primer, and not being complementary to the strand being probed. The nature of the tail should be such that it causes minimal interference with the target DNA or with the rest of the primer or other primers, for instance by causing the formation of secondary or higher structures such as hairpin loops. Also it is preferable that the tail be storage-stable eg. it does not readily hydrolyse in solution. Particularly effective are polyT or polyA tails.
In a second aspect the invention makes available a method for screening a DNA sample for a plurality of genetic disorders comprising carrying out a method as herein before described, wherein the discrete single nucleotide bases being analysed are associated with genetic disorders.
Disorders which are associated with base substitution are particularly suitable for investigation by the current methods as they lead to changes which are readily identifiable. Defects such as base deletion can also be investigated if the deletion leads to a change in the identity of the base at a given position i.e. if the `following` base is different to the one that is deleted. More complex changes, for instance oligo (G) length made available by the present invention simply by careful selection of the primers used.
In a further aspect the invention makes available a method for rapid typing of a DNA sample comprising carrying out a method as described above on a number of discrete single nucleotide bases in that sample, the bases being known to show significant variation within the population from which the sample was drawn (`forensic typing`).
In a still further aspect the invention makes available a method for comparing corresponding discrete single nucleotide bases in a first DNA sample with a second DNA sample comprising carrying out a method as described above on each sample and comparing the results obtained therefrom (`forensic matching`). Under many circumstances it will be desirable to amplify the two samples by PCR--preferably this should be carried out using the same types of primer for each.
Such methods have wide application in the forensic sciences, as well as being useful research tools. The number of bases examined should be chosen according to the application, since a larger number of bases will give a more stringent test but will be more expensive to carry out. Preferably the target samples analysed in these methods comprise hypervariable segments of DNA i.e. sites at which the bases vary widely within a population. Analysis of such sites is more likely to show up differences between samples than comparison of more conserved regions.
When using the method for typing or matching of samples of human origin, the single nucleotide bases being compared are preferably at polymorphic sites in human mitochondrial or chromosomal DNA. For instance, the multiplex analysis of bi-allelic loci is particularly useful for human identification purposes.
Most preferably, forensic typing or matching is carried out on some or all of the bases at any of the following positions on the human mitochondrial genome, each of which has a characterised polymorphism associated with it: L00073 substitution, L00146 substitution, L00152 substitution, L00195 substitution, L00247 substitution, the dinucleotide repeat around L00525, L16069 substitution, L16129 substitution, L16189 substitution, L16224 substitution, L16311 substitution. The sequences at these positions are given in Anderson et al, (1981), Nature 290; p457 and their frequencies given in Piercy et al (1992) Int J Leg Med, 106, 85-90. The designation `L` refers to the `light` strand of the mitochondrial genome (as opposed to the `heavy` or `H` strand). The bases are numbered from 1 upwards in the 5' to 3' direction on the L strand. The simultaneous analysis of all 12 of these polymorphisms allows exceptionally rapid typing of human DNA-containing samples. Additionally, the choice of mitochondrial DNA allows the analysis of forensic samples which are severely degraded or contain low levels of chromosomal DNA such as old bones, shed hairs, old blood, old semen, and faeces.
Polymorphisms at the positions listed above are preferably investigated using respective primers that are targeted at sites on the L or H strand of mitochondrial DNA. If a mixture of primers annealing to both L and H strands are used, it will be necessary to ensure that any amplification stage employed in the process, for instance PCR, amplifies both strands of the duplex. Similarly, if immobilisation is being employed, then all the PCR products to be probed should be immobilisable.
The primers should be designed so as to readily initiate ddNTP incorporation by a nucleotide chain extending enzyme, and yet be easily separable after the elution and incorporation stages are complete. This ease of separation may be provided by altering the length of the primer as described above. Using this techniques several, and in preferred forms all 12, of the primers can be used simultaneously in a multiplex reaction giving a highly distinctive DNA `fingerprint`, with the probability of a random match between two unrelated Caucasians using all of the primers being approximately 0.09, based on published data of Piercy et al (1993).
In situations where data of even higher statistical significance is required, an additional polymorphism (L00309.1--oligo (g) length variation) can be investigated using another primer. The results of this analysis can be combined with the results of the 12-primer multiplex analysis, thereby decreasing the probability of a random match to approximately 0.05, based on the same published data.
Also provided by the present invention are primers suitable for probing the polymorphisms described above and having mobility modifying 5' tails. Preferably these tails are composed of a single type of polynucleotide, eg. polyT tails, or polyA tails. Most preferably each of the primers comprises one of the sequences of Seq ID Nos. 2-13 eg. is identical to the sequence, or is extended at the 5' end (i.e. has an extended tail). The tails in the Seq ID Nos. 2-13 are as shown in Table 1.
TABLE 1______________________________________Seq ID No Tail______________________________________2 1-93 1-94 1-175 1-186 1-167 1-248 1-269 1-2610 1-1911 1-2412 1-4013 1-42______________________________________
Also encompassed by the invention are primers having sequences which are mere workshop variations of Sequence ID Nos. 2-13, but which still have their utility i.e. are useful for probing the polymorphisms described above using the method of the present invention, and are readily separable when used together. For instance the polyT tails could be substituted by polyA tails. Similarly the tails could be shortened by a few bases, provided that this does not compromise their separability. Also, it is well known in the art that template-mediated primer extension may be initiated not with standing that a few bases are not perfectly base-paired; thus primers which differ from the above by only a few bases eg. 1 or 2, but which can still initiate template-mediated primer extension are also embraced by the present invention.
In a further aspect of the invention there is provided a kit for use in the analysis of DNA comprising one or more amplification primer-pairs having capture groups and being suitable for carrying out the polymerase chain reaction on DNA such as to amplify a portion of the DNA encompassing at least two of polymorphisms, together with two or more differently fluorescently labelled ddNTPs and/or two or more nucleotide primers targeted at a sequence adjacent the polymorphism from which chain extension using the ddNTPs can be initiated.
In a further aspect of the invention there is provided a kit for use in the analysis of at least two discrete single nucleotide bases in DNA sample comprising one or more amplification primer-pairs having capture groups and being suitable for carrying out the polymerase chain reaction on DNA such as to amplify a portion of the DNA encompassing the bases, together with two or more differently fluorescently labelled ddNTPs and/or two or more nucleotide primers targeted at a sequence adjacent the bases from which chain extension using the ddNTPs can be initiated.
Preferably the bases represent polymorphisms, and the DNA is human mitochondrial DNA and the primer pairs are suitable for amplifying a portion of the DNA encompassing at least two of the sites described above. Such kits allow the rapid analysis of multiple-nucleotide base variations. Preferably the targetting primers are those discussed above.
The methods and kits of the invention have wide applications in the fields of medical and forensic science, and also in applied molecular biology research, for instance in the screening of microorganisms. The speed and simplicity of carrying out the methods mean that they are well suited to being carried out by unskilled practitioners or to being automated. The facility for obtaining detailed DNA-typing information with minimal effort opens up the possibility of rapidly compiling and comparing forensic evidence from a wide range of sources in a short period of time.
The method and kits of present invention will now be described, by way of illustration only, by reference to the following example. Other embodiments falling within the scope of the invention will occur to those skilled in the art in the light of this.
FIGURES
FIG. 1 shows a schematic diagram of the method described in the Example.
FIG. 2 shows a flow chart of the steps carried out in the method described in the Example.
FIG. 3 shows the results obtained on a Genescan -672 on a primer-extension product mix provided by carrying out the method of the Example. B, G, Y and R indicate blue (G), green (A), yellow (T) and red (C) base markers.
EXAMPLE,
Multiplex minisequencing of human mitochondrial genome
The principles of the method are outlined in diagram shown in FIG. 1, while a more detailed scheme is shown in FIG. 2.
Amplification of Target DNA
The regions of the mitochondrial genome between L00067 and L00325 (using SEQ ID Nos. 14 and 15), L00397 and L00572 (using SEQ ID Nos. 16 and 17), and between L16049 and L16331 (using SEQ ID Nos. 18 and 19) were amplified using a Perkin Elmer GeneAmp PCR system 9600 with 1 ng of template DNA in a total volume of 50 μl. The amplification was carried out using 35 cycles of denaturation for 30s at 94°, annealing for 30s at 57° C. and extension for 90s at 72° C. Primers corresponding to SEQ ID Nos. 14, 15, 17 and 18 had all previously been labelled with biotin at their 5' end (Oswel DNA services, Edinburgh). Concentrations used were 0.1 μM each of all primers in 1× PARR buffer (Cambio Ltd., Cambridge), 200 μM each dNTP (Boehringer Mannheim, Mannheim Germany), and 2.5 U Amplitaq DNA polymerase (Perkin Elmer Corporation, Norwalk, Conn.).
Immobilisation of Target DNA
Dynabeads M-280 Streptavidin (Dynal Oslo) were washed twice in 1× binding and washing buffer (5 mM Tris-HCl pH7.5. 0.5 mM EDTA, 1M NaCl) and resuspended in 2× binding and washing buffer containing 10% formamide. 40 μl of each PCR product was denatured at 94° C. for 1 min and snap-cooled on ice, prior to addition of 40 μl of washed beads. This mixture was incubated at 48° C. for 15 min to allow binding of the biotinylated PCR products to the streptavidin coated Dynabeads. Any remaining unbound PCR product and primers along with dNTPs from the amplification reaction were removed by 6 washes in 2× binding and washing buffer and 1 wash in sterile distilled water. Any fragments of DNA unbound to the beads but annealed to the bound PCR products were removed by incubation with 0.15M NaOH at room temperature for 4 min. followed by a wash with fresh 0.15M NaOH. 250 mM Tris-HCl pH8, 0.1% Tween20, 10 mM Tris-HCl pH7.5, 1 mM EDTA and distilled water.
ddNTP incorporation step
Minisequencing primer multimixes were prepared containing 80 mM Tris-HCl, 20 mM MgCl 2 , 20 mM (NH 4 ) 2 SO 4 10% dimethyl sulphoxide, 0.1 μl of each fluorescent ddNTP (ddGTP, ddATP, ddTTP and ddCTP labelled with R110, R6G, 6-TAMRA and 6-ROX respectively, all supplied in solution by Applied Biosystems), 2.5 U Taq polymerase (Perkin Elmer), minisequencing primers and sterile distilled water to a total volume of 50 μl.
For the incorporation step, the distilled water was removed then the PCR product-bead complex was resuspended in 50 μl of a multimix containing 3.0 μM of primer H00303 (Seq ID No. 1). The tubes were placed in a Perkin Elmer GeneAmp PCR system 9600 thermal cycler preheated to 94° C. The temperature was immediately reduced to 52° C. and after this was attained the 50 μl of the multimix containing all the other primers, also equilibrated to this temperature, was added to the sample. The primers used in the second multimix were as shown in Table 2.
TABLE 2______________________________________Primer number gives the position adjacent the polymorphismat which the primer end base binds.Primer Seq ID No Conc. of primer (μM )______________________________________H00074 2 1.0H16312 3 0.66H16070 4 0.07L00194 5 0.2H00153 6 0.07L00145 7 1.3H00248 8 0.4H16225 9 0.35L00524 10 0.15L00522 11 0.03H16130 12 0.32H16190 13 0.15______________________________________
Incubation was continued at 52° C. for 1 min before removing and placing on ice, prior to removal of the supernatent and 2 washes in 2× binding and washing buffer plus one further wash in 1× binding and washing buffer. The sample was then resuspended in deionized formamide and incubated at 72° C. for 4 min.
Separation of extended nucleotide primers: The samples were snap cooled on ice and the supernatent removed and electrophoresed for 75-90 min in a 19% polyacrylamide gel (19:1 acrylamide: bisacrylamide) using an Applied Biosystems 377 automated sequencer with a well-to-detection distance of 12 cm.
Identification of ddNTPs incorporated into primers: The results of the DNA fragment analysis by the automated sequencer are shown in FIG. 3. As can be seen the 12 peaks (plus 1 absence of peak) can be readily related to the 13 primers used in the minisequencing since the position of the peaks is dependent on the mobility, and hence the length, of the primers. The colour of the peaks corresponds to the emission wavelength of the dye-labelled ddNTP incorporated into each primer. Thus the identity of the bases on the mitochondrial sample used in the experiment can be deduced as follows (peaks being left to right i.e. shortest, most-mobile, first)
TABLE 3______________________________________Sequences of primers are as shown in Table 2.Peak Primer Colour ddNTP target Base______________________________________1 H00303 BLUE G L00302 C2 H00074 YELLOW T L00073 A3 H16312 GREEN A L16311 T4 H16070 BLUE G L16069 C5 L00194 YELLOW T L00195 T6 H00153 GREEN A L00152 T7 L00145 YELLOW T L00146 T8 H00248 RED C L00247 G9 H16225 GREEN A L16224 T-- L00524 -- -- L00525 } indicates10 L00522 RED C L00523 } 4 repeats11 H16130 YELLOW T L16129 A12 H16190 GREEN A L16189 T______________________________________
The H Primers anneal to directly to the L strand of the mitochondrial DNA; thus the ddNTP is complementary to the base to be identified. The L primer ddNTPs have the same identity as the base to be studied. Primers L00524 and L00522 are used in conjunction to see how many repeat units are present at the locus. The blank/red result indicates 4 repeats. Other possible results are red/green (5 repeats) or green/green (6 or more repeats). The bases identified and the presence of the 4 dinucleotide repeats can be used as an accurate means of DNA typing.
__________________________________________________________________________# SEQUENCE LISTING- (1) GENERAL INFORMATION:- (iii) NUMBER OF SEQUENCES: 19- (2) INFORMATION FOR SEQ ID NO: 1:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 31 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO- (vi) ORIGINAL SOURCE: (A) ORGANISM: Homo sapi - #ens (I) ORGANELLE: Mitochondri - #on#1: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 31 CGGG GGGAGGGGGG G- (2) INFORMATION FOR SEQ ID NO: 2:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 37 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO- (vi) ORIGINAL SOURCE: (A) ORGANISM: Homo sapi - #ens (I) ORGANELLE: Mitochondri - #on#2: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 37 CTCG CAATGCTATC GCGTGCA- (2) INFORMATION FOR SEQ ID NO: 3:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 38 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO- (vi) ORIGINAL SOURCE: (A) ORGANISM: Homo sapi - #ens (I) ORGANELLE: Mitochondri - #on#3: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 38 TGTA CGGTAAATGG CTTTATGT- (2) INFORMATION FOR SEQ ID NO: 4:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 42 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO- (vi) ORIGINAL SOURCE: (A) ORGANISM: Homo sapi - #ens (I) ORGANELLE: Mitochondri - #on#4: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 42 TAAA TACATAGCGG TTGTTGATGG GT- (2) INFORMATION FOR SEQ ID NO: 5:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 46 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO- (vi) ORIGINAL SOURCE: (A) ORGANISM: Homo sapi - #ens (I) ORGANELLE: Mitochondri - #on#5: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 46TCT ACGTTCAATA TTAYAGGCGA VCATAC- (2) INFORMATION FOR SEQ ID NO: 6:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 48 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO- (vi) ORIGINAL SOURCE: (A) ORGANISM: Homo sapi - #ens (I) ORGANELLE: Mitochondri - #on#6: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 48CTGT AATATTGAAC GTAGGTGCGA TAAATAAT- (2) INFORMATION FOR SEQ ID NO: 7:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 52 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO- (vi) ORIGINAL SOURCE: (A) ORGANISM: Homo sapi - #ens (I) ORGANELLE: Mitochondri - #on#7: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- TTTTTTTTTT TTTTTTTTTT TTTTGTCGCA GTATCTGTCT TTGATTCCTR CC - # 52- (2) INFORMATION FOR SEQ ID NO: 8:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 54 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO- (vi) ORIGINAL SOURCE: (A) ORGANISM: Homo sapi - #ens (I) ORGANELLE: Mitochondri - #on#8: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- TTTTTTTTTT TTTTTTTTTT TTTTTTCTGT GTGGAAAGTG GCTGTGCAGA CA - #TT 54- (2) INFORMATION FOR SEQ ID NO: 9:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 56 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO- (vi) ORIGINAL SOURCE: (A) ORGANISM: Homo sapi - #ens (I) ORGANELLE: Mitochondri - #on#9: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- TTTTTTTTTT TTTTTTTTTT TTTTTTTTTG GAGTTGCAGT TGATGTGTGA TA - #GTTG 56- (2) INFORMATION FOR SEQ ID NO: 10:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 63 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO- (vi) ORIGINAL SOURCE: (A) ORGANISM: Homo sapi - #ens (I) ORGANELLE: Mitochondri - #on#10: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- TTTTTTTTTT TTTTTTTTTC TCATCAATAC AACCCCCGCC CATCCTACCC AG - #CACACACA 60# 63- (2) INFORMATION FOR SEQ ID NO: 11:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 66 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO- (vi) ORIGINAL SOURCE: (A) ORGANISM: Homo sapi - #ens (I) ORGANELLE: Mitochondri - #on#11: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- TTTTTTTTTT TTTTTTTTTT TTTTCTCATC AATACAACCC CCGCCCATCC TA - #CCCAGCAC 60# 66- (2) INFORMATION FOR SEQ ID NO: 12:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 70 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO- (vi) ORIGINAL SOURCE: (A) ORGANISM: Homo sapi - #ens (I) ORGANELLE: Mitochondri - #on#12: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- TTTTTTTTTT TTTTTTTTTT TTTTTTTTTT TTTTTTTTTT GTACTACAGG TG - #GTCAAGTA 60# 70- (2) INFORMATION FOR SEQ ID NO: 13:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 75 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO- (vi) ORIGINAL SOURCE: (A) ORGANISM: Homo sapi - #ens (I) ORGANELLE: Mitochondri - #on#13: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:- TTTTTTTTTT TTTTTTTTTT TTTTTTTTTT TTTTTTTTTT TTGGTTGATT GC - #TGTACTTG 60# 75- (2) INFORMATION FOR SEQ ID NO: 14:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 21 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO- (vi) ORIGINAL SOURCE: (A) ORGANISM: Homo sapi - #ens (I) ORGANELLE: Mitochondri - #on#14: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:#21 GTCT G- (2) INFORMATION FOR SEQ ID NO: 15:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 22 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO- (vi) ORIGINAL SOURCE: (A) ORGANISM: Homo sapi - #ens (I) ORGANELLE: Mitochondri - #on#15: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 22GCT GT- (2) INFORMATION FOR SEQ ID NO: 16:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 21 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO- (vi) ORIGINAL SOURCE: (A) ORGANISM: Homo sapi - #ens (I) ORGANELLE: Mitochondri - #on#16: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:#21 CTAA C- (2) INFORMATION FOR SEQ ID NO: 17:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 23 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO- (vi) ORIGINAL SOURCE: (A) ORGANISM: Homo sapi - #ens (I) ORGANELLE: Mitochondri - #on#17: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 23AACT GTG- (2) INFORMATION FOR SEQ ID NO: 18:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 20 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO- (vi) ORIGINAL SOURCE: (A) ORGANISM: Homo sapi - #ens (I) ORGANELLE: Mitochondri - #on#18: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 20 TTGG- (2) INFORMATION FOR SEQ ID NO: 19:- (i) SEQUENCE CHARACTERISTICS:#pairs (A) LENGTH: 23 base (B) TYPE: nucleic acid (C) STRANDEDNESS: single (D) TOPOLOGY: linear- (ii) MOLECULE TYPE: DNA (genomic)- (iii) HYPOTHETICAL: NO- (iii) ANTI-SENSE: NO- (vi) ORIGINAL SOURCE: (A) ORGANISM: Homo sapi - #ens (I) ORGANELLE: Mitochondri - #on#19: (xi) SEQUENCE DESCRIPTION: SEQ ID NO:# 23TGCT ATG__________________________________________________________________________
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A method is provided for determining the identity of at least two discrete single bases each adjacent to a predetermined nucleotide base sequence in a target sample having one or more types of polynucleotide chain. The method includes incorporating a capture group into the target sample and immobilizing the target sample by means of the capture group; mixing the target sample with (i) nucleotide primers which are complementary to predetermined base sequences such that they anneal to them at positions adjacent to the bases to be identified and (ii) at least two types of dideoxoy nucleoside triphosphate (ddNTPs), each type labelled with a distinguishable fluorescent group, and (iii) a nucleotide chain extending enzyme such that ddNTPs complementary to the bases to be identified are incorporated into the nucleotide primers; eluting the extending nucleotide primers, separating the types of extended nucleotide primer on basis of size or charge and identifying the ddNTPs incorporated into each type of nucleotide primer by reference to the fluorescent characteristics associated with the distinguishable groups. Primers and a test kit are provided for use in performance of the method.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to an injection valve for injecting a medium, e.g., for injecting fuel into a combustion chamber, which injection process may be developed as a port injection or as a direct injection.
[0003] 2. Description of the Related Art
[0004] The related art includes known injection valves for the injection of Otto fuel. They have a valve needle which is moved against a closing spring by an actuator, e.g., an electromagnet or a piezo actuator, in such a way that a desired fuel quantity is selectively introduced directly into the combustion chamber. In the case at hand, an injection valve is examined in which the magnetic armature is decoupled from the valve needle. When the injection valve is opened, the magnetic armature is meant to rapidly detach from the lower stop (second stop) on the valve needle, to rapidly overcome the armature free travel, and to quickly open the valve when striking the upper (first) stop. If the energization of the valve is stopped, then the valve needle closes again. Once the valve needle seals the valve seat again, the magnetic armature continues its movement until it strikes the lower stop. The armature bounces off the lower stop multiple times before reattaining its idle position. The time until the magnet armature is reset to the idle position again is decisive for the ability of the valve to deliver injections in rapid succession and with high accuracy. A squish gap is usually developed at the lower stop, i.e., between the magnetic armature and the corresponding stop sleeve on the valve needle. The medium to be injected is squeezed into this squish gap, so that the magnetic armature is reset to the idle position in a damped and rapid manner during the closing. However, by damping the movement during the opening, the squish gap prevents a rapid opening. As a compromise, the squish gap must therefore be configured in such a way that the magnet armature opens the valve with sufficient speed and is reset to its idle position with sufficient speed as well.
BRIEF SUMMARY OF THE INVENTION
[0005] The injection valve of the present invention allows for better damping of the magnet armature and thus makes it possible to reset the magnet armature to its idle position more rapidly than previously possible after the injection valve is closed. At the same time, the damping during the opening of the injection valve is reduced in the present invention, so that the injection valve opens more rapidly. More specifically, the following advantages thus result in the opening of the injection valve: The magnet armature detaches from the valve needle more rapidly than previously, which increases the dynamic response of the valve and therefore improves the function. The required opening force is reduced, so that the current consumption of the injection valve, and thus the entire energy requirement of the vehicle, is lower. This lowers the consumption of the vehicle. The following advantages result in the closing of the injection valve: The movement of the magnet armature is damped to a greater extent than before. The magnet armature therefore reaches its idle position earlier than previously, so that injections are able to be delivered in rapid succession and with high repeat accuracy. The injection valve according to the present invention provides new injection strategies that make possible a combustion featuring lower pollutant emissions and lower consumption. The better damping in the closing of the injection valve reduces the noise that is created by the pulse transmission of the magnet armature to the valve needle. All of these advantages are achieved by an injection valve according to the present invention, which includes a housing having at least one spray-discharge orifice on a discharge side, a solenoid coil and a magnetic armature, which is linearly movable with the aid of the solenoid coil. In addition, the injection valve has a valve needle. This valve needle is used for the opening and closing of the at least one spray-discharge orifice. The valve needle extends along a longitudinal axis and is linearly movable. A through hole is developed in the magnet armature, in which the valve needle is situated. The magnet armature is linearly movable between a first and a second stop in relation to the valve needle. This creates a two-mass system. The first stop is formed on a side of the magnet armature facing away from the discharge. For example, the first stop is formed by a ring on the valve needle. The second stop is formed on a side of the magnet armature facing the discharge. According to the present invention, the second stop is formed by a stop element and a counter element. The stop element and the counter element strike each other at the second stop. The stop element has a stop face for this purpose. A counter face situated across from the stop face is developed on the counter element. The stop face and counter face strike each other at the second stop. The stop element has an elastic design, so that an angle between the longitudinal axis and stop face changes when the counter face and the stop face strike each other. In particular, the stop face is inclined toward the counter element prior to and following the contact between stop element and counter element. As soon as the counter element and stop element make contact with each other, the stop element is elastically deformed, so that the space between the stop face and counter face becomes smaller. Because of the elastic development of the stop element according to the present invention, it is possible that there is a change in the squish gap and the throttle flow between the stop face and counter face when the stop face and counter face move towards and away from each other. This enables a very precise adjustment of the damping in the opening and closing of the injection valve.
[0006] The stop element is preferably permanently connected to the valve needle. The counter element will then be situated on the magnet armature. The counter element in particular is an integral component of the magnet armature. In the most straight-forward case, the counter face is the side of the magnet armature that faces the stop face. In an alternative development, it is possible that the stop element is permanently connected to the magnet armature. The counter element will then be permanently joined to the valve needle. Decisive is that at least one of the opposing surfaces on the second stop has an elastic design. This at least one elastic surface is referred to as stop face within the scope of the present application.
[0007] The stop element or counter element is preferably integrated into the valve needle. As an alternative, the stop element or counter element is integrated into the magnet armature.
[0008] It is furthermore preferably provided that the angle between the longitudinal axis and stop face without contact between stop face and counter face is less than 90° at least regionally. The angle is defined on the side of the stop face that faces the counter face. This means that the angle of less than 90° defines that the stop face is inclined toward the counter face. It suffices if the stop face has this inclination at the corresponding angle only in certain places. When the counter face strikes the stop face, the stop face will be deformed, so that the angle becomes greater.
[0009] When lifting off from the stop face and counter face, i.e., during the opening of the injection valve, the stop element relaxes again, so that the angle becomes smaller again. Because of the development of the angle it is possible that the movement of the magnet armature is damped only by a throttle flow but no squish gap when the injection valve opens. As soon as the counter face and the stop face move slightly apart from each other, the stop element relaxes and the stop face thus inclines in the direction of the counter face. As a result, the stop face and counter face are no longer aligned in parallel with one another, and no squish gap is present. Only a throttle flow, i.e., the flow of the medium to be injected, which flows out of the region between stop face and counter face, dampens the opening movement of the magnet armature.
[0010] When the injection valve closes, the stop face and the counter face move toward each other. In so doing, the stop face is initially inclined in the direction of the counter face, so that a relatively large space filled with the medium is present between the stop face and counter face. The movement is initially dampened by a throttle flow, and as soon as the stop face and counter face make contact with each other, the stop face is deformed, so that the stop face aligns itself parallel to the counter face. This creates a squish gap for damping the movement of the magnet armature. The damping effect therefore increases as the clearance between stop face and counter face becomes smaller.
[0011] It is provided, in particular, that the angle without the contact between stop face and counter face amounts to maximally 89.99 degrees, preferably maximally 89.85 degrees. As already described earlier, this angle need not be provided across the entire stop face.
[0012] It is furthermore preferably provided that as a result of the striking contact between counter face and stop face, the angle is elastically deformed by at least 0.01 degrees, preferably at least by 0.15 degrees. In an especially preferred specific embodiment, the stop face is deformed until the stop face and counter face are in parallel alignment with each other.
[0013] It is furthermore advantageous that the stop face is subdivided into an inner section and an outer section. The inner section is closer to the longitudinal axis than the outer section. Especially preferably, the stop face is an annular surface around the valve needle. The inner section is an inner annular surface. The outer section is a further annular surface lying outside of the inner section. The angle without contact between stop face and counter face is larger at the outer section than at the inner section. In this context it is preferably provided that the stop face inclines more heavily in the direction of the counter face as the distance from the longitudinal axis increases.
[0014] Especially preferably, it is provided that the inner section without contact between stop face and counter face is developed parallel to the counter face. As an alternative, the inner section may be slightly inclined in the direction of the counter face or have a concave design.
[0015] On the stop element, a side facing away from the counter face is referred to as outer surface. This outer surface should also be formed appropriately, so that enough elasticity is available for the deformation of the stop face. As a consequence, the outer surface is preferably formed so that it inclines in the direction of the counter element or is at least regionally concave. As an alternative, the outer surface may regionally also lie parallel to the stop face. It is also decisive in this context that the stop element is as thin as possible, so that the stop face is able to deform elastically.
[0016] In order to ensure the elastic deformability of the stop element, and thus also of the stop face, grooves are preferably provided in the stop element. These grooves are especially preferably formed over the entire circumference of the longitudinal axis.
[0017] The first stop is preferably formed by a step or by a ring on the valve needle.
[0018] Exemplary embodiments of the present invention are described in detail below with reference to the accompanying drawing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0019] FIG. 1 shows an injection valve according to the present invention for all exemplary embodiments.
[0020] FIG. 2 shows a detail of an injection valve of the present invention, according to a first exemplary embodiment.
[0021] FIG. 3 shows a further detail of an injection valve of the present invention, according to the first exemplary embodiment.
[0022] FIGS. 4 through 7 show a movement sequence at the injection valve of the present invention, according to the first exemplary embodiment.
[0023] FIG. 8 shows the injection valve of the present invention, according to a second exemplary embodiment.
[0024] FIG. 9 shows the injection valve of the present invention, according to a third exemplary embodiment.
[0025] FIG. 10 shows the injection valve of the present invention, according to a fourth exemplary embodiment.
[0026] FIG. 11 shows the injection valve of the present invention, according to a fifth exemplary embodiment.
[0027] FIG. 12 shows the injection valve of the present invention, according to a sixth exemplary embodiment.
[0028] FIG. 13 shows the injection valve of the present invention, according to a seventh exemplary embodiment.
DETAILED DESCRIPTION OF THE INVENTION
[0029] In the following text, a first exemplary embodiment of injection valve 1 will be discussed with the aid of FIGS. 1 through 7 . Identical components or functionally identical components are designated by identical reference symbols in all exemplary embodiments.
[0030] FIG. 1 illustrates the general structure of injection valve 1 for all the exemplary embodiments. Injection valve 1 includes a housing 2 having a spray discharge orifice 4 on a discharge side 3 . Housing 2 supports a solenoid coil 5 . A valve needle 6 including a ball 7 is disposed along a longitudinal axis 15 in the interior of housing 2 . Ball 7 together with housing 2 forms a valve seat for opening and closing spray orifice 4 .
[0031] In addition, a magnet armature 8 , which is connected to a spring cup 9 , is situated inside housing 2 . On a side of magnet armature 8 that faces away from the discharge is a ring 10 , which is fixedly secured on valve needle 6 . This ring 10 forms a first stop for magnet armature 8 . On a side of magnet armature 8 facing the discharge is a stop element 12 . This stop element 12 forms a second stop together with magnet armature 5 .
[0032] Both valve needle 6 and magnet armature 8 are linearly movable along longitudinal axis 15 . The movement of magnet armature 8 is delimited by the first and second stop.
[0033] A plurality of channels 16 for the medium to be injected are developed in magnet armature 8 . In addition or as an alternative, valve needle 6 may also have a hollow design.
[0034] Valve needle 6 is loaded in the direction of discharge side 3 by means of a first spring 11 . A second spring 13 between spring cup 9 and stop element 12 loads magnet armature 8 , likewise in the direction of discharge side 3 .
[0035] Magnet armature 8 is moved by energizing solenoid coil 5 . By way of the first and second stop, magnet armature 8 carries valve needle 6 along. The distance between the two stops defines an armature free travel 14 .
[0036] FIG. 2 shows a detail of injection valve 1 according to a first exemplary embodiment. It is obvious that stop element 12 is integrally formed with a sleeve 20 . Sleeve 20 is situated on valve needle 6 and permanently joined to valve needle 6 . Magnet armature 8 is simultaneously developed as so-called counter element 18 .
[0037] A surface on stop element 12 facing counter element 18 is referred to as stop face 17 . Situated across from stop face 17 is a counter face 19 on counter element 18 . A side on stop element 12 facing away from counter element 18 is referred to as outer surface 21 . The plotted angle α is defined between stop face 17 and longitudinal axis 15 . Angle α is measured on the side of stop face 17 facing counter element 18 .
[0038] Stop element 12 , and thus also stop face 17 , are elastically deformable. When counter element 18 , i.e., magnet armature 8 , strikes stop element 12 , stop element 12 is elastically deformed, so that angle α becomes larger.
[0039] FIG. 3 shows sleeve 20 and stop element 12 in detail. Sleeve 20 and stop element 12 have a through hole 28 that is coaxial with respect to longitudinal axis 15 . Valve needle 6 is situated in this through hole 28 .
[0040] A first height 25 extends parallel to longitudinal axis 15 , from the upper end of through hole 28 to the outer end of stop face 17 . The outer end of stop face 17 is referred to as peak 27 . A second height 26 designates the extension of stop element 12 parallel to longitudinal axis 15 . The elasticity of stop face 17 in the illustrated exemplary embodiment is achieved in that the two heights 25 , 26 are greater than 0.
[0041] FIGS. 4 through 7 show a movement sequence during the opening and closing of the injection valve. FIG. 4 shows the idle state, in which solenoid coil 5 is not energized and magnet armature 8 merely rests lightly on stop element 12 . Accordingly, stop face 17 is not deformed and stop face 17 is inclined toward counter face 19 at an angle α of less than 90 degrees.
[0042] In the following figures, reference numeral 29 denotes a throttle flow of the medium to be injected. The dashed illustration of stop element 12 shows the elastic deformation.
[0043] Because of the applied magnetic field at solenoid coil 5 , magnet armature 8 is pulled in the direction of the inner pole in FIG. 5 , i.e., in the upward direction in the illustration. Valve needle 6 remains in the valve seat, until magnet armature 8 has overcome armature free travel 14 and carries valve needle 6 along via ring 10 (first stop). As long as a relative movement is present between magnet armature 8 and valve needle 6 , throttle flow 29 comes about between magnet armature 8 and valve needle 6 , i.e., between stop face 17 and counter face 18 . Throttle flow 29 between stop face 17 and counter face 19 decreases with rising clearance, so that the injection valve is able to open rapidly. In FIG. 6 , the current at solenoid coil 5 is switched off, and the magnetic field decays. Valve needle 6 is in the seat, and magnet armature 8 , coming from the first stop on ring 10 , is able to continue its movement in the direction of the second stop on stop element 12 . Because of the relative movement between magnet armature 8 and valve needle 6 , a throttle flow 29 is once again created between stop face 17 and counter face 19 . Throttle flow 29 increases with decreasing clearance, so that the movement of magnet armature 8 is damped to a growing extent. When magnet armature 8 makes contact with stop element 12 , i.e., counter element 19 exerts pressure on stop face 17 , stop element 12 is elastically deformed by the push, and the damping volume situated between stop face 17 and counter face 19 turns into a squish gap. This state is illustrated in FIG. 7 . The movement of magnet armature 8 is decelerated as a result. The elastic deformation of stop element 12 aligns stop face 17 in a coplanar manner in relation to counter face 19 , so that the damping of the magnet armature movement by the squish gap is maximized.
[0044] FIG. 8 shows a detail of injection valve 1 according to a second exemplary embodiment. In the second exemplary embodiment, stop face 17 is subdivided into an inner section 23 and an outer section 24 . Even without contact with counter face 19 , inner section 23 is disposed perpendicularly to longitudinal axis 15 , and thus also in parallel with counter face 19 . In outer section 24 , stop face 17 is inclined at angle α in the direction of counter face 19 .
[0045] Outer surface 21 is situated partially in parallel with counter face 19 and partially inclines toward counter face 19 . More specifically, outer surface 21 is inclined in the direction of the counter face roughly in the region of outer section 24 , so that sufficient elasticity of stop element 12 is provided there.
[0046] FIG. 9 shows a detail of injection valve 1 according to a third exemplary embodiment. In the third exemplary embodiment, stop face 17 is inclined in the direction of counter face 19 both in inner section 23 and in outer section 24 . However, the inclination toward outer section 24 is more pronounced, so that the greatest deformation of stop element 12 occurs there.
[0047] FIG. 10 shows a detail of injection valve 1 according to a fourth exemplary embodiment. In the fourth exemplary embodiment, stop face 17 is inclined in the direction of counter face 19 in inner section 23 and in outer section 24 , in the same way as in the third exemplary embodiment. From sleeve 20 , outer surface 21 is heavily inclined throughout in the direction of counter face 19 . This creates a very narrow stop element 12 , especially in the outer region, which is elastically deformable accordingly.
[0048] FIG. 11 shows a detail of injection valve 1 according to a fifth exemplary embodiment. In the fifth exemplary embodiment, stop face 17 is disposed parallel to counter face 19 across inner section 23 . Stop face 17 is concave along outer section 24 . Outer surface 21 of stop element 12 likewise has a concave design. This creates a relatively narrow stop element 12 having rounded transitions between the various inclinations, so that a dependable elasticity is ensured. Angle α is hereby defined by the tangent, is to the concave development of stop face 17 in outer section 24 and longitudinal axis 15 .
[0049] FIG. 12 shows a detail of injection valve 1 according to a sixth exemplary embodiment. In the sixth exemplary embodiment, a groove has been provided in outer surface 21 of stop element 12 . This groove 22 is developed peripherally about longitudinal axis 15 , in particular. Groove 22 weakens stop element 12 accordingly, so that the desired elasticity is provided.
[0050] FIG. 13 shows a portion of injection valve 1 according to a seventh exemplary embodiment. Seventh exemplary embodiment once again shows a groove 22 for adjusting the elasticity of stop element 12 . In the seventh exemplary embodiment, groove 22 is situated in an area of stop element 12 that extends in parallel with longitudinal axis 15 . This has the result that groove 22 comes very close to peak 27 and stop face 17 , so that not entire stop element 12 but only an upper portion is deformed in this exemplary embodiment.
[0051] The various exemplary embodiments show possible geometries of stop element 12 . In the exemplary embodiments, stop faces 17 are usually in the form of a wedge, since the wedge form is easy to measure and produce. The exemplary embodiments may naturally also be combined. For example, grooves 22 shown in FIGS. 12 and 13 with the appropriate form depth and number in the other exemplary embodiments as well. Furthermore, an adaptation of outer surface 21 according to FIGS. 9 , 10 and 11 is possible in all exemplary embodiments. The different angles and concave developments of stop face 17 of the various exemplary embodiments can be combined with one another. In addition, all other concave and convex forms of stop element 12 are possible, as long as sufficient elasticity is ensured. Additional cross-sectional forms for groove 22 are triangles and ellipses, for example. Even more than one groove 22 per stop element 12 is possible in order to adapt the stiffness appropriately. The exemplary embodiments show rotationally symmetrical valve needles 6 that are not hollow. In the same way, it is possible to use the present invention with hollow and/or not rotationally symmetrical valve needles 6 . Even stop face 17 or counter face 19 need not have a rotationally symmetrical design.
[0052] All exemplary embodiments shown illustrate stop face 17 and counter element 19 in a form in which it is fixedly joined to valve needle 6 . Accordingly, magnet armature 6 in the exemplary embodiments is defined as counter element 18 having counter face 19 . In the same way, it is possible to develop an elastic stop element 12 which is permanently connected to magnet armature 6 . Correspondingly, counter element 18 would then be fixedly joined to valve needle 6 . In the simplest development, counter face 19 is a planar rigid surface. It is also possible for counter face 19 to have a certain inclination and elasticity.
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An injection valve for injecting fuel into a combustion chamber includes: a housing having at least one spray discharge orifice on a discharge side; a solenoid coil; a magnet armature linearly movable by the solenoid coil; a valve needle for opening and closing the spray discharge orifice, which valve needle projects through the magnet armature and is linearly movable along a longitudinal axis, the magnet armature being linearly movable in relation to the valve needle between a first stop and a second stop, the second stop being formed by a stop element having a stop face and a counter element having a counter face situated opposite the stop face, the stop element having an elastic design so that an angle between the longitudinal axis and the stop face is changed when the counter face strikes the stop face.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to papermaking machines and, more particularly, to papermaking machine configured to selectively recirculate exhaust air from a dryer so as to increase dewatering efficiency in processes upstream of the dryer, to reduce emissions from the papermaking machine, and to enhance a vacuum system associated with the papermaking machine.
[0003] 2. Description of Related Art
[0004] Drying devices such as, for example, through-air dryers and Yankee dryers, are often employed in papermaking machines for drying a paper web after the paper web has been formed. Such drying devices often use a combination of heat and flowing air to dry the paper web and, as such, the exhaust from such drying devices comprises moisture-laden hot air. Generally, the venting of the exhaust from a drying device to atmosphere is undesirable for several reasons. For example, venting of the hot, moisture-laden air releases thermal energy that could be applied to other processes within the papermaking machine. Further, releasing the hot, moisture-laden air may increase undesirable papermaking plant emissions and may be unfavorably received by or may adversely affect neighbors surrounding the papermaking plant. In addition, significant and continuous environmental testing associated with the emissions may also be required. Accordingly, it would be desirable to reduce, minimize, or eliminate the emission of exhaust from such papermaking machine drying devices.
[0005] In some instances, the papermaking machine may be configured such that the exhaust from the drying device is recirculated through the drying device in order to reduce the heat input necessary to provide the heated air to the drying device, as well as to reduce emissions. In other instances, some of the exhaust from the drying device may be used to reduce process heat demands or to heat buildings. However, the heat from the exhaust of the drying devices often exceeds the amount of heat that can practically be re-used. In addition, a certain amount of the exhaust from the drying device must often be diverted so as to, for instance, remove excess condensates from the exhaust, wherein the exhaust may then be recirculated through the drying device. In such instances, though, the diverted portion may still be vented to atmosphere and thus will continue to undesirably contribute to plant emissions.
[0006] In order to reduce the amount of moisture to be removed from the web by the drying devices, many papermaking machines employ vacuum devices prior to the drying devices for partially dewatering the web. However, for example, in papermaking machines employing through-air dryers, it often undesirable to press or compact the web, though the web must still be dewatered to, for instance, about 18% to about 32% dryness. The vacuum devices thus employed to provide the necessary vacuum for dewatering the web to such an extent, and without pressing the web, often undesirably consume a significant amount of energy.
[0007] Thus, there exists a need for a papermaking machine having reduced emissions from the exhaust of the drying device(s). Further, it would be desirable for such a papermaking machine to have an efficient non-compacting (in the case of a machine employing a through-air dryer) dewatering process before the web is directed through the drying device(s). In addition, it would be desirable for the papermaking machine to exhibit reduced energy consumption with respect to the vacuum system and/or other high energy-consumption systems associated with the machine.
BRIEF SUMMARY OF THE INVENTION
[0008] The above and other needs are met by the present invention which, in one embodiment, provides an apparatus for decreasing heat emission and enhancing a vacuum system in a papermaking machine. Such an apparatus includes a drying device configured to dry a paper web, wherein the drying device has an air inlet for receiving heated air for removing moisture from the web and an air outlet for exhausting the moisture-containing air from the drying device. A vacuum system is configured to produce a suction and to receive the moisture-containing air. A web handling device is disposed upstream of the drying device and is configured to interact with the web before the web is directed to the drying device. The web handling device is further configured to receive a portion of the moisture-containing air from the air outlet of the drying device, wherein the portion of the moisture-containing air is directed through the web by the web handling device so as to facilitate dewatering of the web before the moisture-containing air is received by the vacuum system. The web handling device is also configured to provide the moisture-containing air at a supply pressure with respect to the suction produced by the vacuum system such that the web handling device operates at an above-ambient pressure.
[0009] Another advantageous aspect of the present invention comprises a method of decreasing heat emission and enhancing a vacuum system in a papermaking machine. The papermaking machine includes a drying device configured to dry a paper web, wherein the drying device has an air inlet for receiving heated air for removing moisture from the web and an air outlet for exhausting the moisture-containing air from the drying device, a web handling device disposed upstream of the drying device and configured to interact with the web before the web is directed to the drying device, and a vacuum system for producing a vacuum. A portion of the moisture-containing air from the air outlet of the drying device is directed to the web handling device, and through the web to the vacuum system, at a supply pressure with respect to the suction produced by the vacuum system such that the web handling device operates at an above-ambient pressure, so as to facilitate dewatering of the web.
[0010] Still another advantageous aspect of the present invention comprises an apparatus for increasing dewatering efficiency of a paper web in a papermaking machine. Such an apparatus includes a drying device configured to dry the web, wherein the drying device has an air inlet for receiving heated air for removing moisture from the web and an air outlet for exhausting the moisture-containing air from the drying device. An air handling device has an air inlet for receiving incoming air to be heated and an air outlet in communication with the air inlet of the drying device for directing the heated air thereto. A web handling device is disposed upstream of the drying device and is configured to interact with the web before the web is directed to the drying device. The web handling device is configured to receive a mixture of a portion of the heated air from the air outlet from the air handling device and a portion of the moisture-containing from the air outlet from the drying device for facilitating dewatering of the web, wherein the web handling device is further configured to interact with the web at an above-ambient pressure.
[0011] Yet another advantageous aspect of the present invention comprises a method of increasing dewatering efficiency of a paper web in a papermaking machine. The papermaking machine includes a drying device configured to dry a paper web, wherein the drying device has an air inlet for receiving heated air for removing moisture from the web and an air outlet for exhausting the moisture-containing air from the drying device. An air handling device has an air inlet for receiving incoming air to be heated and an air outlet for directing the heated air to the drying device, while a web handling device is disposed upstream of the drying device and is configured to interact with the web before the web is directed to the drying device. Accordingly, a portion of the moisture-containing air is first directed from the air outlet of the drying device, while a portion of the heated air from the air outlet of the air handling device is concurrently directed to be mixed therewith, before the mixture of air is directed to the web handling device. Thereafter, the mixture of air is directed through the web at the web handling device, the web handling device being operated at an above-ambient pressure, so as to facilitate dewatering of the web.
[0012] Thus, embodiments of the present invention meet the above-identified needs and provide significant advantages as detailed further herein.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWING(S)
[0013] Having thus described the invention in general terms, reference will now be made to the accompanying drawings, which are not necessarily drawn to scale, and wherein:
[0014] FIGS. 1 A- 1 B schematically illustrate alternative embodiments of a papermaking machine according to the present invention;
[0015] [0015]FIG. 2 is a schematic illustration of an air circulation system showing waste air from the drying devices being directed to upstream web handling devices, with a vacuum system in communication with a web handling devices, according to one embodiment of the present invention;
[0016] [0016]FIG. 3 is a schematic illustration of an air circulation system having a hot air supply device in association with a vacuum system, according to one embodiment of the present invention; and
[0017] [0017]FIG. 4 is a schematic illustration of a through-air dryer showing a hood associated with the TAD extending over a vacuum box, with a blower extending into the hood opposite to the vacuum box, according to one embodiment of the present invention; and
[0018] [0018]FIG. 5 is a schematic illustration of air circulation system showing a mixture of waste air from the drying devices and fresh hot air from an air handling device being directed to upstream web handling devices, with a vacuum system in communication with a web handling devices, according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0019] The present inventions now will be described more fully hereinafter with reference to the accompanying drawings, in which some, but not all embodiments of the invention are shown. Indeed, these inventions may 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 satisfy applicable legal requirements. Like numbers refer to like elements throughout.
[0020] FIGS. 1 A- 1 B illustrates an example of a papermaking machine according to one embodiment of the present invention, the papermaking machine being indicated generally by the numeral 10 . Such a machine 10 includes a former 100 for forming a paper web 20 on a forming fabric 50 . Such a machine 10 further comprises one or more drying devices such as, for example, an impingement dryer (not shown), a through-air dryer 400 , and/or a Yankee dryer 500 . The drying devices generally include a drying fabric 600 configured to receive the web 20 from the forming fabric 50 and to transport the web 20 through the through-air dryer(s) 400 to the Yankee dryer 500 . In some embodiments, the drying fabric 600 may also comprise the forming fabric 50 in that the web 20 may be formed directly on the drying fabric 600 , which may eliminate the forming fabric 50 . At the Yankee dryer 500 , the web 20 is separated from the drying fabric 600 , dried by the Yankee dryer 500 , creped from the Yankee dryer 500 , and then directed to a reel-up 700 . Note, however, that some embodiments may not include a Yankee dryer 500 .
[0021] Generally, the web 20 may be dewatered, transferred between fabrics at various points between the former 100 and the drying devices, and otherwise handled by one or more various web handling devices 75 . For example, after the web 20 is formed on the forming fabric 50 by the former 100 , the web 20 may be directed through a hot air supply device 150 for dewatering the web 20 . In some instances, where the web 20 is transferred from the forming fabric 50 to the drying fabric 600 , a vacuum box 200 may be provided for facilitating transfer of the web 20 to the drying fabric 600 . In still other instances, a molding box 300 may be disposed prior to the drying devices to structure the web 20 , to provide additional dewatering of the web 20 , to pre-heat the web 20 prior to the web 20 entering the drying device, and/or, for example, to provide a seal arrangement for a drying device as discussed, for example, in U.S. Pat. No. 6,199,296, also assigned to the assignee of the present invention and incorporated herein in its entirety by reference. One skilled in the art will appreciate, however, that web handling devices 75 such as the hot air supply device 150 , the vacuum box 200 , and the molding box 300 are only examples of the web handling devices 75 that may be disposed between the former 100 and the drying devices for dewatering the web 20 and that embodiments of the present invention may include any combinations of these devices and/or other dewatering or web handling devices 75 . As will be described further herein, the hot air supply device 150 , the vacuum box 200 , and the molding box 300 are configured to require a suction for operation. Therefore, in some instances, the hot air supply device 150 , the vacuum box 200 , and the molding box 300 are configured to be operably engaged with a common vacuum system 900 (as shown in FIG. 2), though, in some cases, a separate vacuum system (not shown) may be provided for each device. FIG. 1B also shows the web handling devices 75 in phantom, indicating that embodiments of the present invention may include one or more such web handling devices 75 or any combinations thereof and, as such, it will be understood that embodiments of the present invention are neither restricted by the particular number or type of the web handling devices 75 which may be implemented therein.
[0022] As shown in FIGS. 1A, 1B, and 2 , one embodiment of a papermaking machine 10 may include, for example, two consecutive through-air dryers (TADS) 400 and a Yankee dryer 500 . Each TAD 400 and the Yankee dryer 500 may be supplied with air by a common air handling device 800 , or in some instances, by separate air handling devices (not shown), wherein the air is typically heated by a heat source 850 and directed to the drying device by a fan 860 . The heat source 850 may comprise, for example a direct gas-fired heater having a fuel inlet 830 and a combustion air fan 840 , though many different types of direct and indirect heaters may be implemented to provide the necessary heat. The air handling device 800 generally takes in incoming air through an air inlet 810 and provides the air through an air outlet 820 , wherein the air outlet 820 is configured to duct or channel the heated air to the drying devices. In the case of the Yankee dryer 500 , the heated air is introduced into an air inlet 510 in the hood 550 of the Yankee dryer 500 and then exhausted through an air outlet 520 from the hood 550 . The TAD 400 , however, may be configured for either an inward flow or an outward flow, and one skilled in the art will appreciate that both configurations may be implemented herein within the spirit and scope of the present invention. For an inward flow TAD 400 , as shown in FIG. 1, the heated air is supplied to an air inlet 410 in the hood 450 extending about the perforated drying cylinder 460 , and then exhausted through an air outlet 420 extending from the drying cylinder 460 or, for example, an exhaust plenum extending across the dead zone of a single through-air dryer or between adjacent through-air dryers. Accordingly, for an outward flow TAD, the heated air would be supplied through an air inlet extending into the drying cylinder or an intake plenum extending across the dead zone of a single through-air dryer or between adjacent through-air dryers and then exhausted from an air outlet extending from the hood.
[0023] Note that, as shown in FIGS. 2 and 5, several of the drying devices 400 , 500 are shown in phantom to reinforce that a papermaking machine 10 according to embodiments of the present invention may generally include one or more drying devices, such as an impingement dryer, a TAD, and a Yankee dryer, and the TAD 400 not shown in phantom is intended to indicate that the papermaking machine 10 may, in some instances, comprise a single drying device which may be, for example, the TAD 400 , a Yankee dryer, an impingement dryer, or any other suitable dryer, or combinations thereof, consistent with the spirit and scope of the present invention. Likewise, several of the web handling devices 75 are shown in phantom to reinforce that a papermaking machine 10 according to embodiments of the present invention may generally include one or more web handling devices 75 , such as hot air supply device 150 , a vacuum box 200 , and a molding box 300 , and the vacuum box 200 /blower 250 type of drying device 75 not shown in phantom is intended to indicate that the papermaking machine 10 may, in some instances, comprise a single web handling device 75 which may be, for example, the vacuum box 200 , a hot air supply device 150 , a molding box 300 , or any other suitable web handling device, or combinations thereof, consistent with the spirit and scope of the present invention.
[0024] The exhaust air from each of the TAD 400 and the Yankee dryer 500 typically contains moisture extracted from the web 20 during the drying process. In addition, the exhaust air may still include a significant amount of thermal energy, though more so in the case of the exhaust air from the Yankee dryer 500 . As such, in some instances, the exhaust air may be routed back to the air inlet 810 of the air handling device 800 for reheating by the heat source 850 and recirculation through the drying devices by the fan 860 , as shown in FIG. 2, wherein the recirculation of the hot exhaust air may lower the power consumption requirements of the heat source 850 . However, one skilled in the art will appreciate that such recirculation is not always implemented and, in other instances, the hot exhaust air may be used for other purposes or released to atmosphere. As such, in instances, where hot exhaust air recirculation is implemented, it would be disadvantageous to recirculate the moisture present in the exhaust air since this could lower the efficiency of the drying devices and, in some instances, may cause rewetting of the web 20 . Accordingly, in either instance, a portion of the exhaust air, otherwise referred to as the waste air (indicated as element 750 in FIG. 2), is diverted from the air outlet(s) 420 , 520 of the drying device(s) 400 , 500 . Thus, one advantageous aspect of the present invention involves directing the waste air 750 to the web handling devices 75 , such as the hot air supply device 150 , the vacuum box 200 and the molding box 300 , so as to increase the dewatering efficiency thereof. In some situations, all, part, or none of the remainder of the exhaust air may be recirculated through the drying devices 400 , 500 via the air handling device 800 . Where all of the remainder of the exhaust air is recirculated through the drying devices 400 , 500 , substantially none of the exhaust air is vented to atmosphere, thereby advantageously reducing plant emissions, though recirculation of some of the remainder of the exhaust air will also advantageously reduce plant emissions as compared to releasing that exhaust air to atmosphere.
[0025] In one instance where the waste air 750 is directed to a web handling device 75 , the web 20 is first formed by the former 100 on a forming fabric 50 , which may comprise, for example, a Fourdrinier or forming wire, or a through-air drying (TAD) fabric. A hot air supply device 150 is disposed downstream of the former 100 and comprises a hot air supply hood 160 and a vacuum box 170 . As a matter of background, some prior art air presses are configured to direct pressurized ambient temperature air through the web as it is sandwiched between two fabrics, such as shown, for example, in U.S. Pat. Nos. 6,331,230; 6,306,258; 6,306,257; 6,228,220; and 6,080,279. However, a hot air supply device 150 according to one embodiment of the present invention is configured for application with respect to a fabric, in some instances, only a single fabric. That is, in instances, where the web 20 is formed on a single forming fabric 50 , the hot air supply hood 160 is disposed adjacent to the web 20 being transported thereby on the forming fabric 50 , while the vacuum box 170 is disposed adjacent to the forming fabric 50 , opposite the web 20 , as shown in FIG. 3. Accordingly, only a single fabric is present in a hot air supply device 150 in some embodiments of the present invention. In such instances, the hot air supply hood 160 is configured to supply hot air, more particularly, the waste air 750 , to the web 20 , where the waste air 750 then is pulled through the web 20 and the forming fabric 50 by the suction from the vacuum box 170 , and thus any moisture removed from the web 20 is collected by suction from the vacuum box 170 . The vacuum box 170 is in communication with the vacuum system 900 which supplies the necessary suction. As with the web handling devices 75 discloses herein, the hot air supply device 150 is further configured to operate at close to and slightly above ambient pressure. That is, in instances where no suction is provided at the vacuum box 170 , the supply pressure of the waste air 750 to the hot air supply hood 160 is adjusted such that the pressure in the hot air supply hood 160 is close to and slightly above ambient pressure. Thereafter, during operation of the hot air supply device 150 , as the suction from the vacuum box 170 is increased, the supply pressure of the waste air 750 to the hot air supply hood 160 is also increased so as to maintain the pressure therein at close to and slightly above ambient pressure. As such, the effect is thereby to operate the web handling device 75 , such as the hot air supply device 150 , at a pressure close to and slightly above ambient.
[0026] The vacuum system 900 may comprise, for example, a liquid ring pump 910 employing a water source 920 such as, for example, a cooling tower, for providing the necessary seal water therefor, and a water spray source 930 disposed in a spray chamber 940 between the pump 910 and the vacuum box 170 , the function of which will become more evident below. Thus, according to one advantageous aspect of the present invention, the waste air 750 from any single drying device or any combination or all of the drying devices may be directed to the hot air supply hood 160 of the hot air supply device 150 , wherein the hot air supply hood 160 is configured to direct the waste air 750 through the web 20 and the forming fabric 50 for collection by the vacuum box 170 . The waste air from a TAD 400 is typically in the range of about 25° C. to about 180° C., while the waste air from a Yankee dryer 500 is typically between about 250° C. to about 340° C. Thus, directing the heated moisture present in the waste air 750 from the drying devices through the web 20 generally decreases the viscosity of the water in the web 20 , making the water more easily removed by the suction from the vacuum box 170 , and thereby facilitating and increasing the efficiency of the dewatering process, while also preheating the web 20 for further downstream processes. This benefit provides a distinct advantage over double fabric air presses using pressurized ambient temperature air.
[0027] However, the waste air from the hot air supply device 150 collected by the suction from the vacuum box 170 may still contain a significant amount of thermal energy after it has been directed through the web 20 , particularly when the waste air 750 is directed from the Yankee dryer 500 or a combination of both the Yankee dryer 500 and the TAD 400 . According to one purpose of the present invention, this waste air preferably should not be vented to atmosphere. As such, the waste air is directed through the spray chamber 940 where the waste air interacts with a water spray provided by the water spray source 930 . The water spray serves to condense a substantial amount of the moisture in the waste air while removing thermal energy therefrom, thereby cooling and volumetrically contracting or densifying the air. The water to the water spray source 930 may be provided by the cooling tower 920 or another water source, and the condensate collected from the waste air in the spray chamber 940 may be collected and returned to the cooling tower 920 where the thermal energy may be conveniently dissipated. The densified air further produces a pressure drop with respect to the waste air entering the spray chamber 940 and thus also reduces the required capacity of the pump 910 relative to instances in which ambient air is directed through the web handling device. This effect may be more significant where the thermal energy of the waste air 750 is greater, such as in instances where the air directed to the hot air supply device 150 is directed from the Yankee dryer 500 . One skilled in the art, however, will appreciate that condensation of the moisture in the waste air and densification of the air may be accomplished in other manners. For example, in some instances, an increase in the flow of seal water to the pump 910 may provide the necessary condensation of the moisture in the waste air and the densification of the air at the pump 910 . A vacuum system 900 configured in this manner provides, in some instances, an added benefit of removing particulate matter from the waste air, which may then be filtered from the cooling water returning to the cooling tower.
[0028] According to one embodiment of the present invention, after being transported through the hot air supply device 150 , the web 20 may be transferred from the forming fabric 50 to the drying fabric 600 at a transfer area 650 . Where the web 20 is transferred to the drying fabric 600 , another web handling device 75 comprising, for example, a vacuum box 200 , may be disposed adjacent to the drying fabric 600 for facilitating the transfer of the web 20 to the drying fabric 600 . The vacuum box 200 operates with a suction provided thereto by the vacuum system 900 . In such a configuration, the transfer area may further include a blower 250 disposed adjacent to the forming fabric 50 for directing air through the forming fabric 50 and through the web 20 so as to facilitate the transfer of the web 20 to the drying fabric 600 and to provide additional dewatering of the web 20 . Thus, in another advantageous aspect of the present invention, the waste air 750 from the drying devices may also be directed through the blower 250 , the forming fabric 50 , the web 20 , and the drying fabric 600 , and to the vacuum box 200 , so as to facilitate more efficient dewatering of the web 20 while also preheating the web 20 , or maintaining the earlier preheating of the web 20 , for further downstream processes. As previously discussed, in some embodiments, the vacuum box 200 /blower 250 arrangement is configured to operate at a pressure of close to and slightly above ambient. Further, the waste air 750 , after passing through the web 20 , is collected by suction of the vacuum box 200 and then directed from the vacuum box 200 to the vacuum system 900 . As such, the aforementioned advantage of condensing the moisture within the waste air, while densifying the air, so as to decrease the required capacity of the vacuum system 900 , may also be realized.
[0029] In some instances, if necessary, embodiments of the papermaking machine 10 may further include a molding box 300 disposed adjacent to the drying fabric 600 , prior to the drying devices, for further structuring and/or dewatering of the web 20 . The molding box 300 may have a corresponding blower 350 disposed adjacent to the web 20 , opposite the drying fabric 600 , for directing air through the web 20 to assist in the dewatering process. Thus, in another advantageous aspect of the present invention, the waste air 750 from the drying devices may also be directed through the blower 350 , the web 20 , and the drying fabric 600 , and to the molding box 300 , so as to facilitate more efficient dewatering of the web 20 while also preheating the web 20 , to structure the web 20 , or to maintain the earlier preheating of the web 20 , as the web 20 enters the drying devices. Also, as previously discussed, in some embodiments, the molding box 300 /blower 350 arrangement is configured to operate at a pressure of close to and slightly above ambient. Further, the waste air 750 , after passing through the web 20 , is collected by the suction from the molding box 300 and then directed from the molding box 300 to the vacuum system 900 . As such, the aforementioned advantage of condensing the moisture within the waste air, while densifying the air, so as to decrease the required capacity of the vacuum system 900 , may also be realized.
[0030] According to a further advantageous aspect of the present invention, the hood 450 of the first TAD 400 may extend upstream of the drying cylinder 460 thereof so as to at least partially cover and oppose the molding box 300 , as shown in FIG. 4. In such a configuration, the molding box 300 may comprise, for example, part of a sealing arrangement for a plenum extending across the dead zone of a single TAD or between the dead zones of adjacent TADs as described in commonly assigned U.S. Pat. No. 6,199,296. However, embodiments of the present invention may also have the blower 350 operably engaged with the hood 450 generally opposite to the molding box 300 . The air handling device 800 supplies heated air through the heat source 850 at a temperature, for example, of about 225° C. to the TAD 400 , wherein the through-air drying process is more efficient if the web 20 is at or about the temperature of the heated air upon entering the TAD 400 . Accordingly, in some instances, the waste air 750 from the drying device(s) is directed to the blower 350 for pre-heating the web 20 to a desired temperature, immediately as the web 20 enters the TAD 400 . That is, since the blower 350 is incorporated into the hood 450 and the web 20 passing by and being heated by the blower 350 immediately enters the TAD 400 , the web 20 therefore enters the TAD 400 at the desired temperature. In such instances, the molding box 300 /blower 350 arrangement is also configured to operate at a pressure of close to and slightly above ambient, further taking into account the heated air supplied to the hood 450 .
[0031] [0031]FIG. 5 schematically illustrates another embodiment of a papermaking machine 10 according to the present invention. In some instances, the waste air 750 from the drying devices may not have the desired thermal energy for the upstream processes. Such a situation may occur when, for example, the machine 10 comprises only one or more TADs 400 and does not include a Yankee dryer 500 . In such instances, a portion of the heated air (indicated as element 760 in FIG. 5) being directed from the air outlet 820 of the air handling device 800 to the air inlets of the respective drying devices, may be diverted and mixed with the waste air 750 from the drying devices so as to increase the thermal energy thereof. The flow of the diverted portion of the heated air 760 , as well as the waste air 750 from the drying devices, may be controlled, for example, by appropriate fans 870 , 880 , dampers (not shown), and/or controllers (not shown). According to one embodiment of the present invention, the exhaust from the drying device(s) may be configured such that about 10% of the exhaust air is diverted as the waste stream 750 to the web-handling device(s). In another embodiment, the air outlet 820 of the air handling device 800 may be configured such that about 10% of the heated air 760 is diverted to the web handling device(s). The condition of the mixture of the waste air 750 from the drying device(s) and the portion of the heated air 760 from the air handling device 800 may, in some instances, be controlled by varying the flow of the respective streams. However, if necessary, the waste air 750 from the drying device(s), or the mixture of the waste air 750 from the drying device(s) and the portion of the heated air 760 from the air handling device 800 , may be directed through a single conditioning device 890 (shown in phantom) for appropriately adjusting the condition of the air entering all of the web handling device(s) or, in some instances, through an individual conditioning device 895 for each web handling device, wherein each conditioning device 895 is configured to provide heated air having the appropriate condition for the respective web handling device 75 .
[0032] A papermaking machine 10 configured according to embodiments of the present invention as described herein, in some instances, substantially eliminates emissions from the exhaust of drying devices that might normally be undesirably vented to atmosphere. Further, in some instances, an exhaust stack may be eliminated altogether, thereby simplifying construction and reducing the cost of environmental testing. In addition, losses internal to the machine 10 may also be controlled. For example, the supply of the waste air from the drying device(s) or, in some instances, the mixture of the waste air from the drying device(s) and the portion of the heated air from the air handling device 800 , may be controlled so as to match or slightly exceed the capacity of the vacuum system 900 . In this manner, seepage of room air into or excessive hot air leakage out of the web handling device(s) 75 can be avoided. Further, with respect to the drying device(s), pressure sensors (not shown) may, in some instances, be placed within the hood of the respective drying device so as to monitor the pressure therein. As such, the supply of the waste air from the drying device(s) or, in some instances, the mixture of the waste air from the drying device(s) and the portion of the heated air from the air handling device 800 , may be controlled such that the pressure within the hood is maintained at approximately atmospheric pressure, and preferably slightly above ambient. Such a provision also facilitates the avoidance of seepage of room air into or excessive hot air leakage out of the drying device.
[0033] Thus, embodiments of the present invention may advantageously reduce or eliminate emissions due to the exhaust from the drying devices of a papermaking machine, thereby simplifying construction and reducing the need for environmental testing. Further, the enhancement of the web handling device(s) 75 , for dewatering the web upstream of the drying device(s), with the supply of the waste air from the drying device(s) or, in some instances, the mixture of the waste air from the drying device(s) and the portion of the heated air from the air handling device 800 , increases the heat transfer to the web 20 , thus resulting in a more efficient and less energy-consuming dewatering process. In addition, particularly when high temperature air is directed to the web handling device(s) 75 , a substantial reduction in the required capacity of the vacuum system 900 may also be realized.
[0034] In order to demonstrate the advantageous aspects of the present invention, a hot air supply device 150 , having a hot air supply hood 160 as previously described, was implemented in a paper making machine 10 and operated at a slightly above-ambient pressure to prevent ingress of room air. The following process parameters were implemented:
Product: 20.5 g/m 2 towel base sheet Wire Speed: 1040 m/min Vacuum Box Configuration: 2 × 16 mm wide slots Vacuum Box Suction Level: 60 kPa
[0035] The following results, consistent with the advantageous aspects of the present invention
Temp. Vacuum Air in Web Web System Web Web Supply Vacuum Entering Temp. Capacity Entering Dryness Temp. Box Temp. Rise Reduction Dryness Increase (° C.) (° C.) (° C.) (° C.) (%) (%) (%) 25 17.4 26.5 −2.3 Base 25.5 1.7 161 24.1 27.0 4.9 7 25.6 1.9 262 28.5 28.3 9.2 12 26.3 1.9 330 30.8 29.8 10.5 17 25.7 2.3
[0036] Many modifications and other embodiments of the invention set forth herein will come to mind to one skilled in the art to which these invention pertain having the benefit of the teachings presented in the foregoing description and the associated drawings. For example, in some embodiments of the invention, the former may be configured to form the web on a single through-air drying fabric, wherein the single TAD fabric transports the web through the various web handling devices and the drying devices. Accordingly, in such instances, the forming fabric and the drying fabric are one in the same. Therefore, it is to be understood that the invention is not to be limited to the specific embodiments disclosed and that modifications and other embodiments are intended to be included within the scope of the appended claims. Although specific terms are employed herein, they are used in a generic and descriptive sense only and not for purposes of limitation.
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An apparatus for decreasing heat emission and enhancing a vacuum system in a papermaking machine is provided. Such an apparatus includes a drying device having an inlet for receiving heated air for removing moisture from a paper web and an outlet for exhausting the moisture-containing air from the drying device. A vacuum system is configured to produce a suction and receive the moisture-containing air. A web handling device is disposed upstream of the drying device and is configured to interact with the web before the web is directed to the drying device. The web handling device is further configured to receive a portion of the moisture-containing air from the drying device, wherein the portion of the moisture-containing air is directed through the web by the web handling device to facilitate dewatering of the web before the moisture-containing air is received by the vacuum system. The web handling device is also configured to provide the moisture-containing air at a supply pressure with respect to the suction produced by the vacuum system such that the web handling device operates at an above-ambient pressure. Associated apparatuses and methods are also provided.
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BACKGROUND OF THE INVENTION
This invention relates generally to an image forming apparatus, and especially to a device for collecting toner waste from a photosensitive member of the image forming apparatus.
In an apparatus for forming images using a combination of an electrophotographic process and an optical signal generator, (e.g., a laser beam printer or liquid crystal shutter (LCS) printer), an image is formed on a photosensitive member which is then coated with toner. A portion of the toner coated image is then transferred to a recording medium. The non-transferred portion of the toner coated image remaining on the photosensitive member (hereinafter referred to as toner waste) is unsuitable for reuse and must be scraped off the photosensitive member and allowed to accumulate within a container.
Toner waste has a tendency to agglomerate. Such agglomeration near the entrance to the container can prevent additional toner waste from being deposited in the container. Toner waste if not deposited in the container, can settle within the apparatus on various components and thus adversely affect and deteriorate performance of the apparatus. It also increases the frequency of removing the container. Having to empty toner waste from the apparatus before the container is full is also undesirable.
In order to circumvent the problem of toner waste agglomeration, toner waste can be deposited into the container using a spiral carrier method disclosed in Japanese Patent Laid-Open Application No. 56-57076. Moreover, the spiral carrier method suffers from the inherent drawback of accumulating toner in a conical pile like fashion. Consequently, the volume of the container needs to be significantly larger with substantial volume going unused.
One possible solution for overcoming this accumulated conical pile of toner waste is to vibrate or shake the toner waste so as to flatten the pile. Moreover, the oozing and splashing of toner associated with such vibration or shaking as well as noise are undesirable and generally unacceptable.
Another drawback in the prior art relates to the need to alert a user that the container of toner waste needs to be emptied. A proposed solution involves activating a microswitch or other equivalent based on the weight of the toner waste. This solution is considered unreliable. Small amounts of toner waste deposited on the contact points of the microswitch can cause contact failure. Another proposed solution counts the number of revolutions made by the photosensitive member. Generally, each time the photosensitive member completes a revolution approximately 30-40% of the toner coated image is scraped off the photosensitive member and deposited into the container. Therefore, counting the number of completed revolutions of the photosensitive member should presumably indicate when the container is full of toner waste. The exact amount of toner waste is never determined in this latter proposed solution. Therefore, unless an unacceptably low number of revolutions is used as the threshold to trigger the alarm, toner waste can overflow from the container before the alarm is triggered.
Conventional image forming apparatus also splashes and/or oozes toner waste from the container following completion of the copying or printing cycle.
Accordingly, it is desirable to provide a cleaning device which overcomes the problems of toner waste agglomeration without having to increase the size of the container. It is also desirable to provide a toner cleaning device which fully utilizes the volumetric interior of the container for storing toner waste and which prevents splashing and oozing of toner waste following completion of the printing or copying cycle. It is also desirable to provide a cleaning device which alerts a user of the need to empty the container before the toner waste overflows and yet is far smaller in size than cleaning devices presently available.
SUMMARY OF THE INVENTION
In accordance with the invention, an image forming apparatus includes a device for storing toner waste collected from the surface of an image carrier by providing a container for holding the toner waste and a device for compressing the toner waste stored in the toner. The cleaning device also includes alternative diaphragms which expand towards a microswitch or a leaf switch as the toner waste is collected within the container. A predetermined weight on the diaphragm to apply sufficient pressure closes the switch to trigger an alarm to notify a user that the container holding the toner waste needs to be emptied.
Accordingly, it is an object of this invention to provide a cleaning device for an image forming apparatus which more reliably collects toner waste and maintains toner waste within a container than presently available.
It is another object of the invention to provide a cleaning device for an image forming apparatus which prevents toner waste agglomeration from impeding the collection of toner waste from the image carrier of the apparatus.
It is a further object of the invention to provide a cleaning device which more efficiently utilizes the volumetric interior of a container for storing toner waste.
It is still another object of the invention to provide a cleaning device which is more reliable in alerting a user of the need to empty toner waste from a storage container.
It is yet a further object of the invention to provide a cleaning device which reduces the likelihood of toner waste overflowing from a storage container.
It is still a further object of the invention to provide a cleaning device which can be miniaturized compared to cleaning devices presently available.
It is also another object of the invention to prevent splashing and oozing of toner waste especially following the completion of the copying and/or printing cycle.
Still other objects and advantages of the invention will in part be obvious and will in part be apparent from the specification.
The invention accordingly comprises several steps and the relation of one or more of such steps with respect to each of the others, and the device embodying features of construction, combination of elements and arrangements of parts which are adapted to effect such steps, all is exemplified in the following detailed disclosure, and the scope of the invention will be indicated in the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
For a fuller understanding of the invention, reference is made to the following description taken in connection with the accompanying drawings, in which:
FIG. 1 is a diagrammatic side elevational view in cross-section of an image forming apparatus including a cleaning device showing the paper path in accordance with one embodiment of the invention;
FIG. 2 is a cross-sectional view of a portion of the cleaning device of FIG. 1;
FIG. 3 is a perspective view of a bellows-like diaphragm utilized in the device of FIG. 1;
FIG. 4(a) is a perspective view of the contact plates of a microswitch in the cleaning device of FIG. 1;
FIG. 4(b) is a perspective view of the assembled microswitch of FIG. 4(a);
FIG. 4(c) is a side cross-sectional view of the microswitch taken along the lines c--c of FIG. 4(b);
FIG. 5(a), FIG. 5(b), FIG. 5(c) and FIG. 5(d) are cross-sectional views of the bellows-like diaphragm for use in accordance with alternative embodiments of the invention;
FIG. 6 is a side elevational view in cross-section of a cleaning device in accordance with an alternative embodiment of the invention;
FIG. 7(a) and FIG. 7(b) are fragmentary perspective views of the diaphragm region of containers in accordance with an alternative embodiment of the invention;
FIG. 8 is a fragmentary perspective view of the diaphragm in accordance with yet another alternative embodiment of the invention; and
FIG. 9 is a fragmentary perspective view of the container and a leaf switch assembly in accordance with still another alternative embodiment of the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIG. 1, a liquid crystal printing apparatus 100 (commonly referred to as a liquid crystal shutter printer) includes a photosensitive drum 101 which serves as an image carrier, a charging device 104, an optical signal generator 107, a developing device 110, a transfer device 113, a cleaning device 116, and an erasing lamp 119. Apparatus 100 also includes a paper stacker 122 for holding paper 125 which serves as the recording medium, a fixing device 128, a delivery tray 131, register rollers 134 and delivery rollers 140.
Photosensitive drum 101 is coated with an optical conductive material such as Se, OPC and rotates in the direction of arrow A. Initially, photosensitive drum 101 is uniformly electrically charged, either negatively or positively, by charging device 104. As photosensitive drum 101 continues to rotate in the direction of arrow A, certain areas thereof are irradiated with light in accordance with the image information generated by optical signal generator 107. A static latent image on the surface of drum 101 forms and passes developing device 110. A sleeve 111 of developing device 110 brushes charged toner, which is stored within developing device 110, onto photosensitive drum 101 in accordance with the static latent image charge. At the same time and in synchronism with the static latent image formed on photosensitive drum 101, paper 125 is released from paper stacker 122 and advances in a path (denoted by dash lines 143) past register rollers 134 to a transfer position 145. The toner image which is formed on photosensitive drum 101 is transferred to paper 125 at transfer point 145 by transfer device 113. Thereafter, paper 125 advances along path 143 to fixing device 128 for permanently affixing the toner to paper 125.
Fixing device 128 includes a pair of fixing rollers 137 which are connected to a heating source for heating the toner. When the toner is heated it penetrates paper 125 and fuses to the fibers. When paper 125 advances beyond fixing device 128 the fused toner rapidly cools and becomes permanently affixed to paper 128. Paper 128 is then guided to delivery tray 131 by delivery rollers 140.
After the usage is transferred to paper 128, a photosensitive member 101 continues to rotate in the direction A beyond transfer point 145. Excess toner 168 (i.e., toner waste) which has not been transferred onto paper 125, and which typically amounts to about 30-40% of the toner forming the toner image, is removed by cleaning device 116. Thereafter, the entire surface of photosensitive drum 101 is uniformly irradiated with light by erasing lamp 119 and is now ready to be recharged by charging device 104.
As shown in FIG. 2, cleaning device 116 includes a container 150 (otherwise referred to as a toner box) having a hollow interior with a substantially rectangular box-like base 153 and a crooked tilted inlet stack 156 integrally connected to and rising from a neck 180. Connected to one side of stack 156 at its distal end is a cleaning blade 159 for removal of excess/non-transferred toner which remains on photosensitive drum 101. On the other side of stack 156 at its distal end is a seal member 162 having a substantially triangular shaped cross-section with a side 165 conforming substantially to the curved surface of and extending in the axial direction of photosensitive drum 101. Cleaning blade 159, seal member 162 and photosensitive drum 101 together enclose the top of stack 156 to prevent toner waste 168 from splashing and oozing through stack 156 during and/or after the copying/printing cycle. Seal member 162 is formed with materials such as, but not limited to, PET, Teflon or the like. These materials do not adversely affect the performance of photosensitive drum 101, but minimize adherence of toner waste 168 to the surface of seal member 162.
Cleaning device 116 also includes a scraping device 171 located within container 150 near neck 180 for scraping toner from stack 156. Scraping device 171 includes a cleaning plate 174 having a tip 175, rotatable about a shaft 177 and driven by a motor (not shown). Plate 174 has a length L and is positioned within container 150 so that tip 175 can contact the interior front surface of neck 180. Following removal of toner waste 168 from photosensitive member 101 by cleaning blade 159, toner waste 168 drops to the lower interior surface of stack 156 near neck 180. Cleaning plate 174 operably rotates in a circular path designated by arrow B scraping toner waste 168 from the interior surface of stack 156 around neck 180. Therefore, any toner waste 168 which may begin to accumulate around the interior surface of neck 180 is pushed into base 153.
Cleaning device 116 further includes a cantilever shaped compression plate 183 made of a resilient material and connected at its proximal end to an inner wall near a rear end 186 of base 153. The distal end of compression plate 183 is normally adjacent to shaft 177. Each time scraping member 171 travels in its circular path B, tip 175 of cleaning plate 174 after passing beyond and below neck 180 contacts compression plate 183. Due to the resiliency of compression plate 183, cleaning plate 174 depresses compression plate 183 a distance equal to its length L. As cleaning plate 174 swings past compression plate 183, compression plate 183 returns to its nonflexed position with its distal end once again adjacent to shaft 177. Consequently, toner waste 168 will be compressed within base 153 whenever its height approaches the top of base 153 by the reciprocating motion of compression plate 183. Compression of toner waste 168 by compression plate 183 of about 1.5 to 1.6 times its weight in its non-compressed state is possible.
Container 150 is formed with an opening 195 in rear wall 186 of base 153 and a bellows shaped diaphragm 192 is disposed therein. Diaphragm 192 is connected to the interior surface of rear wall 186 and includes a projecting part 198 which is expandable for contacting a microswitch 201.
As shown in FIG. 3, bellows shaped diaphragm 192 includes an expandable brim 204 surrounded by a skirt 207 and a truncated conical cap 198. Diaphragm 192 is made of a variable thin film elastic material such as silicon rubber and the like which maintains its resilient shape as shown in FIG. 3 except when pressed against by toner waste 168.
The pressure exerted on diaphragm 192 by compressed toner waste 168 causes brim 204 to expand outwardly toward opening 195. As compressed toner waste 168 reaches a predetermined height within base 153, the pressure on diaphragm 192 forces brim 204 to travel a predetermined distance causing cap 198 to press against and electrically close microswitch 201. Closure of microswitch 201 activates an alarm system 202 which alerts a user that container 150 needs to be emptied of toner waste 168. The actual alarm may be either a video and/or audio signal such as but not limited to a flashing lamp, buzzer and the like. Additionally, upon activating alarm system 202, the copying/printing operation is interrupted to ensure that no additional toner waste 168 is scraped off photosensitive drum 101 which can lead to oozing of toner waste 168 through the top of stack 156.
Referring now to FIG. 4(a), FIG. 4(b) and FIG. 4(c), microswitch 201 includes a cylindrical outer shell 211 having a circular inner flange 214 forming an inner opening 215, a first contact plate 217 and a second contact plate 220. Contact plate 217 includes a terminal 226 and a flat circular neck 223 having a front surface 227 and a rear surface 228. Contact plate 217 is made from an electrically conductive, resilient material, such as phosphor bronze and the like. Contact plate 217 also includes a circular rib 229 on front surface 227 and a protrusion 230 on rear surface 228 and distanced slightly inwardly from rib 229. Second contact plate 220 is a substantially flat, elongated oval made of an electrically conductive material and includes a terminal 232 and a protrusion 235.
Flange 214 of shell 211 includes a circular lip 241 extending inwardly toward the interior of shell 211 and has a circumference slightly smaller than the circumference of rib 229. Shell 211 also includes two openings 242 and 243 which are slightly larger than terminals 226 and 232. First and second contact plates 217 and 220 are disposed within the interior of shell 211 with terminals 226 and 232 extending through the openings 242 and 243 of shell 211, respectively. Wires 244 and 245 connect terminals 226 and 232 to alarm system 202, respectively. Neck 223 supports contact plate 217 in a cantilever like manner with front surface 227 in contact with lips 241. Contact plate 217 is prevented from moving about laterally by lips 241 contacting rib 238. Similarly, contact plate 220 is disposed within shell 211 in a cantilever like manner.
Microswitch 201 operates as follows. Before cap 198 of diaphragm 192 presses against front surface 227 of contact plate 217, protrusions 230 and 235 are separated from each other. Therefore, microswitch 201 is in an electrically open state. As cap 198 extends through opening 215 and presses with little force against front surface 227 of contact plate 217, contact plate 217 bends slightly resulting in protrusion 230 contacting protrusion 235. Microswitch 201 is now in an electrically conductive state and activates alarm system 202.
FIGS. 5(a)-(d) illustrate a number of alternative embodiments of baffle shaped diaphragm 192 in which skirt 207 is secured to rear wall 186 within a circular groove 250 surrounding the perimeter of opening 195. Additionally, brim 204 includes pleats 25 which always expand outwardly beyond opening 195 towards microswitch 201. FIGS. 5(a) and (b) show pleats 253 which upon expansion assume a cylindrical and truncated conical shape, respectively. In both FIGS. 5(a) and 5(b) pleats 253 prior to expansion are beyond skirt 207 projecting outwardly toward opening 195. In FIG. 5(c), however, pleats 253 prior to expansion are substantially in line with skirt 207 as also shown in FIG. 3. FIG. 5(d) includes pleats 253 which in their unexpanded state overlap skirt 207 and extend beyond opening 195.
As shown in FIG. 6, an alternative cleaning device 116' similar to cleaning device 116 (with the same elements denoted by like reference numerals) includes a rectangular diaphragm 270 and a leaf switch 273 rather than bellows shaped diaphragm 198 and microswitch 201, respectively.
A first embodiment of rectangular diaphragm 270 is shown in FIG. 7(a) and FIG. 7(b). Diaphragm 270 is an open ended, upside down rectangular pyramid and includes sides 276, base 277 and a front face 282. Sides 276 and base 277 are made from a thin film elastic material such as silicon rubber and the like. Front face 282 is also made from the same elastic material but is somewhat thicker than sides 276 and base 277 to create a stiffer surface for toner waste 168 to press against. Alternatively, front face 282 can be of the same thickness as sides 276 and base 277. A stiff thin plate made of phosphor bronze and the like would then be affixed to front face 282 to provide the necessary stiffness. In its non-flexed position, the resiliency of sides 276 and base 277 allow diaphragm 270 to maintain the shape shown in FIG. 7(a).
A pair of bulkhead plates 285 are connected to the interior surface of rear wall 186 surrounding opening 195 in order to direct and thereby concentrate the force of toner waste on face 282 rather than sides 276. Diaphragm 270 is rotatably connected by a shaft 280 at its bottom to bulkhead plates 285. Additionally, a thin film layer 28 is integrally connected to face 282 to prevent toner waste 168 from oozing between front face 282 and bulkhead plates 285.
As toner waste 168 begins to accumulate within base 153 and is further compressed by compression plate 183, the compressed toner waste exerts pressure on face 282. Front face 282 under the mounting pressure by the compressed toner waste 168, pushes against sides 276 and base 277 which begin to buckle as shown by dash lines 291 in FIG. 7(b). Consequently, front face 282 begins to pivot about shaft 280 toward opening 195.
Referring once again to FIG. 6, leaf switch 273, which is connected to the interior of image forming apparatus 100, is positioned so that an arm 294 thereof is located a predetermined distance from face 282 prior to sides 276 and base 277 buckling. Upon face 282 moving this predetermined distance toward arm 294, leaf switch 273 will activate alarm system 202 and thereby notify a user that base 153 needs to be emptied of toner waste 168. At the same time all printing/copying will be interrupted to ensure that no toner waste oozes from stack 156.
Another type of rectangular diaphragm is illustrated in FIG. 8 which is similar to rectangular diaphragm 270 of FIG. 7(a) and FIG. 7(b). In FIG. 8, a pressure plate 304 rotatably connected to the bottom of bulkhead plates 285 by a shaft 307 is positioned parallel to and slightly spaced apart from plate 282 with walls 276 and base 277 in their nonbuckled state. The major axes of shaft 307 and shaft 280 are substantially parallel to each other. Pressure plate 304 is made from a hard film such as, but not limited to, resin, metal and the like. Layer 288 is connected integrally to pressure plate 304. Similar to FIG. 7, when toner waste 168 exerts pressure against pressure plate 304, sides 276 and base 277 buckle resulting in pressure plate 304 pushing face 282 sufficiently forward to move arm 294 of leaf switch 273 a predetermined distance to activate alarm system 202.
In FIG. 9 diaphragm 270, bulkhead 285 and rear wall 186 are denoted by phantom lines and a hinge 310 is used to circumvent the need for face 282 to be more rigid than surfaces 276 and base 277. Hinge 310 includes a leg 313 which is secured to leaf spring 273 at its distal end and a plate 316. Plate 316 is substantially parallel and next adjacent to face 282 of diaphragm 270 and is made from a hard film such as resin, metal and the like. When pressure begins to mount on face 282 by the build up of toner waste 168 in base 153, sides 276 and base 277 begin to buckle. Plate 316 which is positioned relatively close to face 282 begins to pivot toward opening 195 and plate 316 is urged towards leaf switch 273. After plate 316 moves a predetermined distance, plate 316 forces leaf switch 273 to switch to its electrically closed state and thereby activates alarm system 202.
Of course, the actual shape of diaphragms 196 and 270 and switches 201 and 273 are not limited to the embodiments and materials shown and described herein. For example, other methods for detecting the level of toner waste within base 153 other than a diaphragm such as, but not limited to, employing piezoelectric elements, photointerrupters and proximity switching can be used.
In view of the foregoing, it can now be readily appreciated that cleaning device 116 prevents oozing and splattering of toner waste, reliably alerts a user as to the need for emptying the toner waste from container 150, and reduces the size of container 150 compared to the prior art.
It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained and, since certain changes may be made in carrying out the above method and in the constructions set forth without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.
It is also to be understood that the following claims are intended to cover all the generic and specific features of the invention herein described and all statements of the scope of the invention which, as a matter of language, might be said to fall therebetween.
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In storing toner waste collected from the surface of an image carrier within an image forming apparatus, the toner waste is compressed within a container by a resilient cantilever member. A diaphragm located within the container expands through an opening of the container based on the pressure exerted on the diaphragm by the compressed toner waste. Upon traveling a predetermined distance, the diaphragm forces a switch to close which triggers an alarm indicating that the container is full of toner waste.
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BACKGROUND OF THE INVENTION
The present invention relates to casting machinery, and more particularly to a device useful in casting and curing plastic in the manufacture of decorative emblems.
Decorative emblems may be produced in which a foil substrate of metalized Mylar polyester film, vinyl or paper, or thin aluminum is coated with a clear plastic material. A sheet of substrate material may be prepared by screening a plurality of decorative emblems on one side of the sheet, embossing, and applying a layer of adhesive on its opposite side. A release paper is placed over the adhesive-coated side of the substrate material. A kiss cut die operation may then be used to cut through the substrate around each of the printed emblem designs without cutting the release paper. The excess substrate material between the emblems is then peeled from the release paper and discarded. Alternative methods of substrate preparation may be used. The general objective is the same, however -- to produce a sheet of release paper upon which a plurality of printed emblems are adhesively mounted.
The sheet of release paper, upon which are positioned a number of printed emblem substrates which have been embossed, is then ready for a casting operation in which a precise amount of plastic material is deposited on the upper surface of each emblem substrate. As the plastic material is placed upon each substrate, it will spread uniformly over the surface of the substrate. Because of the surface tension of the plastic, however, it will not flow off of the substrate, but will create a lense effect in that it will be slightly thicker at the center than at the edges. The plastic is then cured, resulting in an attractive decorative emblem.
It is important during the casting process that each of the foil substrates be held substantially flat. If this is not done, a portion of the fluid plastic will flow off of the substrate and the emblem will thus be ruined. Additionally the substrate must be held flat during the curing process. Since curing of the plastic will typically involve irradiation with a source of ultraviolet or infrared radiation, as well as the application of heat, dimensional changes in the sheet of release paper or the substrate, or both, may tend to warp the substrate slightly. Even if this occurs after the plastic is cured sufficiently such that it will not flow off of the surface of the substrate, the resulting emblem will be distorted in shape and, therefore, probably not acceptable.
Depending on the type of substrate used and the size of the emblem desired, it may be necessary or desirable to heat the substrates prior to casting so that the viscosity of the plastic material cast on the substrates will be reduced, thus permitting flow over larger areas. Additionally, it is desirable to be able to control the temperature of the substrates while the emblems are being irradiated with infrared or ultraviolet radiation and the plastic is undergoing a curing reaction. The sheet of release paper and emblem substrates must be held substantially flat during the entire casting and curing process. Thus it is desirable that the casting and curing apparatus be movable into operative positions rather than moving the sheet of release paper and emblems.
Ventilation must be provided during the casting and curing process. Additionally, it may be desirable, under certain circumstances, to be able to apply radiation to the plastic material only periodically during the curing process.
Thus a need exists for a device which will hold a substrate in position during casting and curing and which will control the application of radiation and the temperature of the substrates during the entire process. Such a device should be well ventilated and should permit the sequence of machine steps to be altered, depending on the type of casting operation.
SUMMARY OF THE INVENTION
A machine for holding a release sheet on which is mounted a plurality of emblem substrates while plastic is cast on the pieces of substrate material and for thereafter curing the plastic includes a platen means for holding the release sheet while plastic is cast and cured. The platen means defines a first cavity and second cavity and a plurality of openings communicating between the first cavity and the flat upper surface of the platen. Means are provided for maintaining a partial vacuum in the first cavity and means are provided for supplying liquid to the second cavity. A radiation source means is movable into a position above the upper surface of the platen means.
More than one temperature of liquid may be supplied to the second cavity of the platen means. Means may also be provided for moving the radiation source means into a position above the upper surface of the platen means prior to casting the plastic material and to heat the pieces of substrate material before casting. The radiation source means may be operated periodically during the curing process. The radiation source means may be a source of infrared radiation or ultraviolet radiation depending on the type of plastic curing process used. An exhaust means is provided for drawing air across the platen and past the radiation source means and thereafter exhausting the air via an exhaust duct.
Accordingly, it is an object of the present invention to provide a machine for holding a substrate substantially flat while plastic is cast and cured thereon; to provide such a machine in which the temperature of the substrate may be controlled; to provide such a machine in which a radiation source is movable into and out of an operating position adjacent said substrate; and to provide such a machine in which volatile fumes are effectively exhausted.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the present invention, illustrating the manner in which a portion of the device may be moved;
FIG. 2 is a side view of the device;
FIG. 3 is a sectional view of an emblem made by the device of the present invention and including a portion of the release sheet upon which the emblem is mounted;
FIG.4 is a plan view of the platen of the present invention with portions broken away to reveal the interior structure;
FIG. 5 is a view showing the bottom of the platen with portions broken away to revel the interior structure;
FIG. 6 is a sectional view taken generally along line 6--6 in FIG. 4;
FIG. 7 is a sectional view taken generally along line 7--7 in FIG. 4;
FIG. 8 is a sectional view taken generally along line 8--8 in FIG. 4; and
FIGS. 9A and 9B, when assembled, depict the circuit which controls the operation of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
The present invention relates to a device for use in the casting and curing of plastic on pieces of substrate material. As seen in FIG. 1,a number of pieces of substrate material 15 will typically be provided on a release sheet 17. The substrate material may typically be provided on a release sheet 17. The substrate material may be a metralized Mylar polyester film which has been printed and embossed and has an adhesive backing. The release sheet will typically be a paper material having a low adherence surface such as wax or silicone treated ones from which the pieces of substrate material may be easily removed.
A simple casting operation consists of an operator applying measured portions of a plastic material, such as a liquid polyurethane, to the upper surface of each of the substrates 15. Preferred are polyurethane resins to which a catalyst is added just prior to casting to initiate a curing reaction. In order to drive off rapidly whatever volatile liquids which are present in the liquid polyurethane and promote the curing, an infrared radiation source means for supplying infrared radiation may be provided to irradiate the polyurethane. Such a source is included in member 20 which is shown extended in FIG. 1 in dashed lines.
It is thought preferable to move the source of radiation rather than to move the release sheet and substrates, since movement of the latter could result in the cast liquid polyurethane flowing onto the release sheet 17. The extended position of the member 20 is shown also in FIG. 2, along with lamps 23 which provide the infrared radiation. Member 20 is moved by means of air cylinder 25. It should be understood that an ultraviolet curable plastic may also be cast using the device of the present invention; in such a case, lamps 23 would be ultraviolet radiation sources.
FIG. 3 is a sectional view of an emblem produced by the device of the present invention, showing how the plastic 27 tends to form in the shape of a lense on the substrate 15. The curvature in plastic 27 is a result of the surface tension of the polyurethane liquid. It is important that the substrate 15 and release sheet 17 be held substantially flat during the entire casting and curing process. If this is not done, the cast plastic 27 may flow over the edge of emblem 15 and onto the release sheet, or the emblem may be distorted in shape. In either case, the emblem is not usable and must be discarded.
While only very small amounts of volatiles will be given off by the plastic during curing, an exhaust means including blower 29, exhaust duct 30, and associated motor (not shown) are provided in order to insure that the operator of the machine does not inhale fumes unnecessarily. As illustrated in FIG. 2, ambient air is drawn into the cabinet 31 by fan 29. The air will be drawn over the top of the platen means 35 which holds the release sheet bearing the cast emblems. The air will also be drawn past the lamps 23 preventing fumes from escaping upwardly through member 20 and also cooling lamps 23.
It may be desirable to control the temperature of the substrates prior to and during the casting and curing process. Under some circumstances it may be desirable to maintain the substrates at one temperature during casting and a portion of the curing process, and then to maintain the substrates at a second temperature. Toward this end, water inlets 36 and 37 and one or more outlets 38, are provided to receive and discharge water supplied at more than one temperature.
It may also be desirable to irradiate the substrates prior to the casting process, such that the substrates are heated and the viscosity of the cast plastic reduced as it flows onto the substrates. This reduction in viscosity will cause the plastic to flow more evenly over a larger foil substrate. Since it is desirable to be able to change readily the sequence of steps and the order of these steps, a number of timers and controls shown generally at 39 are provided. Vacuum pump 41 is also provided to supply a vacuum platen 35 with a vacuum for holding the release sheet 17, as described below.
The construction of platen means 35 is shown in greater detail in FIGS. 4-8. FIG. 4 is a plan view of the platen with portions of the upper plate broken away of reveal internal structure. Central member 45 and upper plate 47 define a first cavity 49 which is adjacent the upper surface of the platen 35. Opening 51 communicates between first cavity 49 and vacuum pump 41 via appropriate vacuum tubing (not shown). As seen in FIG. 7, opening 51 may be threaded to receive a fitting for such tubing. A plurality of openings or suction ports 55 are provided in plate 47 and communicate with cavity 49. When vacuum pump 41 is running, air will be drawn continuously through openings 55. When a sheet of release paper bearing substrates is placed on the upper surface of the platen, the suction through openings 55. When a sheet of release paper bearing substrates is placed on the upper surface of the platen, the suction through openings 55 will hold the release paper and the substrates securely in a substantially flat position during the subsequent casting and curing steps.
As seen in FIG. 5, a second cavity 57 is defined by member 45 and bottom plate 60. An inlet means 62 and an outlet means 64 are provided for supplying temperature stabilizing fluid to the second cavity 57. Water will e applied to inlet and outlet means 62 and 64 from water inlets 36 and 37 (FIG. 2.) by appropriate solenoid controlled valves, to be described below. As seen in FIG. 5, ridges 66 define a surpentine path through which the water flows. Thermal conductive means comprising ridges 68 extend upwardly through first cavity 49 and are provided for thermal conduction between the upper surface of the platen 35 and the second cavity 57. Gaps 70 in ridges 68 are provided in order to maintain a partial vacuum throughout cavity 49.
Referring now to FIGS. 9A and 9B, a schematic representation of the control circuit of the present invention is shown when these two FIGURES are assembled with FIG. 9A above 9B. An indication is provided beneath each timer controlled set of contacts as to its condition when the timer is reset, when the timer is timing, and when the timer is timed out but prior to reset. An "X" indicates closed contacts and an "O" indicates open contacts.
The following is illustrative of the manner in which the control circuit operates with the Heat Control switch 75 and Heat Delay switch 80 in their OFF positions. Power is applied to input terminals 85 and, as a result, to transformer 90 via fuses 91. The machine is turned on by momentarily closing the POWER ON switch 93. Relay R1 is thereby energized, and contacts R1a lock in relay R1.
Assuming that a pre-heat operation is desired, switch 95 will be momentarily closed, energizing relay R2. Contacts R2a will then be closed, causing timer T1 to begin timing the pre-heat process. Contacts T1b will close and, as indicated will be closed for the duration of the timing procedure. Contacts R2c will close and electromechanical actuator HC1 will be energized via R3a. Solenoid HC1 will close contacts HC1a, HC1b, and HC1c and lamps 23 will be energized. Although only three lamps 23 are shown in FIG. 9A, it is clear that a substantial number of additional lamps may be connected in parallel with these three. Actuator AV1 will also be energized by relay contacts R2b. Actuator AV1, when energized, causes air to be supplied to cylinder 25 and the lamps to be moved into position above the platen. The preheating operation will then take place for the time determined by timer T1. At the end of this time period, contacts T1a will open, deenergizing relay R2 and, thus causing the lamps and the air cylinder AV1 to be deenergized.
The cure operation is initiated by closing switch 100. Switch 100 energizes relay R8 through contacts T6a. Contacts R8a lock in relay R8. Contacts R8b are then closed and cure timer T4 begins its timing cycle. Contacts T4b and T4c close, thus energizng relay coil R9. Contacts R9a and R9b will then close, causing the solenoid valve AV1 to extend the lamps 23 over the platen and solenoid HC1 to close contacts HC1a, HC1b, L and HC1c. At the end of the cure timing cycle, timer T4 will time out, and deenergize relay R9. This will in turn open the contacts which energize the air valve AV1, and the solenoid HC1, and thus causing the lamps to be extinguished and retracted.
When the Water Control switch 110 is in the automatic position, the application of hot and cold water to the platen is controlled by timers T5 and T6 and air valves AV2 and AV3. At the time the cure switch 100 is pressed, and relay R8 energized, relay contacts R8c close, starting the timing cycle of timer T5. Contacts T5b and T5c apply power to air valve AV2 via contacts R11a only during the timing cycle. Air valve AV2 controls application of hot water to the platen. At the end of the timing cycle of timer T5, contacts T5d energize timer T6. Additionally contacts T6c close energizing both the air valve AV3, which controls the application of cold water to the platen, and the coil of R11. Contact R11a then opens preventing further application of hot water to the platen. Since contacts T5c have opened, coil R10 is deenergized and contacts R10a are closed. Timer T6 will then time through its timing cycle. At the end of the cycle, the timer will be disengaged and the application of cold water to the platen will cease.
Under the control of switches 75 and 80, timers T2 and T3 permit irradiation by the lamps 23 in periodic or duty cycle manner. Timer T2 controls the length of time which the lamps are on, while timer T3 controls the intervening periods of time in which the lamps are off. Switches 75 and 80 are switched according to whether it is desired to provide such cyclical irradiation during the curing or pre-heating phases of machine operation, or both.
Switch 75 is a 4-position switch controlling application of power to relay coils R3 and R4. When the duty cycle form of operation is desired for the pre-heat cycle, switch 75 switched into its second position in which contact 75a is closed and contact 75b is open. Heat delay switch 80 is switched OFF so that 80a are closed and 80b are open. In this mode of operation timers T2 and T3 will alternate timing cycles with timer T2 initially timing and controlling the amount of time that HC1 is energized and timer T3 controlling the length of alternate periods during which HC1 is not energized.
If the heat delay switch 80 is switched OFF and the heat control selector switch 75 is switched to its third position, contacts 75a and 75b will both be closed and duty cycle operation will occur during both the pre-heat and cure cycles. In this mode as well, the timer T2 will begin operation initially with subsequent alternate periods timed by timer T3. If placed in the fourth position, heat control switch 75 will close only contacts 75b, thus causing timers T2 and T3 to time a similar duty cycle sequence only during the curing cycle.
If heat delay switch 80 is switched ON, duty cycle operation will occur for each setting of switch 75, but with the initial period will be timed by timer T3. Thus lamps 23 will not be actuated initially but an initial delay period will be timed by timer T3.
The application of cold or hot water to the platen may, of course, be controlled manually by means of switch 110. Switch 120 applies power to pump motor solenoid 125 which closes contacts M1a and M1b, thus supplying power to the pump motor driving vacuum pump 41 (FIG. 2). The pump will normally run continuously during the operation of the device. In like manner, switch 130 will permit fan motor 135 to run driving fan 29 continuously. Switch 140 energizes solenoid V1 which controls application of vacuum to the platen from pump 41.
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A machine for holding a release sheet on which emblem substrates are mounted while plastic is cast on the substrates and for holding the release sheet and substrates and curing the plastic includes a radiation source which is movable into a position above the release sheet. The platen holding the release sheet has a first cavity which is partially evacuated and which communicates with the upper surface of the platen through a plurality of openings. A second cavity in the platen receives temperature stabilizing fluid. Control circuitry is provided permitting alteration of the operation sequence of the machine.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is related to, and incorporates by reference, the contents of application Ser. No. 282,311, of Ariyan, filed Aug. 21, 1972.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The neurochemistry of aggression has recently attracted much attention, since it has been recognized that aggressive behavior in animals and man can be produced by alterations in ordered brain function. In man, aggressive behavior is very often associated with almost every type of mental disease. Thus, aggression is a major side effect of most mental disorders.
This invention relates to a broad class of novel o-triazenobenzamides which are useful as psychotherapeutic agents, particularly as anti-aggression agents. Thus, certain of these o-triazenobenzamides have been found to be highly selective for the abolition of aggressive behavior at doses which cause little or no signs or symptoms of central nervous system depression or toxicity.
It is well accepted in neuropharmacology that there is no clear distinction between sedative-hypnotics and minor tranquilizers. Virtually all known minor tranquilizers which are effective in reducing anxiety also produce drowsiness, ataxia (inability to coordinate muscular movements), and sleep when given in larger doses. Virtually all sedative-hypnotic drugs in small doses are "anxiolytic" (causing apprehension or anxiety). Sedative hypnotics such as alcohol and short-acting barbiturates tend to produce behavioral excitation prior to promoting drowsiness and sleep. The sedative-hypnotics and minor tranquilizers produce discrete, predictable changes of behavior that can be applied to therapeutic advantage in neurotics. Aside from their ability to promote sleep, their major behavioral action of therapeutic advantage is their ability to slightly reduce the level of arousal-excitability, overcome passive avoidance (social withdrawal, suppressed or submissive behavior), slightly diminish aggressive hostility, and increase the response to environmental stimuli. The effect, for example, of a "psychomimetic" drug (inducing psychosis-like symptoms) on animal behavior, such as LSD in rats and cats, has been said to increase excitement and aggression.
Currently, aggressive behavior in mental disease patients is usually controlled by such major tranquilizers as chlorpromazine. This approach to the problem of controlling mental disorders is not entirely satisfactory since patients under the influence of this type of medication are overly depressed and have difficulty in satisfactorily returning to society and in functioning normally. Chlorpromazine is a strong central nervous system depressant, both in normal and schizophrenic patients. It has been the drug of choice for the treatment of so-called "back ward" schizophrenics, and is now used in out-patient therapy in cases of simple schizophrenia. The compound has many side effects, the most serious being that it causes depression at the same time that it alleviates the schizophrenic symptoms. It also is disadvantageous in that it is extremely toxic and has been known to cause liver damage and blood disorders.
The abolition of aggressive behavior in schizophrenics without neurotoxicity as characterized by depression would be a most desirable feature for a new drug in the therapy of mental disease. The o-triazenobenzamide compounds of the present invention have been found to selectively block aggressive behavior but without causing significant depression.
Accordingly, in one aspect, the invention is a broad class of novel o-triazenobenzamides. In another aspect, the invention is a method of treating aggressive behavior using these compounds. In yet another aspect, the invention is directed to psychotherapeutic pharmaceutical compositions comprising the novel o-triazenobenzamides. In a still further aspect, the invention is directed to methods of preparing the novel o-triazenobenzamides.
2. Description of the Prior Art
Triazene derivatives, including triazenobenzamide derivatives are, of course, known.
For example, Shealy et al, J. Pharm. Sci., 60, 1426 (1971) disclose 2-(3,3-dialkyl-1-triazeno)-benzamides (II) as anti-cancer agents which are related to their 5-(3,3-dimethyl-1-triazeno)-imidazole-4-carboxamide (III), a known anti-cancer compound. Lin et al, J. Med. Chem., 15, 201 (1972) also disclose 2-(3,3-dimethyl-1-triazeno)-benzamide as an anti-cancer agent. The triazeno group in the position ortho to the carboxamide on the benzene ring of these compounds shows a similarity to the novel o-triazenobenzamides of the present invention. ##SPC1##
These disclosures are the only previous examples of o-triazenobenzamides. Ordinarily, when anthranilamide (IV) is diazotized with sodium nitrite in dilute aqueous hydrochloric acid, the intermediate o-carbamoylbenzenediazonium chloride (V) cyclizes to 1,2,3-benzotriazin-4(3H)-one, (VI), a known compound, the use of which is described in Ser. No. 282,311 of Ariyan mentioned above. ##SPC2##
Shealy, however, succeeded in preparing and isolating the o-carbamoylbenzenediazonium tetrafluoroborate (VA) in place of the chloride, and this enabled them to couple the indicated diazonium compound with a number of dialkylamines to obtain their compounds (II): ##SPC3##
It is also known from Schulze, Ann., 251, 163 (1888) that when 3-aminobenzamide is diazotized under acid deficient conditions, 3,3'-diazoaminodibenzamide, an isomer of one of the present compounds, is produced. Derivatives of 3,3'-diazoaminodibenzamide have been reported by Julia et al, Bull. Soc. Chim. Fr., 376 (1968).
No reference, however, has reported the preparation of any o-phenyltriazenobenzamides.
Several examples of heterocyclic rings coupled to either an identical ring or to a benzene ring are well known, e.g., Mohr, Ber., 31, 3495 (1898) and Stark et al, Ber., 46, 2702 (1913); however, no reference has reported the preparation of any heterocyclic o-triazenobenzamides.
SUMMARY OF THE INVENTION
The present invention provides a broad class of novel compounds having psychotherapeutic activity in controlling aggressive behavior. These compounds are o-triazenobenzamides of the formula: ##SPC4##
wherein R is ##SPC5##
in which A and B are hydrogen and C is chloro, methyl, nitro, methoxy, ethoxy, carbamoyl or carboxymethyl; or
A is hydrogen, B is chloro and C is methyl or methoxy; or
A is hydrogen and B and C are both methyl; or
A is hydrogen or methyl, B is nitro and C is methoxy; ##SPC6##
in which D is hydrogen or methyl and E is hydrogen or ##EQU1## wherein F is hydrogen and G is phenyl, halophenyl or trimethylphenyl or benzyl; or F and G together with the nitrogen atom to which they are bonded, form a morpholine ring; or
(3) pyridyl, halopyridyl, methoxypyridyl, quinolyl, anthraquinolyl or N-ethylcarbazolyl;
R i is hydrogen or methyl and R II is hydrogen, lower alkyl, phenyl or the sulfate of a dimethylamino lower alkyl group.
The novel compounds of the formula (A) actually exist in two tautomeric forms, which, for explanatory purposes are given below as formulae (Ia) and (Ib): ##SPC7##
The tautomer (Ia), wherein R is, for example, phenyl is called 2-(3-phenyl-1-triazeno-benzamide, while tautomer (Ib) is called 2-(3-phenyl-2-triazeno)-benzamide. These tautomers are readily interconvertible, and any particular triazene may be either of the two tautomers or a mixture of both. For all unsymmetrically substituted triazenes this application will, therefore, use the nomenclature 2-(3-phenyl-1(or 2)-triazeno)-benzamide (R=phenyl) to describe the novel compounds.
The present invention also provides a method of controlling aggressive behavior in an animal subject without causing the central nervous system depression which is a typical side effect of drugs heretofore used to treat aggressive behavior. This is achieved by administering to an animal subject a therapeutically effective amount of at least one of the o-triazenobenzamides of the formula (A).
Generally, the amount of such o-triazenobenzamide that will be administered will be from about 0.1 to 250 mg/kg/day of body weight, preferably, from about 1 to 25 mg/kg/day. In humans, the amount will be from about 0.1 to 4 mg/kg/day.
The invention further provides new pharmaceutical compositions comprising at least one of the above specified o-triazenobenzamides of the formula (A).
Such pharmaceutical compositions comprise, in combination, a therapeutically effective amount of such an o-triazenobenzamide and a pharmaceutically acceptable carrier and/or diluent therefor.
For example, in the case of a tablet, the composition will comprise, in addition to the active ingredient, fillers, binders, and/or diluents such as lactose, methylcellulose, talc, gum tragacanth, gum acacia, agar, polyvinylpyrrolidone, stearic acid and corn starch. In the case of a liquid suspension for oral administration, the composition will comprise, in addition to the active ingredients, a filler such as sodium carboxymethylcellulose and/or a syrup, e.g., a glycerine based syrup. In the case of a parenteral solution or suspension, the composition will comprise the active ingredient and a suitable liquid solvent or dispersant such as a saline solution.
The above compounds of the formula (A) are prepared by novel methods and thus, the invention also provides methods for the preparation of the compounds of the invention.
According to the invention, compounds of the formula (A) are prepared by diazotizing an amine of the formula:
R--NH.sub.2
wherein R is as described above, to form an intermediate diazonium salt of the formula:
R--N.sub.2 .sup.+ X.sup.-
wherein X - is an anion such as chloride or hydrogen sulfate. The diazonium salt is then coupled with an anthranilamide of the formula: ##SPC8##
wherein R I and R II are as defined above, to yield a compound of the formula: ##SPC9##
In some cases, it will be expedient to diazotize the anthranilamide in ethanolic fluoroboric acid rather than the amine and then couple the diazotized anthranilamide with the amine.
Various methods, some of which are novel, are employed in such diazotizations as follows:
Method A:
The amine is diazotized in dilute aqueous hydrochloric acid at about 0°C by the dropwise addition of aqueous sodium nitrite. The solution of the diazonium chloride is then neutralized with sodium acetate (pH4 - 5) followed immediately by the addition of the anthranilamide to the vigorously stirred solution. This method is applicable to anilines including nitroanilines, to heterocycles with a fused benzene ring substituted with the amino group, and to several heterocyclic amines forming stable aqueous diazonium chlorides.
Method B:
The amine is diazotized in glacial acetic acid or a 50% v/v mixture of propionic acid and acetic acid containing 10% concentrated sulfuric acid at 5°- 10°C by portionwise addition of dry, solid sodium nitrite. The solution of the diazonium salt is filtered into a vigorously stirred suspension of the anthranilamide in aqueous sodium acetate solution. This modification to the method is applicable to most heterocyclic amines with the exception of those aminothiazoles of the formula (A) wherein G is phenyl, halophenyl or trimethylphenyl.
Method C:
The amine is diazotized in glacial acetic acid or a 50% v/v mixture of propionic acid and acetic acid containing 5 - 10% sulfuric acid at 5°- 20°C by the dropwise addition of isoamyl nitrite. The diazonium salt is then treated as described in Method B. This modification of the method is applicable to heterocyclic amines including those for which Method B is not suitable.
Method D:
For the self coupling of anthranilamide, diazotization is performed at about 0°C, in tetrahydrofuran containing a catalytic amount of trichloroacetic acid, by the addition of isoamyl nitrite.
Method E:
In those cases where the amine is difficult to diazotize or forms an unreactive diazonium salt, the diazonium tetrafluoroborate derived from the anthranilamide is coupled with the amine in ethanol at room temperature.
Preparative examples representative of each of these methods will be given below.
DETAILED DESCRIPTION OF THE INVENTION
The compounds of the present invention are prepared according to the methods described above by diazotizing an aromatic or heterocyclic amine and coupling the diazonium salt with an anthranilamide, or in some cases, by diazotizing an anthranilamide and coupling the diazonium salt with an aromatic or heterocyclic amine.
There will now follow working examples showing the preparation of some of the compounds according to the invention using one or more of the above-described modifications of the method of the invention.
EXAMPLE 1 (Method D):
Preparation of 2,2'-diazoaminobenzamide
To 13.6 gm (0.10 mole) of anthranilamide dissolved in 100 ml. of tetrahydrofuran, a catalytic amount (0.1 - 0.2 gm.) of trichloroacetic acid was added. The solution was stirred in an ice-bath while 22 ml. (0.16 mole) of isoamyl nitrite were slowly added. The reaction was then transferred to a water bath at room temperature. After 1 hour, a yellow product precipitated. This product was filtered off, washed with ethanol and then ether, and air dried. Yield: 8.5 gm. (60% of theoretical). The solid was recrystallized from dimethylformamide and washed with ethanol and ether. m.p. 217°- 218°C. (dec.).
EXAMPLE 2 (Method B):
Preparation of 2-[3-(2-thiazolyl)-2(or 1)-triazeno]-benzamide
to 10.0 gm. (0.10 mole) of 2-aminothiazole dissolved in 100 ml. of glacial acetic acid to which 10 ml. of concentrated sulfuric acid had been added, 6.9 gm. (0.10 mole) of dry solid sodium nitrite were added portionwise, while the solution was stirred in an ice bath. The reaction mixture was filtered into a stirred suspension of 13.6 gm. (0.10 mole) anthranilamide in an aqueous solution of 21 gm. of sodium acetate in 100 ml. water. The yellow-brown precipitate was filtered off, washed with ethanol, dissolved in hot ethanol, charcoaled with Norit A, filtered, and permitted to crystallize on cooling. Yield: 12.0 gm. (50% of theoretical). The yellow solid was recrystallized from ethanol.
(Method C):
Alternatively, 15 ml. of isoamyl nitrite (0.11 mole) were added instead of sodium nitrite. The product obtained was somewhat less black in crude yield, and the overall yield was also 12 gm. m.p. 181°- 182°C. (dec.).
EXAMPLE 3 (Method A):
Preparation of 2-[3-(3-chloro-4-methylphenyl)-1(or 2)-triazeno]-benzamide
To 14.15 gm. (0.10 mole) of 3-chloro-4-methylaniline dispersed in 100 ml. of 3N hydrochloric acid, 7.0 gm. (0.10 mole) of sodium nitrite in 25 ml. of water were added dropwise, while the solution was stirred at about 0°C in an ice bath. The reaction mixture was then neutralized to pH 4 - 5 with 21 gm. of sodium acetate, and 13.6 gm. (0.10 mole) of anthranilamide were quickly stirred into the solution. The yellow precipitate was filtered off, and washed with a minimal amount of ethanol, then ether and petroleum ether. The solid was recrystallized from ethanol to give 18 gm. of yellow crystals. Yield 62%. m.p. 185°- 186.5°C. (dec.).
EXAMPLE 4 (Method A):
Preparation of 2-[3-(9-ethyl-3-carbazolyl)-2(or 1)-triazeno]-benzamide
To 10.5 gm. (0.05 mole) of finely divided 3-amino-9-ethylcarbazole dispersed in 50 ml. of 3N hydrochloric acid at about 0°C, 3.5 gm. (0.05 mole) of sodium nitrite in 15 ml. of water were added dropwise. The reaction mixture was filtered into a stirred suspension of 6.8 gm. (0.05 mole) of anthranilamide in an aqueous solution of 10.5 gm. of sodium acetate in 50 ml. of water. The solution was immediately filtered and let stand until precipitation had occurred. The precipitate was filtered off and washed with a minimal amount of ethanol, and then ether. The obtained yellow solid (2 gm.; 11% yield) was recrystallized from ethanol. m.p. 192.5°- 193°C. (dec.).
EXAMPLE 5 (Method B):
Preparation of 2-[3-(4-methyl-5-morpholinocarbonyl-2-thiazolyl)-2(or 1)-triazeno]-benzamide
To 5.0 gm. (0.022 mole) of 2-amino-4-methyl-5-morpholinocarbonyl thiazole dissolved in 20 ml. of glacial acetic acid to which 2ml. concentrated sulfuric acid had been added, 1.5 gm. (0.022 mole) of dry solid sodium nitrite were added portionwise, while the solution was stirred in an ice bath. The reaction mixture was poured into a stirred suspension of 3.0 gm. (0.022 mole) of anthranilamide in an aqueous solution of 8.4 gm. of sodium acetate in 100 ml. of water. The precipitate was filtered off, washed with ethanol and ether, and recrystallized from ethanol and petroleum ether to obtain 1 gm. (12% Yield) of a product having a m.p. of 187.5°- 188°C. (dec.)
EXAMPLE 6 (Method C):
Preparation of 2-[3-(4-methyl-5-(N-benzyl-carbamoyl)-2-thiazolyl)-2(or 1)-triazeno]-benzamide
To 50 gm. (0.20 mole) of 2-amino-4-methyl-5-(N-benzylcarbamoyl)-thiazole dissolved in 200 ml. 50% v/v propionic acidglacial acetic acid and 20 ml. concentrated sulfuric acid, stirred in an ice bath, 30 ml. of isoamyl nitrite were added. The reaction mixture was poured into a stirred suspension of 27.2 gm. (0.20 mole) anthranilamide in an aqueous solution of 84 gm. sodium acetate in 1 liter of water. The orange precipitate was filtered off and washed with ethanol and then ether. The solid was purified by dissolution in dimethylformamide warmed to about 100°C, charcoaling with Norit A, and reprecipitation with ethanol to give 24 gm. (32% yield) of a deep yellow-gold product. m.p. 204° - 204.5°C. (dec.).
EXAMPLE 7 (Method C):
Preparation of N-(3-dimethylaminopropyl)-2-[3-(4-methyl-5-(N-benzylcarbamoyl)-2-thiazolyl)-2(or 1)-triazeno]-benzamide (2:1) sulfate salt
To 50 gm. (0.20 mole) of 2-amino-4-methyl-5-(N-benzylcarbamoyl)thiazole dissolved in 200 ml. of 50% v/v propionic acid-glacial acetic acid and 20 ml. concentrated sulfuric acid, stirred in an ice bath, 30 ml. of isoamyl nitrite were added. The reaction mixture was poured into a stirred suspension of 44 gm. (0.20 mole) of o-amino-N-(3-dimethylaminopropyl)-benzamide in an aqueous solution of 84 gm. sodium acetate in ice water. The finely-divided red precipitate was filtered through Celite, washed with cold water and air dried. The solid was dissolved in lukewarm dimethylformamide, diluted with an equal volume of acetonitrile and then with sufficient benzene to cause precipitation. The purification is repeated to afford 14 gm. (13% yield) of an orange solid. m.p. 145°-147°C. The solid isolated by this procedure is the (2:1) sulfate salt.
EXAMPLE 8 (Method E):
Preparation of 2-[3-p-tolyl-1(or 2)-triazeno]-benzamide
To 1.36 gm. anthranilamide (0.01 mole) dissolved in 50 ml. ethanol containing 5.4 gm. 58% fluoroboric acid, and stirred in an acetone-ice bath (about -5°C), 1.5 ml. of isoamyl nitrite were added all at once. After 1/2 hour, the o-carbamoylbenzenediazonium tetrafluoroborate suspension was diluted with 200 ml. cold anhydrous ether. After 1/2 hour more, the diazonium salt (2.25 gm; 95% yield) was filtered and dried in a desiccator. dec. 131° - 133°C. (lit. 114° - 115°C.).
To 1.07 gm. of p-toluidine (0.01 mole) dissolved in 20 ml. ethanol, about 1.0 gm. of the above diazonium salt (0.004 mole) was added. The solution immediately turned orange and the product precipitated within a couple of minutes. The precipitate was filtered off, washed with ether and recrystallized foom ethanol to obtain 1.25 gm. (98% yield) of a product having a m.p. of 187° - 188°C. (dec.).
Other examples of the preparation of compounds of the formula (A) are given in Table I as follows:
TABLE I__________________________________________________________________________EXAMPLE (dec.) Method IFM* %NO. R R.sup.I R.sup.II m.p. °C. Preparation protected__________________________________________________________________________1 H H 217-218° D 100%2 H H 181-182 B, C 803 H H 185-186.5 A 1004 H H 192.5-193 A 1005 H H 187.5-188 B 1006 H H 204-204.5° B, C 100%7 H --(CH.sub.2).sub.3 NMe.sub.2 1/2 H.sub.2 SO.sub.4 145-7 C 100.sup.(a)8 H H 187-188 A, E 1009 H H 190-190.5 C 6010 H H 186-188 A 8011 H H 179-180 A 4012 H H 211-213 A 10013 H H 176-178 A 100%14 H H 179-180 A 8015 H H 206-208 A 10016 H H 189.5-190 A 6017 H H 191-191.5 C 6018 H H 194-195 C 6019 H H 191-192 A, B 8020 H H 216-217° A 40%21 H H 187-188 A 4022 H H 186-187 A 10023 H H 235-236 A 4024 H H 175-176 E 10025 H H 179-180 E 6026 H Me 154-156 A 10027 H Me 153-154 A 8028 H n--Bu 110-111° A 60%29 H Me 170-172 C 10030 H Et 181-182 C 60.sup.(b)31 Me Me 190-191 C 6032 H Ph 158-60 A 6033 H H 215-216 A 10034 H H 211-212° A 100%35 H H 184-184.5 A 8036 H H 185-187 A 4037 H H 185-186 A 6038 H H 179-180 A 4039 H H 195-196 A 40%40 H H 168-169 A 40__________________________________________________________________________ In TABLE I: Me = CH.sub.3 ; Et = C.sub.2 H.sub.5 ; n--Bu = C.sub.4 H.sub.9 ; and Ph = C.sub.6 H.sub.5 *IFM - Isolated fighting mouse test at a dose of 30 mg/kg intraperitoneally; those compounds which protected at least 40% of the mice in this test were considered to be active. .sup.(a) 60 mg/kg intraperitoneally .sup.(b) per os
The most outstanding property of the triazenobenzamides of the formula (A), according to the present invention, is their highly selective abolition of aggressive behavior in doses which cause little or no signs or symptoms of central nervous system depression or toxicity.
Two models of aggression are used in the primary screening for neuroleptics, (1) isolation-induced fighting in mice (IFM), and (2) aggression induced in rats by destruction of the septal area (septal rat). Compounds are first submitted, however, to the neuropharmacological profile, a standard procedure (see, e.g., Samuel Irwin, Science, 136, 123 [1962]) employed in screening a compound to determine its usefulness as a central nervous system active compound. Those agents which cause depression over a wide dose range are then submitted to the first anti-aggression screen, the isolation-induced fighting mouse assay. As indicated in Table I, above, compounds which protect at least 40% of the mice in this test are considered to be active as anti-aggression agents.
Since they possess outstanding anti-aggressive activity in doses which cause little or no signs of central nervous system depression, the compounds of the present invention differ from known psychoactive agents, all of which cause marked depression in experimental animals. Thus, they inhibit the aggressive behavior of septal rats and inhibit isolation-induced fighting behavior in mice in doses much below those required to produce central nervous system depression or other signs of neurotoxicity.
The compounds of formula (A) of the present invention each have a neuropharmacological profile (see Samuel Irwin, Science, 136, 123 [1962]) in mice which resembles those of the major tranquilizers such as chlorpromazine. These compounds differ from chlorpromazine, however, in that each is a much weaker depressant of motor activity in the mouse.
For instance, considering the compound of Example 6, 2-[3-(4-methyl-5-(N-benzylcarbamoyl)-2(or 1)-thiazolyl)-2-triazeno]-benzamide, as shown by the data hereinafter, this compound was found to be highly selective in abolishing aggressive behavior when administered in doses which caused little or no signs of central nervous system depression or toxicity. It was found to possess some of the activities of a major tranquilizer such as chlorpromazine yet it also had one of the properties of a minor tranquilizer such as chlordiazepoxide. It was not a potent inhibitor of spontaneous motor activity in rats, nor did it produce neurotoxicity in mice or rats to the extent that chlorpromazine or chlordiazepoxide does. It was outstanding in inhibiting septal rat aggression and fighting mouse behavior.
In the latter assay the above compound was more potent that chlorpromazine or chlordiazepoxide and when one correlates the dose necessary to block aggression with that which induced neurotoxicity, it is more than two thousand times more selective in blocking aggression than chlropromazine and one thousand times more selective than chlordiazepoxide. With respect to inhibition of aggressive behavior in the septal rat, it is two hundred and twenty-two times more selective than chlorpromazine. Although this compound was effective in blocking fighting behavior in the electroshock-induced fighting mouse assay, chlorpromazine and chlordiazepoxide were almost twenty times more potent. It is still more selective than either of the latter agents, since the NTD 50 /ED 50 ratio for the compound was 13.3 whereas with chlorpromazine or chlordiazepoxide their ratios were less than one. This is the only test in which this compound resembled chlordiazepoxide in its activity. Like chlorpromazine, this compound is virtually devoid of anti-convulsant activity. It differs from chlorpromazine, however, in that it does not protect against amphetamine aggregation-induced lethality. The compound differs significantly from chlordiazepoxide with respect to the hypothalamus, since in cats it was found that the compound had no effect on the threshold for hypothalamicinduced rage; whereas, chlordiazepoxide is specific in inhibiting this response. The compound is devoid of anti-depressant activity since it failed to (1) potentiate dihydroxyphenylalanine-induced fighting behavior in mice, and (2) antagonize tetrabenazine-induced ptosis.
The compound of Example 6 was studied in the neuropharmacological profile, which, as indicated above, is a standardized multi-dimensional observation technique used on mice to grade symptomatology and acute toxicity relative to dosage.
Loss of spontaneous motor activity accompanied by mild depression were the only symptoms observed at the 300 mg/kg dose level. A reduction in spontaneous motor activity was the only symptom observed at the 100 mg/kg dose level, whereas no dominant signs or symptoms were observed at the 30 mg/kg level. No deaths occurred at any of the dose levels. No hypothermia was observed. The results of the neuropharmacological profile indicate that this compound is a very weak central nervous system depressant.
From the IFM data in Table I, it is apparent that each of the above tested o-triazenobenzamides showed, at doses which caused little or no signs of CNS depression or toxicity, selective abolition of aggressive behavior.
2-[3-(4-methyl-5-(N-benzylcarbamoyl)-2(or 1)-thiazolyl)-2-triazeno]-benzamide, the compound of Example 6, was subjected to additional evaluation tests as described below.
Spontaneous Locomotor Activity
The compound of Example 6 and chlorpromazine, a commonly used major tranquilizer, were each subjected to the spontaneous locomotor activity test, in which six mice per dose were placed in individual photocell activity cages 30 minutes after i.p. (intraperitoneal) administration of the drug, for a 30 minute activity count. Table II shows the results obtained by comparing drug treated groups with control activity, SD 50 being that dose which causes a 50% reduction from control activity.
TABLE II______________________________________Spontaneous Locomotor Activity______________________________________ I.P. SD.sub.50 (mg/kg) Rats______________________________________Compound of Example 6 ˜500Chlorpromazine 1.7______________________________________
The compound of Example 6 thus has a much weaker depressant action in rats in comparison with chlorpromazine.
Neurotoxicity
In the neurotoxicity test, the value (NTD 50 ) is defined as the dose necessary to cause 50% of mice or rats trained to walk a rotating wooden rod (5 rpm) to fall at the time of peak effect, and is a measure of drug effects on motor function or central nervous system toxicity. The results set forth in Table III were obtained when the compound of Example 6 was tested against chlorpromazine and chlordiazepoxide.
TABLE III__________________________________________________________________________Neurotoxicity NTD.sub.50 (mg/kg) 95% Confidence Limits__________________________________________________________________________I.P. MiceCompound of Example 6 >1280Chlorpromazine 0.7 (0.4 - 1.1)Chlordiazepoxide 13.8 (7.1 - 27.0)I.P. RatsCompound of Example 6 ˜500Chlorpromazine 5.3 (3.1 - 9.1)Chlordiazepoxide 4.3 (2.6 - 7.1)__________________________________________________________________________
Again, the compound of Example 6 was considerably less potent than chlorpromazine or chlordiazepoxide. In addition, the compound of Example 6 appeared to be more toxic in rats than in mice.
Anti-Agressive Activity
The compound of Example 6 was compared with chlorpromazine and chlordiazepoxide for its anti-aggressive activity. Three models of experimentally-induced aggression in rodents were studied (R. D. Sofia, Life Science, 8: 705, 1969). The results of these experiments are summarized in Table IV.
TABLE IV__________________________________________________________________________Anti-Aggressive ActivityED.sub.50 (95% Confidence Limits) (mg/kg) i.p. AdministrationAgent ED.sub.50 NTD.sub.50 ED.sub.50__________________________________________________________________________ Isolated Mouse AggressionCompound of Example 6 1.8 (.62 - 5.22) 710Chlorpromazine 2.8 (2.0 - 3.9) 0.3Chlordiazepoxide 20.5 (11.3 - 37.5) 0.7 Electroshock-Induced Fighting in MiceCompound of Example 6 96.0 (43.6 - 211) 13.3Chlorpromazine 5.5 (3.1 - 9.9) 0.1Chlordiazepoxide 4.2 (2.3 - 7.7) 3.3 Septal Rat AggressionCompound of Example 6 ˜4.5 111.0Chlorpromazine 10.7 (4.5 - 25.7) 0.5Chlordiazepoxide 25.8 (14.0 - 47.5) 0.6__________________________________________________________________________
From these data it can be seen that the compound of Example 6 was active in antagonizing the three models of agressive behavior. It was outstanding in its ability to block aggressive behavior in the isolated mouse. It was more potent than chlorpromazine or chlordiazepoxide in this assay and when one correlates the dose necessary to block aggression with that which induces neutrotoxicity, it is greater than two thousand times more selective in blocking aggression than chlorpromazine and one thousand times more selective than chlordiazepoxide. With respect to inhibition of aggressive behavior in the septal rat, it is 222 times more selective than chlorpromazine and 185 times more selective than chlordiazepoxide. Although the compound of Example 6 was effective in blocking fighting behavior in the electroshock-induced fighting mouse assay, chlorpromazine and chlordiazepoxide were almost 20 times more potent. It is still more selective than either of the latter agents, since the NTD 50 /ED 50 ratio for the compound of Example 6 was 13.3 whereas with chlorpromazine and chlordiazepoxide their ratios were less than one.
Anti-Convulsant Activity
Anti-convulsant activity was tested according to the following procedures.
1. Maximal Electroshock Seizures (MES 50 )
Groups of ten mice each were injected i.p. with a vehicle and the compound of Example 6 and placed in individual Plexiglas squares. Thirty minutes after i.p. injection, each mouse was administered an electric shock transcorneally at 50mA intensity, 0.2 seconds duration (Swinyard, et al, J. Pharmacol. Exptl. Ther., 106: 319, 1952). The criterion for activity is protection against tonic extension of the hind limbs. The dose necessary to protect 50% of the mice (MES 50 ) was determined. The following results were obtained.
TABLE V______________________________________Maximal Electroshock SeizuresAgent I.P. MES.sub.50 mg/kg______________________________________Compound of Example 6 Inactive (200 mg/kg)Chlorpromazine Inactive (25 mg/kg)Chlordiazepoxide 14.3 (8.4 - 24.3)______________________________________
The compound of Example 6, like chlorpromazine, did not protect against maximal electroshock seizures even at high doses, although chlordiazepoxide was effective in this test.
2. Pentylenetetrazol Seizures (MET 50 )
In this test (modification of the method introduced by Everett and Richard, J. Pharmacol. Exptl. Ther., 81: 402, 1944), groups of ten mice each are pretreated i.p. with vehicle and various doses of the compound of Example 6 and placed in Plexiglas squares. Thirty minutes later, all mice are injected subcutaneously (s.c.) with pentylenetetrazol at 125 mg/kg and observed immediately thereafter for convulsions and death for a period of 1 hour. The dose necessary to protect 50% of the mice (MET 50 ) for both parameters was determined and reported in Table VI.
TABLE VI______________________________________Pentylenetetrazol SeizuresAgent I.P. MET.sub.50 mg/kg______________________________________Compound of Example 6 Inactive (200 mg/kg)Chlorpromazine Inactive (100 mg/kg)Chlordiazepoxide 7.1 (5.6-90) convulsions 2.6 (2.2-3.1) death______________________________________
Neither the compound of Example 6 nor chlorpromazine exhibited anti-pentylenetetrazol activity, although chlordiazepoxide was effective.
d-Amphetamine Aggregation
Protection from d-amphetamine aggregation-induced lethality is usually afforded by alpha-adrenergic-blocking agents such as chlorpromazine, phenoxybenzamine, etc. Percent protection was determined and an ED 50 value was calculated. The results are summarized in Table VII.
TABLE VII______________________________________d-Amphetamine AggregationAgent ED.sub.50 mg/kg______________________________________Compound of Example 6 Inactive (200 mg/kg)Chlorpromazine 1.2 (0.8 - 1.8)Chlordiazepoxide Inactive (50 mg/kg)______________________________________
The compound of Example 6 and chlordiazepoxide were inactive in this procedure. Chlorpromazine was very active, probably due in part to the alpha-adrenergic blocking activity of this compound.
Drug Interaction Studies
The compound of Example 6, chlorpromazine and chlordiazepoxide were compared in the following drug interaction studies.
1. Dihydroxyphenylalanine (d2-DOPA) Fighting Test
It is well known that when monoamine oxidase inhibitors are administered prior to the administration of d1-DOPA, which is a noradrenaline precursor, convulsions or excitation occur. In this study, the MAO inhibitor pargyline (80 mg/kg) was given 1, 2 and 4 hours prior to administering 200 mg/kg of d1-DOPA. Results of this experiment are manifested by excitation, salivation, jumping, and fighting. When the compound of Example 6 (100 mg/kg), chlorpromazine (5 mg/kg) and chlordiazepoxide (15 mg/kg) were administered instead of pargyline, these symptoms were not observed. Thus, in this procedure, none of the agents tested appears to be a MAO inhibitor.
2. Antagonism of Tetrabenazine-induced Ptosis
Groups of mice were given 32 mg/kg of tetrabenazine intraperitoneally 30 minutes after an injection of the compound of Example 6 (200 mg/kg). The degree of ptosis (eyelid drooping or closure) was then determined exactly 30 minutes after tetrabenazine administration. The compound of Example 6 did not reverse tetrabenazine-induced ptosis, as do the anti-depressants desipramine or amitriptyline.
Toxicity
Table VIII gives the results of 5 day lethality studies following single injections of drug. All values presented represent tests conducted when animals were housed 10 per cage. The compound of Example 6 was compared with chlorpromazine and chlordiazepoxide. In these and all the preceding calculations, the method of Litchfield and Wilcoxon (J. Pharmacol. Exptl. Ther., 96: 99, 1949) was used to estimate effective (ED 50 ) or lethal (LD 50 ) dose.
TABLE VIII______________________________________LD.sub.50 (95% Confidence Limits) mg/kg Mice RatsAgent I. P. P. O. I. P.______________________________________Compound of Ex. 6 >1280 >800 >1400Chlorpromazine 136 280 138 (106-174) (187-418) (133-141)Chlordiazepoxide 400 810 265 (265-604) (688-958) (224-313)______________________________________
These data show that the compound of Example 6 is much less toxic than chlorpromazine or chlordiazepoxide when administered i.p. or orally to mice and rats.
In addition to the above tests conducted on the compound of Example 6, the compounds of Examples 3 and 7 (each of which protected 100% of the test animals in the IFM test) were subjected to additional testing. The test data are given below.
__________________________________________________________________________Neurotoxicity Rotorod DeterminationCompound Dose Animal Route % Successful__________________________________________________________________________Compound of Example 3 30 mg/kg rat P. O. 100 %Compound of Example 7 80 mg/kg rat P. O. 100 %Compound of Example 7 100 mg/kg mouse I. P. 100 %Compound of Example 7 100 mg/kg mouse P. O. 100 %__________________________________________________________________________
These data indicate that the compounds of Examples 3 and 7 do not cause depression and have NTD 50 values greater than 100.
In the isolated fighting mouse aggression test, the compounds of Examples 2, 3, 5, 10, 33, 34 and 35 were found to have the following ED 50 values (i.p. administration):
Compound of Example No. ED.sub.50 (IFM) mg/kg)______________________________________2 9.4 (6.27-14.1)3 9.1 (6.89-12.56)5 6.7 (5.23-8.40)10 6.0 (4.34-8.30)33 14.0 (7.86-24.9)34 14.5 (8.3-25.8)35 5.2 (1.8-15.1)______________________________________
In the septal rat aggression test, the compound of Example 7 was found to give 100% protection at both 6.25 mg/kg and 12.5 mg/kg i.p., indicating an ED 50 of less than 6.25 mg/kg.
Evoked Hypothalamic Rage Response - Cats
The effect of the compound of Example 6 on the hissing response elicited by hypothalamic stimulation in cats was studied in an effort to determine if it had properties similar to that of chlordiazepoxide and other anti-anxiety-like agents. Chlordiazepoxide has been shown by Baxter, Life Sciences, 3: 531, 1964, to increase the threshold of the hypothalamus to electrical stimulation. Cats with chronically implanted electrodes, stereotaxically placed in the perifornical region of the hypothalamus, were used in this study. Stimulation was accomplished in the unanesthetized, freely moving animal, and the threshold for the hissing response was determined with the following stimulus parameters: square wave stimulation of 150 Hz with a duration of 0.5 msec and voltage ranging from 5.4 to 30. The compound of Example 6 was administered orally in capsule form. Following administration, the stimulation threshold for the hiss response was determined at 1, 2, 4, 6 and 24 hours. If an effect was observed, the stimulation was carried out daily until the thresholds returned to control values. The compound of Example 6 was administered orally at a dose of 25 mg/kg for three days. The compound of Example 6 had no effect on hypothalamic stimulation. The rage response was not changed in intensity or character and the delay from stimulus to response was not changed. A few measurements were made in an effort to establish if this compound decreased the threshold for the rage response, but this effect was not observed during the experiments. It can be concluded that the compound of Example 6 has no effect on hypothalamic excitability in cats and in this respect differs markedly from chlordiazepoxide.
The compounds of the present invention, either alone or in the form of a pharmaceutical composition, may be administered to an animal subject in any of a number of forms and via any of several routes. Thus, the compounds or compositions thereof may be orally administered in the form of tablets, pills, or capsules, or in the form of a solution or liquid suspension. They may also be administered in the form of a parenteral suspension or solution. The compounds or compositions thereof may also be administered rectally, in the form of a suppository.
When orally administering the compounds of compositions, use can be made of a tablet, pill or capsule consisting entirely of one of the desired compounds, although ordinarily a composition comprising an effective amount of the compound and varying amounts of one or more physiologically inert materials such as carriers, vehicles, binders and the like will be used. Additionally, the compounds may be orally administered in the form of a suspension thereof in a suitable vehicle such as a syrup.
When parenterally administering the compounds or compositions, use may be made of a parenteral solution or suspension of the compounds in a suitable solvent or suspension medium.
The compounds and compositions of the present invention may also be administered rectally in the form of a suppository comprising an effective amount of the desired compound and a suitable vehicle such as petroleum jelly.
The following examples are specific formulations of compositions according to the invention:
EXAMPLE 41:
Tablets may be prepared by the compression of a wet granulation containing the following:
Ingredients In each______________________________________2-[3-(4-methyl-5-(N-benzylcarbamoyl)-2-thiazolyl)-2(or 1)-triazeno]-benzamide 25 mg.Polyvinylpyrrolidone 6 mg.Lactose 25 mg.Alcohol, 3A, 200 proof 1 ml.Stearic Acid 3 mg.Talc 4 mg.Corn Starch 15 mg.Dosage: 1 tablet 3 times a day.______________________________________
EXAMPLE 42:
A liquid suspension for oral administration may be prepared in the following formulation:
Ingredients In each 5 cc.______________________________________2-[3-(4-methyl-5-(N-benzylcarbamoyl)-2-thiazolyl)-2(or 1)-triazeno]-benzamide 25 mg.Sodium carboxymethylcellulose 5 mg.Syrup USP 5 cc.Dosage: 1 teaspoonful (5 cc.) every 3 to 4 hours.______________________________________
EXAMPLE 43:
Dry filled capsules (DFC) consisting of two sections of hard gelatin may be prepared from the following formulation:
Ingredients In each______________________________________2-[3-(4-methyl-5-(N-benzylcarbamoyl)-2-thiazolyl)-2(or 1)-triazeno]-benzamide 25 mg.Lactose USP q.s.Dosage: 1 capsule 3 times a day.______________________________________
EXAMPLE 44:
A parenteral suspension for intra-muscular administration may be prepared in the following formulation:
Ingredients In each______________________________________2-[3-(4-methyl-5-(N-benzylcarbamoyl)-2-thiazolyl)-2(or 1)-triazeno]-benzamide 10 mg.Isotonic solution (0.85% saline) 5 cc.Surfactant (a 1% solution of polysorbate 80 USP) 1 cc.Dosage: Inject 1 cc. when needed.______________________________________
EXAMPLE 45:
A suppository capsule may be formulated as below:
Ingredients In each______________________________________2-[3-(4-methyl-5-(N-benzylcarbamoyl)-2-thiazolyl)-2(or 1)-triazeno]-benzamide 25 mg.Cocoa butter q.s.Dosage: 1 suppository every 3 to 4 hours.______________________________________
Variations can, of course, be made without departing from the spirit and scope of the invention.
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Certain o-triazenobenzamides are useful as anti-aggression agents. Certain methods of perparation are novel.This is a division of application Ser. No. 311,878, filed Dec. 4, 1972.
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This application is a continuation of U.S. patent application Ser. No. 07/915,204, filed Apr. 20, 1992 U.S. Pat. No. 5,671,382, which is a continuation of U.S. patent application Ser. No. 07/550,566, filed Jul. 10, 1990, now abandoned, which is a continuation of U.S. patent application Ser. No. 07/123,139, filed Nov. 20, 1987, which issued as U.S. Pat. No. 4,942,525 on Jul. 17, 1990.
BACKGROUND OF THE INVENTION
The present invention relates to an information processing unit such as a general purpose computer in which instructions are executed one by one conceptually as viewed from a program, and more particularly to a system important in parallel execution a plurality of instructions in a plurality of execution units to improve a processing speed.
Of computers in which instructions are executed one by one conceptually, those which are intended to improve the processing speed by parallel execution are shown in "An Efficient Algorithm for Exploiting Multiple Arithmetic Units" by R. M. Tomasulo, IBM Journal, 1967 January which relates to IBM 360/91, JP-A-58-176751 entitled "Instruction Decode Unit", U.S. Pat. No. 4,626,989 (or corresponding EU-A-101,596 or JP-A-59-32045) and EU-A-150,449 (or corresponding U.S. patent application Ser. No. 682,839 or JP-A-60-129838). In those computers, since a plurality of conceptually ordered instructions are executed in different execution units, results thereof may be written in a different order than the conceptual order. Thus, when an interruption occurs, it is generally difficult to determine up to which instruction has been executed with regard to the instruction causing the interruption. Where execution based on prediction is done until branch is determined by a branch instruction, if a result of prediction is miswritten when the prediction fails, a recovery thereof is necessary.
In an information processing apparatus in accordance with the IBM 370 architecture, the reversal of the write order as described above should not be observed from the program. Accordingly, in order to comply with the instruction execution order in the 370 architecture in an information processing apparatus which has a plurality of execution units and in which instructions may be simultaneously or disorderly executed, data and addresses thereof on fields of a memory which will be lost by the writing of the result are previously buffered before she execution of the instructions, and when the instruction execution overruns and it should be invalidated, the buffered data must be returned to the original fields. This method may be used for similar purpose as disclosed in JP-B-56-40382 entitled "Information Processing Apparatus" or its corresponding U.S. Pat. No. 4,385,365. However, this method is complex in control, needs buffer registers for data and addresses and hence is expensive, needs a time to recover data and hence an overall performance of the processing apparatus is lowered if the invalidation of instruction execution frequently occurs. When write overrun occurs to a main memory in the 370 architecture, data written by overrun from other processor or channel prior to recovery of the field may occur. In this case, the order rule of the architecture is not complied with even by the order assurance system by the buffer and recovery.
Such an overrun of the instruction execution occurs when an interrupt associated with the instruction execution occurs or when misprediction is detected during predicted execution of a succeeding instruction of a branch instruction.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide an information processing apparatus which has a plurality of execution units and which can efficiently execute a plurality of instructions.
It is another object of the present invention to provide an information processing apparatus which can execute a plurality of instructions in parallel and can readily interrupt the execution of an instruction.
The above objects of the present invention are achieved by controlling the execution of instructions such that the passing of writing of a result does not take place between a plurality of simultaneously executed instructions. To this end, the following control means for the execution of instructions is used.
(1) Instruction set-up means for simultaneously setting up to the execution unit a plurality of instructions which are continuous from a standpoint of conceptual order of execution. A succeeding instruction to a branch instruction is considered to be continuous to the branch instruction whether the branch succeeds or not.
(2) Set-up instruction limit means for limiting a combination of instructions to be set-up in the execution unit such that succeeding instructions which execute writing prior to a final execution step in which a factor to invalidate an instruction in a plurality of instructions to be simultaneously set-up or succeeding instructions thereto may be detected, are not simultaneously set up.
(3) Succeeding instruction execution reserve means for controlling the execution of a plurality of instructions simultaneously set up, when a factor to reserve the execution occurs for one of the instructions, such that the execution of all succeeding instructions which possibly execute writing are reserved.
(4) Succeeding instruction execution suppress means for suppressing, before a write stage, the execution of all instructions to be invalidated, or of the instruction and all succeeding instructions thereof which are simultaneously executed, when a factor to invalidate the instruction or succeeding instructions thereof is detected in the execution of one of instructions simultaneously set up.
By the provision of the means (1)-(4), when there is no factor to invalidate the instruction or succeeding instruction thereof in the plurality of instructions simultaneously executed, the executions thereof are at the same time. Accordingly, a processing time is considerably shortened. If an invalidation factor is detected in any instruction, write overrun does not take place, and a correct instruction or interrupt can be immediately started without the recovery process described above.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows an overall block diagram of a computer of the present invention,
FIG. 2 shows a detailed diagram of an instruction control unit 2 of FIG. 1,
FIG. 3A shows a detailed diagram of a portion of an operation control unit 7 of FIG. 1,
FIG. 3B shows a detailed diagram of a rest of the execution control unit 7 of FIG. 1,
FIG. 4 shows a general diagram of an input exchange circuit 8 of FIG. 1,
FIG. 5 shows a general diagram of an output exchange circuit 9 of FIG. 1,
FIG. 6 shows a detailed diagram of an operand wait control circuit 210 of FIG. 2,
FIGS. 7A to 7D show detailed diagrams of different portions of an instruction set-up control circuit 213,
FIG. 8 shows a detailed diagram of an instruction queue control circuit 212 of FIG. 2,
FIG. 9 shows an instruction format used in the apparatus of FIG. 1,
FIGS. 10A and 10B show time charts of various signals in a simple instruction sequence, and
FIG. 11 shows a configuration of an operation unit 4, 5, 6 of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
An embodiment of the present invention is now explained. A computer in accordance with an architecture of Hitachi M-Series is specifically described.
Examples of instruction format in the above architecture are shown in FIG. 9. (1) shows an instruction format used for a load instruction, a store instruction and add/subtract/multiply/divide instruction. OP denotes an operation code which indicates a type of instruction. R1 indicates a general register number which stores a first operand. X2 and B2 indicate an index register number and a base register number used to generate a second operand address. The index register and base register specify a general register. D2 indicates an address displacement used to generate an address. The operand address is generated by adding the index register, base register and address displacement. An add instruction reads a main memory data at the second operand address, adds it to the first operand in the general register designated by R1, and stores the result into the general resister R1. (2) shows an instruction format used for a conditional branch instruction. OP denotes an operation code which indicates a type of instruction. M1 denotes a mask value which designates a condition code which meets a branch condition. X2, B2 and D2 designate a second operand address. When the branch condition is met, instruction execution is resumed from the instruction at the second operand address.
FIG. 1 shows an overall configuration of a computer of the present invention. Numeral 1 denotes a memory, numeral 2 denotes an instruction control unit, numeral 3 denotes an execution unit, numerals 4, 5 and 6 denote n execution units E1, E2, . . . En, numeral 7 denotes an execution control unit, numeral 8 denotes an input exchange circuit, numeral 9 denotes an output exchange circuit and numeral 10 denotes an input/output device.
The memory 1 is a conventional one which stores data and programs and controls reading and writing thereof. The input/output device 10 is also a conventional one which requests writing of external data and reading of data to the memory 1. The instruction control unit 2 fetches a plurality of instructions from the memory 1, decodes a maximum of p instructions simultaneously, and simultaneously reads operands necessary for those instructions. To this end, an instruction fetch address MAI is sent to the memory 1 from the instruction control unit 2 and an instruction sequence MDI is sent from the memory 1 to the instruction control unit 2. Up to p operand addresses MA i (i=1-p) are simultaneously sent from the instruction control unit 2 to the memory 1 and p fetched operand data MDO i (i=1-p) are sent from the memory 1 to the instruction control unit 2. As the operand addresses MA i (i=1-p) are sent, p input pointers QIP i (i=1-p) of the instruction queue 211 (FIG. 2) are sent from the instruction control unit 2 to the memory 1, and as the operand data MDO i (i=1-p) are sent, advance signals ADV i (i=1-p) indicating the sendout of data and addresses OBNO i (i=1-p) of operand buffer 216 (FIG. 2) at which the data are to be temporarily stored are sent from the memory 1 to the instruction control unit 2. In the present embodiment, OBNO i (i=1-p) correspond to the input pointers QIP i (i=1-p), because the instruction queue 211 (FIG. 2) and the operand buffer 216 (FIG. 2 ) have one-to-one correspondence and they are controlled by the same input/output pointer, as will be explained later.
The instruction control unit 2 selects up to m continuous instructions in the order of execution from the decoded instruction, and simultaneously sets up those instructions and associated information in the execution unit 3. To this end, m sets of signal lines for m instructions for setting up the information are provided. They are called set-up ports i (i=1-m). The information set up in the input exchange circuit 8 includes an instruction INST i (i=1-m) a register operand RD i (i=1-m), memory operand MD i (i=1-m), an operand address MA i (i=1-m) and a write register number RWA i (i=1-m), for each set-up port i (i=1-m). The information set up in the execution control unit 7 includes a valid instruction signal IRDY i (i=1-m) which identifies a valid one of the instructions set up by the set-up ports i (i=1-m), an execution unit number ENO i (i=1-m) for executing the instruction, decode information BC i (i=1-m) indicating a conditional branch instruction, an M1 field (mask) BCM i (i=1-m) of the conditional branch instruction and an operand wait signal ADVW i (i=1-m) indicating that the readout of memory operand is delayed. In order to control the set-up of the instructions, the instruction control unit 2 receives from the execution control unit a signal OBT i (i=1-m) indicating the end of set-up, a last start time signal LBOP indicating the last time of the execution start times for the instructions simultaneously set up, and a signal LINO indicating the number of instructions simultaneously set up, for each of the set-up ports i (i=1-m). The instruction control unit 2 further receives from the execution control unit a branch condition accept signal TKN of the conditional branch instruction, and a signal INT indicating the occurrence of interruption.
The instruction control unit 2 receives from the output exchange circuit 9 an execution result ED i (i=1-m) for the set-up port i (i=1-m), a register write command RWC i (i=1-m) and a write register number RWA i (i=1-m), and writes the results into the general register stack 200.
The execution units 4, 5 and 6 each may execute only specific type of instruction group or all instructions. Input data necessary for execution and execution control information are sent from the input exchange circuit 8 to each execution unit. The input data to the execution unit E i (i=1-m) includes an operation code INSTE i , a register operand RDE i , a memory operand MDE i , an operand address MAE i and a write register number RWAE i . The execution control information includes a set-up end signal OBTE i , an execution permit signal EXE i and an execution cancel signal RESE i . Each execution unit E i sends execution output data and execution control information to the output exchange circuit 9. The output of the execution unit E i includes an execution result EDE i , register write command RWCE i for the result, a write register number RWAE i , a memory write command STCE i for the result, a write memory address STAE i , a signal CCSE i indicating modification of a condition code, and a condition code CCE i . The execution control information includes a signal EOPE i indicating an end of execution, a signal INTCE i indicating occurrence of competition type interrupt condition, and a signal INTSE i indicating occurrence of suppression type interrupt condition.
The execution cancel signal RES is applied to all execution units E i (i=1-n) from the execution control unit 7. The execution cancel signal RES is "1" when the interrupt condition occurs or a branch prediction fails for a conditional branch instruction. In this case, the execution unit E i (i=1-n) cancels the execution of the succeeding instructions. Particularly, it suppresses the register write command RWCE i (i=1-n) and the memory write command MWCE i (i=1-n) to prevent the result of the instruction to be cancelled as a result of being written. At the same time, the execution end signals EOPE i (i=1-n) of all execution units E i (i=1-n) are rendered "1".
The execution unit E i reads the input data in synchronism with the set-up end signal OBTE i . Thereafter, the instruction is executed in one to several cycles depending on the instruction and operands, and the execution in each cycle is permitted only when the signal EXE i is "1". When the signal EXE i is "0", the execution is reserved. The signal EXE i is "0" when a necessary memory operand has not yet been received. When the signal RESE i is "1", the execution unit E i immediately cancels the execution, and the register write command RWCE i and the memory write command MWCE i are suppressed to prevent the result of the instruction to be cancelled a result of being written, and the execution end signal EOPE i is rendered "1". The control for complex instruction execution is done by microprogram control, and the control for simple instruction execution is done by a conventional logic circuit.
FIG. 11 shows a configuration of the j-th execution unit E j . Numerals 1101 and 1102 denote work registers which hold operands. A register operand RDE j is supplied to the register 1101 from the input exchange circuit, a memory operand MDE j is supplied to the register 1101 from the input exchange circuit, and an instruction set-up end signal OBTE j is supplied to both registers. When the signal OBTE j is "1", the work registers 1101 and 1102 read the signal RDE j and the signal MDE j , respectively. Numeral 1103 denotes a register which receives the signal OBTE j from the input exchange circuit, and when it is "1", reads an operand address MAE j and a write resister address RWAE j . Numeral 1104 denotes an arithmetic logic circuit ALU, which comprises an adder/subtractor, a shifter and an arithmetic and logic circuit. Operands are supplied to the ALU 1104 from the work registers 1101 and 1102, and an ALU control signal is supplied to the ALU 1104 from an ALU control circuit 1107 to execute the instruction. An output data bus of the ALU 1104 is connected to the work register 1101 and 1102 to enable execution over a plurality of cycles. The ALU control circuit 1107 supplies a data read control signal to the work registers 1101 and 1102. The signals OBTE j , INSTE j and EXE j are supplied to the ALU control circuit 1107. The ALU control circuit 1107 is a conventional one which comprises a microprogram and an execution control circuit therefor. When the signal OBTE j is "1", the ALU control circuit 1107 reads the signal INSTE j and reads the first microinstruction of the microprogram corresponding to the instruction. For the instruction whose execution stage completes in one cycle, the end of execution is specified to the first microinstruction, and for the instruction whose execution stage needs a plurality of cycles, the end of execution is specified to the microinstruction which controls the last operation stage, and signal EOPE j is an output representing the end of execution. The microinstruction designates the ALU control For each execution cycle but it is actually executed when the signal EXE j is "1". Numeral 1108 denotes a condition code generator which receives the execution result from the ALU and the condition code generation information from the ALU control circuit 1107 and generates the condition code CCE i one cycle after the execution stage. Numeral 1109 denotes an interrupt condition detector which receives the execution result from the ALU and the interrupt detect control information from the ALU control circuit 1107 and generates interrupt condition generation signals INTCE j and INTSE j one cycle after the execution stage. Numeral 1110 denotes a write control circuit which receives result write control information from the ALU control circuit 1107 and generates signals STCE j , RWCE j and CCSE j one cycle after the execution stage. The control circuit 1110 also receives the signal RESE j from the input exchange circuit 8 and the signal RES from the execution control unit 7, and when either one of them is "1", immediately suppresses the signals STCE j , RWCE j and CCSE j to "0". The signals RES and RES j are also supplied to the ALU control circuit 1107, and when any one of them is "1", the ALU control by the ALU control circuit 1107 is canceled. Numerals 1105 and 1106 denote pipeline registers which hold the execution results, write memory address and write register number, and they output signals EDE j , STAE j and RWAE j one cycle after the execution stage. The execution units E1 to En each have circuits corresponding to the ALU control circuit 1107 and the write control circuit 1110, and the response to the signals RES and RES i is the same as described above.
The execution control unit 7 controls the parallel execution of the instructions by the plurality of execution units. It watches the execution end signal EOP i (i=1-m), and when all instructions have been executed, it issues a set-up end signal OBT i (i=1-m) to up to m succeeding instructions designated by the valid instruction signal IRDY i (i=1-m) and sends them to the instruction control unit 2 and the input exchange circuit 8. It also reads an execution unit number ENO i (i=1-m) sent from the instruction control unit 2, holds it during the execution of the set-up instructions, and sends it to the input exchange circuit 8 and the output exchange circuit 9.
The execution control unit 7 monitors the operand wait signal ADVW i (i=1-m), and if there is an instruction whose memory operand has not yet arrived, it renders the execution permit signals EX i (i=1-m) of that instruction and succeeding instruction to "0". Thus, the succeeding instructions are prevented from being executed earlier.
The execution control unit 7 determines a branch condition of a conditional branch signal and sends a branch success signal TKN to the instruction control unit 2. It receives a condition code change signal CCS i (i=1-m) and a condition code CC i (i=1-m) from the output exchange circuit 9. In the present embodiment, when the conditional branch instruction is decoded, it is predicted that the branch instruction will fail as is done in a conventional computer, and succeeding instructions are decoded. Accordingly, since the "1" branch success signal means the failure of prediction, the instruction which is currently being decoded by the instruction control unit 2 is cancelled and the instruction on the target stream is decoded. The signal RES i (i=1-m) which indicates the cancellation of the execution of the succeeding instruction to the instruction currently being executed is sent to the input exchange circuit 8.
The execution control unit 7 receives interrupt condition generate signals INTC i (i=1-m) and INTS i (i=1-m) for the instruction being executed, from the output exchange circuit 9, and when a completion type interrupt condition occurs, it cancels the execution of the succeeding instruction to the instruction for which the interrupt condition has occurred, and when a suppression type interrupt condition occurs, it generates a cancel signal RES i (i=1-m) to cancel the execution of the instruction for which the interrupt condition has occurred and the succeeding instructions. It further sends to all execution units a cancel command signal RES to cancel the execution of the succeeding instruction group which have been set up immediately thereafter. It also sends an interrupt signal INT to the instruction control unit 2.
The input exchange circuit 8 sends the set-up data for m instructions which are set up through the set-up ports i (i=1-m), for each of the execution units which execute those instructions. It receives the execution unit number ENO i (i=1-m) from the execution control unit 7 for each set-up port.
The output exchange circuit 9 receives the output data and execution control information from the execution unit i (i=1-n) and rearranges them in the order of set-up ports i (i=1-m). It receives the execution unit number ENO i (i=1-m) from the execution control unit 7. The output information is sent to each unit, as described above. For the execution result to be written into the memory 1, the data ED i (i=1-m), address STA i (i=1-m) and memory write command STC i (i=1-m) are sent to the memory 1. The memory 1 receives them and writes them into the memory 1.
FIG. 2 shows a detailed configuration of an instruction control unit 2. Numeral 201 denotes an instruction fetch circuit which monitors a vacant state of a prefetch instruction buffer 202, and if it is vacant, it sends an instruction fetch address MAI to the memory 1 and sets the fetched instruction data MDI into the instruction buffer 202. Usually, several continuous instructions are fetched in one instruction fetching. Accordingly, the prefetch instruction buffer 202 has a a capacity which is at least as large as the size of the instructions fetched in one fetching. Another instruction buffer 203 for storing a target instruction sequence for a branch instruction is provided. Before branch success for the branch instruction is detected, a selector 204 selects the prefetch instruction buffer 202 and sends the content thereof to the instruction fetch circuit 201. When the branch success for the branch instruction is detected, the execution control unit sends a branch success signal TKN to the selector 204, which responds thereto to select the instruction buffer 203 and send the content thereof to the instruction fetch circuit 201. The above instruction fetch control is not typical one in a conventional general purpose computer and it can be readily attained by conventional means.
Numerals 205 and 206 denote p instruction registers. The instruction fetch circuit 201 extracts p continuous instructions from an instruction sequence on the instruction buffer 202 or 203 selected by the selector 204 and sets them in order in the instruction registers 205 and 206. The instruction fetch circuit 201 may be one disclosed in JP-A-58-176751 entitled "Instruction Decode Unit". Numerals 207 and 208 denote p instruction decoders which decode instructions for the instruction registers 205 and 206 and output the decoded information. As the decoded information, each of the decoders DEC i (i=1-p) sequentially sends an instruction index register designation field XA i (i=1-p) and a base register designation field BA i (i=1-p) to a general register stack 209, an address displacement field DSP i (i=1-p) to p address adders 214 and 215, and information UOB i (i=1-p) indicating an instruction which uses a memory operand to an operand wait control circuit 210. As further decoded information, an instruction code INSTD i (i=1-p), a register operand number RA i (i=1-p), a write register number WA i (i=1-p) for storing an execution result, a number of instruction execution cycles EL i (i=1-p), information E1SD i (i=1-p) E2SD i (i=1-p), . . . , EnSD i (i=1-p) indicating that the instruction can be executed by the execution unit E i (i=1-n), information BCD i (i=1-p) indicating that the instruction is a conditional branch instruction, and a mask value BCMD i (i=1-p) of the conditional branch instruction are sent to an instruction queue 211. A signal DS i (i=1-p) indicating that the instruction has been decoded is sent from the decoder DEC i (i=1-p) to an instruction queue control circuit 212, an instruction set-up control circuit 213, the instruction queue 211 and an operand wait control circuit 210.
The general register stack 209 comprises 16 4-byte registers designated by the instruction. They receive the index register designation field XA i (i=1-p) and the base register designation field BA i (i=1-D) from the decoders 207 and 208, read the content of the register of the designated number, and sequentially send them to an address adder AA i (i=1-p) as index register data XD i (i=1-p) and base register data BD i (i=1-p). The general register stack 209 receives register operand numbers RRA i (1=1-m) for m set-up ports from the instruction queue 211, reads the contents of the registers designated thereby, and sends them to the input exchange circuit 8 as register operand data RD i (i=1-m). The general register stack 209 further receives from the output exchange circuit 9 execution results ED i (i=1-m) for m set-up port, write register numbers RWA i (i=1-m) and register write command RWC i (i=1-m), and writes them into the designated registers. The general register stack 209 simultaneously reads and writes a plurality of instructions and it can be readily attained by conventional means.
The address adder AA i (i=1-p) receives index register data XD i (i=1-p), base register data BD i (i=1-p) and address displacement DSP i (i=1-p) and sends the execution result thereof to the memory 1 and the instruction queue 211 as the operand address MA i (i=1-p). If the instruction is not a branch instruction, the operand address MA i (i=1-p) is an address of the memory operand, and the data read from the memory 1 is sent to an operand buffer 216 by a data signal MO i (i=1-p). On the other hand, if the instruction is the branch instruction, a target instruction address corresponds to the memory operand address MA i (i=1-p), and the data read from the memory 1 is sent to the instruction buffer 202 or 203 by a data signal MDI.
The instruction queue 211 comprises a k-instruction queue register and an input/output circuit thereof. The number k is no smaller than p or m. The instruction queue 211 receives decode information for p continuous instructions from the decoder DEC i (i=1-p) and simultaneously queues them. The instructions actually queued are those having "1" corresponding decode end signals DS i (i=1-p), and they are set into the queue registers pointed by input pointers QIP i (i=1-p). The contents of the input pointers QIP i (i=1-p) sequentially point p continuous queue registers next to the queue register for the latest instruction in the instruction queue. The k-th cueue register is followed by the first queue resister. The decode information of up to m continuous instructions starting from the oldest instruction in the uueue are simultaneously read from the instruction queue. thus, the m output pointers QOP i (i=1-m) sequentially point m continuous queue registers starting from the oldest instruction in the queue. The m-instruction output pointed by the output pointers QOP i (i=1-m) is the content of the m set-up ports. If the valid instruction signal IRDY i (i=1-m) supplied by the instruction set-up control circuit 213 is "1", it is deemed that the instruction has been actually fetched. As the output of the instruction queue, an instruction code INST i (i=1-m), an operand address MA i (i=1-m), a write register number RWA i (i=1-m) are sent to the input exchange circuit 8, a register operand number RRA i (i=1-m) is sent to the general register 209, a conditional branch instruction indication BC i (i=1-p) and a mask value BCM i (i=1-p) of the conditional branch instruction are sent to the execution control unit 7, and the number of execution cycles EL i (i=1-m) and executable indication information E1S i (i=1-m), E2S i (i=1-m), . . . , EnS i (i=1-m) of the execution unit E i (i=1-n) are sent to the instruction set-up control circuit 213.
The operand buffer 216 comprises k buffer registers (not shown) for holding operand data MDO i (i=1-p) sent from the memory 1 and input/output circuits together. When the operand buffer 216 receives an advance signal ADV i (1=i-p) from the memory 1, it stores the operand data MDO i (i=1-p) into the buffer register designated by the operand number OBNO i (i=1-p). The operand buffer 216 stores up to p data. In the present embodiment, the k buffer registers correspond to k queue registers of the instruction queue. For the instruction which needs a memory operand, the queue register for storing the decode information and the buffer register for storing the memory operand have the same number.
The operand buffer 216 simultaneously reads up to m instructions operand data MD i (i=1-m) for the set-up ports and sends them to the input exchange circuit 8. The operand buffer 216 receives the instruction queue output pointer QOP i (i=1-p) from the instruction queue control circuit 212.
The instruction queue control circuit 212 generates p input pointers QIP i (i=1-p) of the instruction queue 211 and m output pointer QOP i (i=1-m). It sends the input pointers QIP i (i=1-p) to the instruction set-up control circuit 213, instruction queue 211, operand queue control circuit 210, and memory 1. The control circuit 212 sends the output pointer QOP i (i=1-m) to the instruction set-up control circuit 213, instruction queue 211, operand queue control circuit 210 and operand buffer 216. The control circuit 212 also receives a decode end signal DS i (i=1-p) from the decoder DEC i (i=1-p), a last start time signal LBOP, in instruction count signal LINO, a branch success signal TKN and an interrupt signal INT from the execution control unit 7.
A more detailed configuration of the instruction queue control circuit 212 is shown in FIG. 8. Numeral 801 denotes a register for holding QIP i (i=1-m). Numerals 802 and 803 denote constant incrementers which receive the content of the register 801, sequentially add 1, . . . , p-1 thereto (in modulo p) and has an output of the resulting sums as the input pointers QIP2-QIPp. Numeral 804 denotes an input pointer update circuit which receives p decode and signals DS i (i=1-p) and the input pointer QIP1, adds the number of "1" branch success signals DS i (i=1-p) and the content of the input pointer QIP1 in modulo p, and sets the result into the register 801. For example, if there are two instructions which have been simultaneously decoded, the signals DS1 and DS2 are "1" and the signals DS3-DSp are "0". The decode information of those two instructions are stored into queue registers (not shown) pointed by the input pointers QIP1 and QIP2. The content of the register 801 is incremented by two. An initial value of the register 801 is zero. Namely, it is previously set to zero for executing the first instruction. Numeral 805 denotes an OR gate which receives the branch success signal TKN and interrupt detect signal INT from the execution control unit 7, outputs a logical OR thereof, and sends it to the input pointer update circuit 804 and the output pointer update circuit 806. When the output of the OR gate 805 is "1", the output pointer update circuit 804 sets the register 801 to "0". Since it means prediction failure when the conditional branch instruction succeeds the branch, all succeeding instructions in the instruction queue are invalidated and the execution should be resumed from the decoding of the target instruction. This is the reason why the register 801 is set to "0".
Numeral 807 denotes a register for holding QOP1. Numerals 808 and 809 denote (m-1) incrementers which receive the content of the register 807 and output values incremented by 1, . . . , (m-1) in modulo m as output pointer signals QOP j (j=2-m). The output pointer update circuit 806 receives the content of the register 807, the last start time signal LBOP from the execution control unit 7 and the instruction count LINO, and when the signal LBOP is "1", it adds the signal LINO and the content of the register 807 in modulo m, and sets the sum into the register 807. The register 807 is initially set to "0" as the register 801 is done. When the output of the OR gate 805 is "1", the register 807 is set to "0" by the same reason for the input pointer.
The instruction set-up control circuit 213 of FIG. 2 selects up to m settable instructions from the decoded instructions in the instruction queue 211 and displays them by the valid instruction signal IRDY i (i=1-m). The control cirucit 213 displays, by the valid signal IRDY i (i=1-m) those set-up ports i (i=1-m) for m instructions parallelly sent from the instruction queue 211 to the logic circuits which bear decode information of valid instructions. The instruction which corresponds to "1" valid instruction signal IRDY i (i=1-m) is valid and it is to be next set up. A condition for a group of instructions which can be set up in one cycle is as follows.
(1) The group of instructions which can be set up comprise up to m instructions with a first instruction thereof being the oldest instruction in the instruction queue or the instruction to be first executed in the order of execution in the program.
(2) There are a sufficient number of execution units having functions to parallelly execute all instructions in the instruction group.
(3) For two adjacent instructions in the instruction group, the number of execution cycles for the succeeding instruction is equal to or larger than the number of execution cycles of the preceding instruction.
The instruction set-up control circuit 213 determines an execution unit which executes each of the set-up instructions, and sends a signal END i (i=1-m) indicating the execution unit number to the execution control unit 7.
The instruction set-up control circuit 213 which generates an instruction valid signal IRDY i (i=1-m) and a signal END i (i=1-m) which meets the conditions (1)-(3) is explained in detail with reference to FIGS. 7A to 7D. FIG. 7A shows a circuit for generating a signal QRDY i (i=1-m) indicating the necessary condition. Numerals 701 and 702 denote k flip-flops which correspond to k queue registers (not shown) of the instruction queue and indicate that decoded instructions which are ready to be set up are stored in the queue registers. Numerals 703 and 704 denote k OR gates which correspond to the flip-flops 701 and 702 and send signals to set the flip-flops to "1". Numerals 705 and 706 denote p decoders which correspond to p instruction decoders DEC i (i=1-p) shown in FIG. 2 and which sequentially receive instruction decode and signals DS i (i=1-p) and instruction queue input pointer signals QIP i (i=1-p) and sequentially send k decode outputs to OR gates 703 and 704. When the instruction decode end signal is "1", the decoder 705 or 706 renders the decode output signal corresponding to the queue register pointed by the instruction queue input pointer signal to "1". The corresponding one of the OR gates 703 and 704 outputs a "1" signal so that the corresponding flip-flop is set to "1". When two or more instructions have simultaneously been decoded, as many instruction decode end signals as the number of those instructions counted from the signal DS1 is set to "1", and as many flip-flops as the number of those instructions, which are continuous starting from the flip-flop pointed by the input pointer QIP1 are set to "1". Numerals 707 and 708 denote k OR gates which correspond to the flip-flops 701 and 702 and send signals to reset the flip-flops to "0". Numerals 709 and 710 denote m decoders which correspond to m-instruction output ports of the output exchange circuit 9, or set-up ports i (i=1-m), and which sequentially receive the set-up end signals OBT i (i=1-m) and instruction queue output pointer signals QOP i (i=1-m) and sequentially send k decode outputs to the OR gates 707 and 708. When the set-up end signal is "1". the decoders 709 and 710 set the decode output signals corresponding to the queue register pointed by the instruction queue output pointer signal to "1". The corresponding one of the OR gates 707 and 708 outputs "1" signal so that the corresponding flip-flop is reset to "0". When two or more instructions have simultaneously been decoded, as many set-up end signals as the number of those instructions counted from the signal OBT1 are set to "1", and as many flip-flops as the number of those instructions which are continuous starting from the flip-flop pointed by the output pointer QOP1 are reset to "0". Numeral 711 denotes an OR gate which sends a logical OR of the signal TKN sent from the execution control unit 7 and the signal INT to the OR gates 707 and 708. Accordingly, when the conditional branch instruction succeeds the branch, that is, when prediction fails, or when an interrupt condition occurs and subsequent instruction execution is to be cancelled, the signals TKN and INT are set to "1" and all flip-flops 701 and 702 are reset to "0" through the OR gates 711, 707 and 708. Numerals 712 and 713 denote m selectors which correspond to the set-up ports i (i=1-m). Each of the selectors receives k queue busy signals QBSY i (i=1-k) from the flip-flops 701 and 702. Each selector also receives the instruction queue output pointer QOP i (i=1-m), selects the queue busy signal QBSY i (i=1-k) which corresponds to the queue register pointed by the pointer QOP i (i=1-m), and outputs it as a signal QRDY i (i=1-m).
In the present invention, up to p continuous instructions are stored in the instruction queue continuously to the previously queued instructions, and up to m continuous instructions are fetched for set-up. The pointer QOP i (i=1-m) points m continuous queue registers starting from the queue register which stores the oldest one of the decoded instructions. When there are i decoded instructions, QRDY j (j=1-i) is "1" and ORDY j (j=1+i-m) is "0" if i is smaller than m, and QRDY i (i=1-m) is "1" if i is no smaller than m. It is thus seen that the signal QRDY i (i=1-m) indicates the condition (1).
FIG. 7B shows a circuit for generating m-1 signals EA i (i=2-m) indicating necessary conditions for the signals IRDY i (i=1-m) to meet the condition (2). It also has a function to determine the execution unit number ENO i (i=1-m) which executes the instruction set up through the set-up port i (i=1-m). Numerals 720 and 721 denote execution unit assignment control circuits EAC which generate signals EA i , ENO i and EA i+1 , ENO i+1 for the i-th and (i+1)th instructions of up to m instructions set up through the set-up ports. There are m circuits EAC, one for each of the set-up ports i (i=1-m). Numerals 722 to 725 denote n AND gates, one for each of the execution units. Each of the AND gates receives a signal E1A i , . . . , EnA i indicating a vacant state of the i-th instruction and an instruction decode information E1S i , . . . , EnS i indicating to the execution unit whether it has a function to execute the i-th instruction, and outputs a logical AND thereof. If the logical AND is "1", it means that the corresponding execution unit is vacant and it has the function to execute the instruction and hence it is a candidate for assignment. Usually, there are more than one candidate execution units for assignment. Numeral 726 denotes an OR gate which logically Ors the outputs of the AND gates 722-725 and outputs it as a signal EA i . If one of the outputs of the AND gates 722-725 is "1", it means that there is an execution unit to which the instruction is to be assigned and hence the signal EA i is "1". Numerals 727-729 denote n-1 AND gates which, when there are more than one candidates, selects one execution unit for assignment. Each of the AND gates 727-729 outputs a signal "1" when the execution unit E2, . . . , En is assigned. It receives the output signal of the AND gate 723, . . . 725 so that it is conditioned to output the signal "1" when the corresponding execution unit is the candidate. A negative of the output signal of the AND gate 722 is supplied to the AND gates 727-729, and the output signal of the AND gate 723 is inverted and supplied to the AND gates 728-729. In general, an inverted output signal of that one of the AND gates 722-725 which is associated with the execution unit E j is supplied to that one of the AND gates 727-729 which is associated with the execution unit E j+1 , . . . , E n . As a result, when there are more than one candidate execution units, only one of the outputs of the n gates 722, 727-729 which is associated with the execution unit having the smallest number is "1", and the remainders are "0". Numeral 730 denotes an encoder which receives the n gate outputs and outputs the execution unit number i corresponding to the "1" output, as a signal ENO i . Numerals 731-734 denote n AND gates, one for each of the execution units, which receive the execution unit vacant state signals E1A i , . . . , EnA i and the an inverted outputs of the n gates 722, 727-729, and output logical AND thereof as execution unit vacant state signals E1A i+1 , . . . , EnA i+1 for the (i+1)th instruction. As seen from the above description, only those of the signals E1A i , . . . , EnA i which correspond to those of the signals E1A i , . . . , EnA i and are associated with the execution unit assigned to the i-th instruction are "0". In the EAC for the first instruction, the execution unit vacant state signals E1A1, . . . , EnA1 are "1" indicating the vacant state.
FIG. 7C shows a circuit for generating m-1 signals ELOK i (i=2-m) indicating necessary conditions for the signal IRDY i (i=1-m) to meet the condition (3). Numeral 740 denotes a comparator which compares the numbers of execution cycles EL1 and EL2 for the first and second instructions supplied from the instruction queue 211, and if the latter is equal to or larger than the former, outputs a "1" signal ELOK2. Numerals 741 and 742 denote m-2 comparators identical to the comparator 740, for the third to m-th instructions. Each of them compares the number of execution cycles of the current instruction with that of the immediately preceding instruction and outputs a "1" signal when the number of execution cycles for the current instruction is equal to or larger than the preceding. Numerals 743 and 744 denote m-2 AND gates for the third to m-th instructions and output signals ELOK i (i=3-m). The outputs of the comparators 740 and 741 are supplied to the AND gates 743 and 744. In general, an output of that one of the comparators 741 and 742 which is for the i-th (i>2) instruction is supplied to all of those AND gates 743 and 744 which are for the i-th and subequent instructions. Accordingly, the outputs of the comparators 740 to 742 are supplied to the AND gate 744. Thus, the signal ELOK i is "1" only when the condition (3) is met for all of the first to i-th instructions.
FIG. 7D shows a circuit for generating a valid instruction signal IRDY i (i=1-m) by using the signals QRDY i (i=1-m), EA i (i=2-m) and ELOK i (i=2-m) explained in FIGS. 7A, 7B and 7C. Numeral 750 denotes an AND gate which receives only the signal QRDY1 and outputs a signal IRDY1. Thus, the decoded instruction pointed by the pointer QOP1 can always be set up. Numerals 751-753 denote AND gates for m-1 instructions (second to m-th instructions) of up to m simultaneously set-up instructions. They receive the signals QRDY i (i=2-m) and ELOK i (i=2-m). The signal EA2 is supplied to the AND gates 751-753, and the signal EA3 is supplied to the AND gates 752 and 753. In general, the execution unit assignment signal EA i for the i-th (i>1) instruction is supplied to those of the gates 751-753 which are for the i-th and subsequent instructions. Accordingly, for example, all of the signals EA i (i=2-m) are supplied to the gate 753. The gates 751-753 output the logical AND or the inputs thereto as the signals IRDY i (i=2-m). Thus, the signal IRDY i (i=1-m) is the valid instruction signal which meets all of the conditions (1)-(3).
The operand wait control circuit 210 of FIG. 2 generates a signal ADVW i (i=1-m) indicating whether necessary operand data has been read into the operand buffer, for each of up to m set-up instructions, and sends it to the execution control unit 7. It receives the signals DS i (i=1-p) and UOB i (i=1-p) from the instruction decoders 207 and 208, the signals QIP i (i=1-p) and QOP i (i=1-m) from the instruction queue control circuit 212, and the signals ADV i (i=1-p) and OBNO i (i=1-p) from the memory 1.
The operand wait control circuit 210 is explained in further detail with reference to FIG. 6. Numerals 601 and 602 denote k flip-flops, one for each of k buffer registers of the operand buffer 216. It indicates that a necessary operand has not yet arrived at the buffer register. When the flip-flop is "1", it indicates that an operand is to be read into the corresponding buffer register but it has not yet arrived. When it is "0", it indicates that the operand need not be read into the corresponding buffer register or it has already arrived. Numerals 603 and 604 denote k OR gates which output values to be set into the flip-flops 601 and 602. Numerals 605 and 606 denote p decoders, one for each of the p instruction decoders of FIG. 2, which receive the signals UOB i (i=1-p) and instruction queue input pointer signals QIP i (i=1-p) and send k decode outputs to the OR gates 603 and 604. When the signal UOB i (i=1-p) is "1", the decoders 605, 606 render the decode output signal corresponding to the buffer resister pointed by the instruction queue input pointer signal to "1". The corresponding one of the OR gates 603 and 604 outputs a "1" signal. Numerals 607 and 608 denote k OR gates which send clock signals to the flip-flops 601 and 602 to set the input data from the OR gates 603 and 604. Numerals 609 and 610 denote p decoders, one for each of the p instruction decoders DEC i (i=1-p) of FIG. 2, which receive the signals DS i (i=1-p) and the instruction queue input pointer signals QIP i (i=1-p) and send k decode outputs to the OR gates 607 and 608. When the signal DS i (i=1-p) is "1", the decoder 609, 610 renders the decode output corresponding to the buffer register pointed by the instruction queue input pointer signal to "1". The corresponding one of the OR gates 607 and 608 outputs a "1" clock signal. As a result, the input data is set into the corresponding flip-flop. When two or more instructions have been simultaneously decoded, as many instruction decode end signals as the number of those instructions counted from DS1 are "1", and as many flip-flops as the number of those instructions which are continuous from the flip-flop pointed by the pointer QIP1 are set by the input data. Numerals 611 and 612 denote k OR gates corresponding to the flip-flops 601 and 602, which send signals to reset the flip-flops to "0". Numerals 613 and 614 denote p decoders corresponding to p output ports from the memory 1, which receive the advance signals ADV i (i=1-p) and the operand buffer numbers OBNO i (i=1-p) and send k decode outputs to the OR gates 611 and 612. When the advance signals are "1", that is, when the operand has been sent from the memory 1, the decoder 613, 614 renders the decode output corresponding to the buffer register designated by the operand buffer number to "1". The corresponding one of the OR gates 611 and 612 outputs a "1" signal so that the corresponding flip-flop is reset to "0". When two or more operands are simultaneously read, as many advance signals as the number of operands are "1", and as many flip-flops as the number of operands are reset to "0". Numerals 615 and 616 denote m selectors corresponding to the set-up ports i (i=1-m). Each selector receives k operand wait signals ADVWQ i (i=1-k) from the flip-flop 601 and 602. Each selector also receives the instruction queue output pointer QOP i (i=1-m), selects an operand wait signal corresponding to the buffer register pointed by the pointer QOP i (i=1-m) from the signals ADVWQ i (i=1-k), and outputs it as the signal ADVW i (i=1-m). It is thus seen that the signal ADVW i (i=1-m) indicates that a necessary operand has not arrived at the operand buffer, for each of up to m set-up instructions.
The execution control unit 7 is explained with reference to FIGS. 3A and 3B. FIG. 3A shows a circuit for generating execution permit signal EX i (i=1-m), set-up end signal LOBT i (i=1-m), last execution start signal LBOP and number of set-up instruction LINO. Numerals 301-303 denote m NOR gates corresponding to the set-up ports i (i=1-m), which receive execution reserve conditions for the instructions set-up through the set-up ports, and inverted the output of logical ORs thereof. A condition FW1 which indicates that the operand for the first instruction of the set-up instructions to the port 1 has not yet arrived is supplied from an AND gate 317 to the NOR gates 301-303 as the execution reserve condition. A condition FW2 which indicates that the operand for the second instruction for the port 2 has not yet arrived is supplied from an AND gate 318 to the NOR gates 302 and 303. In general, a signal FW i for the i-th instruction is supplied to those of the NOR gates 301-303 which correspond to the ports i to m. Numerals 304-306 denote m flip-flops corresponding to the set-up ports i (i=1-m), which hold corresponding outputs of the NOR gates 301-303 each cycle and output them as the signals EX i (i=1-m). When the signal FW i is "1" for the i-th instruction, the execution permit signals EX j (j=i-m) for the i-th and subsequent instructions are "0" so that the execution of the i-th to m-th instructions is suppressed. In the present embodiment, the execution reserve condition is only the non-arrival of the operand. The passing of the execution may be prevented by supplying other reserve conditions to the NOR gates 301-303.
Numerals 307-309 denote m AND gates corresponding to the set-up ports i (i=1-m), which receive the execution end signals EOP i (i=1-m) sent from the output exchange circuit 9 and the execution permit signals EX i (i=1-m) sent from the flip-flops 304-306, and output logical ANDs thereof as the signals EOPEX i (i=1-m). The signal EOPEX i indicates that the execution of the i-th instruction has been permitted. Numeral 310 denotes an AND gate which receives the signals EOPEX i (i=1-m) and outputs a logical AND thereof as a signal ERDY. The signal ERDY indicates that all of the set-up instructions have been executed and all execution units E i (i=1-n) are vacant. In the present embodiment, the succeeding instructions are set-up only after the signal ERDY has been set to "1". Numerals 311-313 denote m AND gates corresponding to the set-up ports i (i=1-m), which receive the valid instruction signals IRDY i (i=1-m) sent from the instruction control unit 2 and the signal ERDY, and outputs a logical AND thereof. The outputs of the AND gates 311-313 indicate that the instructions have been set-up through the corresponding ports in that cycle. Numerals 314-316 denote m flip-flops corresponding to the set-up ports (i=1-m), which receive the set-up end conditions from the AND gates 311-313 at the data input terminals, and the signals EX i (i=1-m) from the flip-flops 304-306 at the clock terminals, and output set-up end signals OBT i (i=1-m). For the flip-flop of the flip-flops 314-316 which corresponds to the set-up port i, if there is a valid instruction for that port, the signal OBT i is "1" n the cycle in which the instruction has been set up, and when the execution actually starts, the signal OBT i is set to "0" in the next cycle. Numerals 337-339 denote m registers corresponding to the set-up ports i (i=1-m), which receive the signals ENO i (i=1-m) from the instruction control unit 2 and read the signals ENO i (i=1-m) when the outputs of the corresponding gates 311-313 are "1". The contents of those registers are sent to the input exchange circuit 8. Numerals 317-319 denote m AND gates corresponding to the set-up ports i (i=1-m), which receive the operand wait signals ADVW i (i=1-m) from the instruction control unit 2 and the signals OBT i (i=1-m) from the flip-flops 314-316, and output logical ANDs thereof as operand non-arrival condition sianals FW i (i=1-m). Numerals 320-322 denote m AND gates corresponding to the set-up ports i (i=1-m) which receive the execution permit signals from the NOR gates 301-303 and the set-up end signals OBT i (i=1-m) from the flip-flops 314-316, and output logical ANDs thereof as the execution start signals BOP i (i=1-m). Numerals 323-325 denote m AND gates corresponding to the set-up ports i (i=1-m) which detect that the instructions set-up through the corresponding ports are the conceptually last instructions of the simultaneously set-up instructions and the execution of those instructions has been started. The signal BOP i and the inverse of the signal OBT i+1 are supplied to the AND gate corresponding to the set-up port 1. Only the signal BOP m is supplied to the gate 325. When the signal BOP i (i<m) is "1" and the signal OBT i+1 corresponding to the next port i+1 is "0", the i-th instruction is the last instruction, because if it is assumed that the i-th instruction is not the last instruction, it would mean that the instructions have been set-up for the (i+1)th to m-th ports. If the instruction has been set up for the port i+1, the signal OBT i+1 cannot be "0" when the signal BOP i is "1" because the start of execution of the (i+1)th instruction does not pass that of the i-th instruction. This is contradictory to the above. If it is assumed that the instruction has not been set up for the port i+1, it would mean that the instruction has not been set up for the i+2 to m ports. This cannot occur in the present embodiment because the instructions are set up for the continuous ports. This is because of an error in the assumption that the i-th instruction is not the last one. Accordingly, in this case, it may be said that the i-th instruction is the last one of the set-up instructions. When the signal BOP m is "1", it is clear that the m-th instruction is the last one. The output of the i-th one of the gates 323-325 is "1", and the outputs of other gates are "0". Numeral 326 denotes an OR gate which logically ORs the outputs of the gates 323-325 and outputs it as a signal LBOP. Numeral 327 denotes an encoder which receives the outputs of the AND gates 323-325, generates a port number corresponding to the gate which outputs the signal "1", and outputs it as a signal LINO.
FIG. 3B shows a circuit of the execution control unit for generating the conditional branch decision signal TKN, interrupt detect signal INT and execution cancel signal RES i (i=1-m). Numeral 350 denotes a condition code selector which receives condition codes CC i (i=1-m) of instructions corresponding to the set-up ports and set signals CCS i (i=1-m) thereof from the output exchange circuit, selects a condition code for that one of the "1" CCS i (i=1-m) signals which has the largest number, and sends it to a register 351. Numeral 352 denotes an OR gate which receives the signals CCS i (i=1-m) and sends a logical OR thereof to a clock terminal of the register 351, which is a condition code register and sets the condition code supplied from the selector 350 when the clock signal from the OR gate 352 is "1". The condition code CCP from the register 351 indicates that all of the simultaneously set-up instructions have been executed. Numeral 353 denotes a branch decision control circuit when a conditional branch instruction is set-up to the set-up port 1. Numerals 354 and 355 denote branch decision control circuits corresponding to the set-up ports i (i=2-m). Numerals 356, 358 and 359 denote m registers corresponding to the set-up ports i (i=1-m), which set those of the conditional branch instruction signals BC i (i=1-m) and mask signals BCM i (i=1-m) supplied from the instruction control unit which relate to the corresponding ports. The signal OBT i (i=1-m) generated in the execution control unit is supplied to each register as a clock signal. Numerals 362 and 363 denote condition code selectors, which output the latest condition codes for the conditional branch instruction when the conditional branch instruction is set us from the corresponding set-up port. The signals CCP, CC1 and CCS1 are supplied to the selector 362. When the signal CCS1 is "1", it means that the first instruction sets the latest condition code, and the selector 362 outputs the signal CC1. If the signal CCS1 is "0", it outputs the signal CCP. In general, the signals CCP, CC1, . . . , CC i-1 , CCS1, . . . , CCS i-1 are supplied to the selector 362, 363 which corresponds to the set-up port i (i>1). If all of the signals CCS1, . . . , CCS i-1 are "0", that is, if there is no instruction in the simultaneously set-up instructions which sets the condition code prior to the conditional branch instruction, the selector outputs the signal CCP. If at least one of the signals CCS1, . . . , CCS i-1 is "1", the selector outputs the condition code which corresponds to the largest port number. It is thus seen that the selectors 362 and 363 output the latest condition codes for the conditional branch instruction when the conditional branch instruction is set up from the corresponding set-up port. Numerals 357, 360 and 361 denote branch decision circuits. The circuit 357 receives the signal CCP from the condition code register 351, the signals BC1 and BCM1 from the register 356, and the signal EOPEX1 generated in the execution control unit. The signal EOPEX1 indicates the cycle in which the first instruction has been executed. if the signal BC1 is "1", that is, if the instruction is a conditional branch instruction, the presence or absence of branch is determined based on the mask value BCM1 and the latest condition code CCP, and the result is outputted as a signal TKN1. Similarly, the circuits 360 and 361 receive the latest condition codes thereto from the selectors 362 and 363, the signals BC i (i=2-m) and BCM i (i=2-m) from the registers 358 and 359, and the signals EOPEX i (i=2-m) generated in the execution control unit. They determine the branch conditions and output the results thereof as signals TKN i (i=2-m), as the circuit 353 does. Numerals 354-366 denote m OR gates corresponding to the set-up ports i (i=1-m), which output execution cancel signals RES i (i=1-m) for the corresponding instructions. The signal TKN1 and the signal INTC1 from the output exchange circuit are supplied to the OR gates 365 and 366. In general, the signals TKN i (i=2-m) and INTC i (i=2-m) are supplied to those of the gates 365 and 366 which correspond to the ports i+1 to m. The signal INTS1 from the outout exchange circuit is supplied to the OR gates 364-366. The signal INTS i (i=2-m) is supplied to those of the gates 365 and 366 which correspond to the ports i to m. It is thus seen that when a branch succeeds or a completion type interruption occurs for the i-th instruction, the cancellation signals RES i+1 , . . . , RES m are sent to the execution units which execute the (i+1)th and subsequent instructions, and when a suppression type interruption occurs for the i-th instruction, the cancellation signals RES i+1 , . . . , RES m are sent to the execution units which execute the i-th and subsequent instructions. Numerals 367 and 368 denote OR gates which send logical ORs of the branch success signals TKN i (i=1-m) and the interrupt detect signals INTC i (i=1-m) and INTS i (i=1-m) to the instruction control unit as signals TKN and INT. Numeral 369 denotes an OR gate which sends a logical OR of the signals INT and TKN to a flip-flop 370, which holds the output of the OR gate 369 for one cycle and sends the output signal RES to the execution units E i (i=1-n). The signal RES suppresses the execution of the instructions set us in the immediately suceeding cycle.
FIG. 4 shows the input exchange circuit 8. Numerals 401-403 denote n OR gates corresponding to the execution units E i (i=1-n), which output the data to be set up in the execution units. Numerals 404-406 denote m decoders corresponding to the set-up ports i (i=1-m) which receive input data d i (i=1-m) and execution unit numbers ENO i (i=1-m) and send n decode signals corresponding to the execution units E i (i=1-n) to the OR gates 401-403. When the input data is "1", each decoder sets the decode signal designated by the execution unit number to "1". The input data d i (i=1-m) may include INST i , RD i , MA i , MD i , RWA i , OBT i , EX i and RES i (i=1-m), and the exchange circuit of FIG. 4 is provided for each of the input data.
FIG. 5 shows the output exchange circuit 9. Numerals 501-503 denote m selectors corresponding to the set-up ports i (i=1-m). Each of the selectors 501-503 receives the execution unit number ENO i (i=1-m) from the execution control unit 7 and the output data e i (i=1-n) from the execution units, and outputs that input data e i (i=1-n) which is designated by the corresponding execution unit number, as the signal d i (i=1-m). The output data may include the signals ED i (i=1-m), RWA i (i=1-m) and STA i (i=1-m).
The operation of the computer of the present embodiment is now explained for a typical instruction sequence. FIG. 10A shows an operation time chart for a four-instruction sequence, Load, Multiply, Load and Store. In the present embodiment, one instruction process comprises six stages excluding instruction fetching. In a stage D, an instruction is decoded and an operand address is generated. In a stage A, the decoded information is stored into the instruction queue and a memory operand or a target instruction of a branch instruction is read. In a stage L, the instruction is set up. In a stage E, the instruction is executed. In a stage P, the execution result is checked or a conditional branch is determined, and a write command for the execution result is issued. In a stage S, the execution result is written into a register or memory. The stage S may be omitted depending on the instruction. For a simplest instruction, each stage comprises one cycle, but depending on the instruction, certain, stases comprise a plurality of cycles. In FIG. 10A, an abscissa represents axis a time measured by a machine cycle and an ordinate axis indicates the instruction sequence and major signals or major processes. The four instructions are designated by the instruction numbers 1-4.
In FIG. 10A, the instructions 1 and 2 are simultaneously set up. As they are executed, a completion type interruption occurs in the instruction 2. Thus, the execution of the succeeding instructions 3 and 4 are cancelled. The instructions 1 and 2 are simultaneously decoded in a cycle C1. In a cycle C2, the instruction decode end signals DS1 and DS2 are "1". In a cycle C3, the valid instruction signal IRDY1 and IRDY2 are "1". If none of the execution units is vacant, the signal ERDY is "1". Accordingly, the instructions are set up in this cycle and the signals OBT1 and OBT2 are set to "1". Since there is no execution reserve condition, the execution is immediately started and the signals BOP1 and BOP2 are set to "1". In a cycle C4, the execution permit signals EX1 and EX2 are set to "1". Since the stage E for the instruction 1 ends in one cycle, the execution end sianal EOP1 is set to "1" in the cycle C4. On the other hand, since the instruction 2 requires three cycles for the stage E, the signal EOP2 is set to "1" in a cycle C6. Accordingly, it is in the cycle C6 that the signal ERDY is next set to "1". In the present example, since the completion type interrupt condition is detected at the end of the stage E for the instruction 2, the signal INTC2 is set to "1" in the stage P and the signal RES is set to "1" in the stage S. On the other hand, the instructions 3 and 4 start in the stage D, one cycle delayed with respect to the instructions 1 and 2, and the signals IRDY1 and IRDY2 are set to "1" in the cycle C4. However, since the execution of the preceding instruction group has not yet been completed and the signal ERDY is "0", the set-up of the instructions is reserved. In the cycle C6, the signal ERDY is set to "1" and the instructions 3 and 4 are set-up. The instructions 3 and 4 are then executed through the stages E and P, and enter into the stage S in a cycle C9. However, since the interruption has occurred in the preceding instruction 2 and the signal RES has been set to "1" in the cycle C8, the write commands RWC1 and MWC2 for the results of the execution of the instructions 3 and 4 in the cycle C8 are inhibited. Since the instructions 3 and 4 are set up after the instructions 1 and 2 have been executed, the issuance of the write commands to the instructions 3 and 4 is done after the stage P in which the interruption in the instructions 1 and 2 is detected. As a result, the inhibition of the write commands RWC1 and MWC2 is attained. In the conventional computer, the instructions 3 and 4 are set up and executed without waiting for the completion of the instructions 1 and 2 and hence the result has been written when the interruption of the instruction 2 is detected. Accordingly, It is necessary to recover previously buffered data when a register is used, and it is difficult to comply with the specification of the M Series architecture when a memory is used.
In FIG. 10B, a branch-on-condition instruction of a four instruction sequence, Compare, Branch on Condition, Load and Store on a main memory succeed the branch, the pre-executed instructions Load and Store are cancelled, and a target instruction Add is executed. In the present example, the memory operand readout of the instruction 1 is delayed two cycles. The instructions 1, 2 and 3 are decoded in a cycle C1, and the signals DS1, DS2 and DS3 are set to "1" in a cycle C2. In a cycle C3, the signals IRDY1, IRDY2 and IRDY3 are set to "1". If all execution units are vacant and the signal ERDY is "1", the instructions are set up and the signals OBT1, OBT2 and OBT3 are set to "1". For two cycles from C3 to C5, the signal ADVW1 is "1" to indicate that the memory operand for the instruction 1 has not yet arrived. In response thereto, the execution permit signals EX1, EX2 and EX3 and the execution start signals BOP1, BOP2 and BOP3 for the succeeding instructions are inhibited for the two-cycle period. In a cycle C6, the execution of the instructions 1, 2 and 3 starts and the branch success signal TKN2 for the branch-on-condition instruction is set to "1" in the stage P (C7). In response thereto, the signal RES3 is set to "1" in the cycle C7 and the signal RES is set to "1" in a cycle C8, and the register write command RWC3 of the instruction 3 and the memory write command MWC1 to the memory 1 by the instruction 3 are inhibited. The inhibition of the write command of the result by the instruction 3 is attained because the execution thereof is started after the execution of the instructions 1 and 2 has been started and the issuance of the write command of the instruction 3 is done after the stage P in which the branch of the instruction 2 is determined since the number of cycles of the execution stage of the instruction 3 is not shorter than that of the instruction 2. The decoding of the target instruction starts from the cycle C8. In the conventional computer, since the execution of the instruction 3 is not necessarily reserved based on the execution reserve condition of the instruction 1, the result has usually been written when the branch success of the instruction 2 is detected. Accordingly, it is necessary to recover the previously buffered data into the register, or if the instruction 3 is a Store instruction, it is difficult to comply with the specification of the M Series architecture. The inhibition of the write command to the memory for the instruction 4 is attained by the same reason as that for FIG. 10A.
In accordance with the present invention, in an information processing apparatus based on an architecture in which instructions are executed one by one as viewed from a program, the assurance of order in case of interruption or prediction failure by a branch instruction is very easy to attain when high speed operation by parallel execution is to be attained. If the present system is not used, it is necessary to always buffer the initial content of the register for the instruction to store the result into the register and recover the register in the above case. As a result, a control circuit is necessary and a process time is long. For the instruction to write the result into the main memory, it is impossible with the currently available technique to comply with the order specification.
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An information processing apparatus in which instructions are processed one by one conceptually and results thereof are conceptually orderly written into a memory comprises an instruction control circuit capable of decoding M instructions and reading operands in parallel, N (N≧M) execution circuits capable of executing a plurality of instructions mutually in parallel, a detection circuit for determining whether all of M execution circuits of the N execution circuits required by the M instructions decoded by the instruction control circuit are vacant or not, and a reserve circuit for reserving the execution of the M decoded instruction while the detection fails to detect sufficient vacancy.
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FIELD OF THE INVENTION
The present invention relates to an apparatus and a method for treating a pulp slurry of waste paper containing relatively large deformable impurities of strings, foils, and clumps of glue, and relatively fine impurities of small particles, printing ink and filler material such as ashes and clay.
BACKGROUND OF THE INVENTION
In the conventional process of creating a fibre pulp from waste paper, initially the waste paper is repulped to form a pulp slurry of waste paper, and then the pulp slurry is treated in a number of consecutive stages to separate various undesirable impurities. Typically, said consecutive stages include:
(a) centrifugal separation of the pulp slurry to remove relatively large and dense impurities, such as staples and other metallic particles;
(b) coarse pressure screening of the pulp slurry to remove the relatively large impurities which have not been removed by said centrifugal separation;
(c) flotation separation of the pulp slurry to remove printing ink;
(d) washing of the pulp slurry to remove filler material, such as ashes and clay, and residual printing ink;
(e) fine pressure screening of the pulp slurry to remove fine impurities in the form of small particles; and
(f) centrifugal separation of the pulp slurry to remove residual fine materials such as ink, dirt specks and other fine impurities.
The pulp slurry substantially freed from impurities includes a variety of fibres from a variety of paper grades. Depending on the final requirement of the pulp, the pulp slurry may require an increase in brightness obtained by mixing a bleaching chemical with the fibres.
A primary deficiency with the conventional process is the lack of an efficient selective separation of undesirable, relatively large and relatively small impurities, such as plastic foils, fragments of other plastic particles, and so-called "stickies", formed from glue and other adhesives. Thus, the above-noted stage (b) of the conventional process--coarse pressure screening--has a poor efficiency with regard to rejecting undesirable relatively large impurities in the form of flexible plastic foils and fragments of other flexible plastic particles. Such large flexible particles often occur in low-selective waste paper. Said poor efficiency is due to the fact that the coarse screening has to be operated under high pressure, in order to ensure passage of long fibres and limit the liquid content of the rejected coarse fraction, so that the amount of polluting printing ink in the coarse fraction is reduced. In consequence of said high pressure some undesirable large flexible particles are pushed, with deformation, through the screen openings. Furthermore, some large impurities in the form of deformable clumps of glue occurring in the slurry of waste paper may escape through the screen by extrusion of said clumps through the screen openings, as the clumps are subjected to said high pressure. The term "glue" is used to mean any glue-like substance, such as adhesives, hot-melts, waxes, so-called "stickies" etc.
In the above-noted stage (e) of the Conventional process--fine pressure screening--the screen openings of the screen have to be large enough to allow bulkier long fibres to pass as accept. In consequence, small deformable impurities, such as glue, may also pass through the screen by extrusion through the screen openings.
Another deficiency of the conventional process is that a considerable amount of good fibres, particularly long fibres, are lost with the impurities rejected. In the above-noted stage (c)--flotation separation--some long fibres tend to float and be rejected with printing ink. In stage (e)--fine pressure screening--some long fibres or flocks of fibres may be blocked by the fine screen used and rejected with the undesired small particles.
SUMMARY OF THE INVENTION
The above-mentioned deficiencies of the conventional process of creating a fibre pulp from waste paper are eliminated by the apparatus in accordance with the present invention. Thus, the apparatus of the invention reduces loss of good fibres, in particular long fibres, and provides a more efficient separation of impurities from the waste paper pulp slurry.
In a principal aspect, the invention includes an apparatus for treating a pulp slurry of waste paper, comprising:
means for spraying jets of the pulp slurry through a gaseous medium;
a first screen positioned in said gaseous medium, so as to be hit by said jets of pulp slurry, said first screen having screen openings sized such that the pulp slurry hitting said first screen is fractionated into a rejected first aqueous fraction containing relatively long fibres and the large impurities, and an accepted second aqueous fraction containing relatively short fibres and substantially all of the fine impurities;
a second screen having screen openings sized to allow passage of the long fibres and to block the large impurities, provided that the large impurities are not deformed;
means for conducting said first aqueous fraction from said first screen to said second screen, and
means arranged to press said first aqueous fraction gently through said second screen, such that the large deformable impurities are not deformed as they are pushed against the screen openings of said second screen, for separating said first aqueous fraction into a rejected third aqueous fraction containing the large impurities, and an accepted fourth aqueous fraction containing the long fibres.
By spraying the pulp slurry through a gaseous medium, preferably air, the sprayed long fibres and large impurities, which have relatively large specific surfaces, are retarded by the frictional drag of the surrounding gas medium and thereby are easily blocked by said first screen, whereas short fibres and small impurities, which have a relatively small specific surface, substantially keep their velocity and thereby penetrate said first screen. As a result, substantially all of the printing ink in the slurry penetrates said first screen, except for an insignificant amount adhering to the long fibres, so that said first aqueous fraction containing long fibres is substantially freed from loose particles of printing ink. This permits said first aqueous fraction to be gently pressed through said second screen in spite of the consequence that a significant amount of liquid will be rejected, because the rejected liquid will be free from polluting printing ink. In addition, the screen openings of said second screen can be larger than conventional, without risking deformable impurities to penetrate said second screen, whereby the rejection of good long fibres is reduced.
While the definition of "long fibers" is somewhat variable, in general, we refer to relatively long fibers as those having a length equal to or greater than 1.5 mm, usually in the range ≧1.5-2.0 mm. Relatively short fibers are in general those having a length of less than 1.5 mm, typically 1.0 to 1.5 mm.
Advantageously, the apparatus further comprises a flotation device, in which the printing ink is floated off from said second aqueous fraction containing short fibres, whereby no desirable long fibres are lost by flotation. Since said second aqueous fraction is richer in printing ink, compared to the unfractionated slurry, the flotation operation can be carried out more efficiently.
The apparatus may further comprise means for separately mixing chemicals with the long fibres obtained through said second screen and with the short fibres obtained through said third screen, for bleaching the fibres, and means for mixing bleached long fibres with bleached short fibres, for creating a final bright fibre pulp suited for making white paper. This is of advantage because the short fibres need to be bleached in a chemicals-containing solution which is up to five times stronger than that of the solution required for bleaching long fibres. Thus, the consumption of chemicals can be substantially reduced, as compared to bleaching a fibre pulp containing long fibres as well as short fibres, because in the latter case a larger volume of the stronger solution has to be employed.
In another aspect, the invention includes a method of treating the slurry of waste paper, comprising the steps of:
spraying the slurry in the form of jets through a gaseous medium;
screening said jets of slurry such that the slurry is fractionated into a rejected first aqueous fraction containing relatively long fibres and the large impurities, and an accepted second aqueous fraction containing relatively short fibres and substantially all of the fine impurities, and
screening said aqueous first fraction of the slurry, without substantially deforming the large impurities therein, such that said first aqueous fraction is separated into a rejected third aqueous fraction containing the large impurities, and an accepted fourth aqueous fraction containing the long fibres.
BRIEF DESCRIPTION OF THE DRAWING
The FIGURE is a schematic flow chart of a preferred embodiment of the apparatus in accordance with the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to the drawings, a pulp slurry of waste paper to be treated, which has initially been cleaned from large and dense impurities, such as staples and other metallic particles, is pumped by a pump 1 via a conduit 2 to a spray filter 3 having a screen 4. The spray filter 3 comprises a vessel of any convenient dimensions having fixtures suitable for retaining the screen 4. The diameter of the screen openings of the screen 4 is chosen in the range of 500 to 1000 micron. The spray filter also comprises one or more spray nozzles 5 positioned to receive the slurry from conduit 2 and spray the slurry in the form of jets through air in the spray filter 3 against the screen 4, so that the pulp slurry is fractionated into a rejected first aqueous fraction containing relatively long fibres and relatively large deformable impurities of strings, foils and clumps of glue, and an accepted second aqueous fraction containing relatively short fibres and relatively fine impurities of small particles, printing ink and filler material, such as ashes and clay.
Although the filter 3 is shown as a flat screen, it may take the form of a rotating disc (or a plurality of rotating discs) or a drum.
The first aqueous fraction containing long fibres is pumped by a pump 6 from the spray filter 4 to a coarse screen 7 via a conduit 8. The diameter of the screen openings of the screen 7 is chosen in the range of 0.2 to 0.3 millimeters, preferably 0.2 millimeters. The pump 6 is adapted to press said first aqueous fraction gently through the screen 7, without substantially deforming large flexible impurities occurring in said first aqueous fraction, so that the latter is separated into a rejected third aqueous fraction containing the large flexible impurities, and an accepted fourth aqueous fraction containing the long fibres. Said rejected third aqueous fraction is discharged from the screen 7 through a conduit 9. Alternatively, the screen 7 may be replaced by a spray filter of a type similar to the spray filter 3.
As a further alternative, the screen 7 may be a rotary drum filter, i.e. a cylinder whose walls have holes or slots of the desired size. The pressure drop across the screen is such that the fibers are forced gently through the screen openings while the impurities are retained on the other side. This will normally require a feed pressure of, say, about 5 to about 20 psi.
The fourth aqueous fraction normally contains not more than 2-4% bone dry solids and is therefore dewatered, in a dewatering apparatus 7a, to a bone dry solids content of about 30%, in order to be suited for bleaching. The dewatering device may be any conventional equipment capable of filtering out liquid from the slurry. It can, for example, be a drum filter, a disc filter, a screw press or a belt press.
Through a conduit 10 said dewatered fourth aqueous fraction is pumped by a pump 11 from the screen 7 to a mixing device 12, in which the long fibres are mixed with conventional bleaching chemicals supplied to the mixing device 12 via a conduit 13. The mixture of chemicals and long fibres is pumped by a pump 14 from the mixing device 12 to a reaction vessel 15 where the bleaching is carried out, via a conduit 16.
This reaction vessel may be an agitated tank or chest, or a tower, in accordance with conventional practice.
The second aqueous fraction containing short fibres and fine impurities is pumped by a pump 17 from the spray filter 3 to a flotation device 18 via a conduit 19. The flotation device 18 may again be any of a variety of commercially available models, such as the Beloit "PDM-Cell" or the Black Clawson "BC-Flotator". In the flotation device 18 printing ink is floated off from the second aqueous fraction to produce a substantially de-inked aqueous fraction of short fibres, which is pumped by a pump 20 from the flotation device 18 to a washing device 21 via a conduit 22. The washing device may be any of a variety of conventional models such as the Celleco GDX, FDW or SD Filters or the Black Clawson DNT Filter. In the washing device 21, filler material, such as ashes and clay, and residual printing ink are washed from the de-inked aqueous fraction of short fibres.
The washed aqueous fraction of short fibres is pumped by a pump 23 from the washing device 21 to a fine screen 24 via a conduit 25. The diameter of the screen openings of the screen 24 are chosen in the range of 0.1 to 0.2 millimeters, preferably 0.15 millimeters. The screen 24, which may again be flat or rotary in construction, separates fine impurities in the form of small particles from said washed aqueous fraction of short fibres to produce an accepted clean aqueous fraction of short fibres. The separated fine impurities are discharged from the screen 24 through a conduit 26.
The clean aqueous fraction of short fibres having a bone dry solids content of not more than 5% by weight is dewatered to a bone dry solids content of about 30% by weight in an apparatus 24a. This device may be of the same general design as the device 7a.
Through a conduit 27 the dewatered aqueous fraction of short fibres is pumped by a pump 28 from the dewatering device 24a to a mixing device 29, in which the short fibres are mixed with bleaching chemicals supplied to the mixing device 29 via a conduit 30. The mixture of chemicals and short fibres is pumped by a pump 31 from the mixing device 29 to a reaction vessel 32, like the vessel 15 via a conduit 33.
Through conduits 34 and 35, bleached long and short fibres are transferred from the reaction vessels 15, 32 to a mixing device 36, in which the bleached long and short fibres are mixed to produce a final bright pulp suited for making white paper. The final bright pulp is drawn from the mixing device 36 via a conduit 37.
The above-described embodiment is particularly suited for treating a pulp slurry of low-selective waste paper, e.g. mixed office waste. However, it is possible to eliminate one or more of the treatment stages if the pulp slurry is obtained from a more selected waste paper and/or the quality of the final pulp is not crucial. For example, either the flotation device 18 or the washing device 21, or both devices, may be eliminated.
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An apparatus for treating a pulp slurry of waste paper including long fibers, short fibers and large and fine impurities includes the step of spraying the slurry through a gaseous medium upon a screen to separate long fibers and large impurities from small fibers and fine impurities.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a §371 National Stage Application of International Application No. PCT/IB2015/051540 filed on Mar. 3, 2015, claiming the priority of Italian Patent Application No. MI2014A000336 filed on Mar. 5, 2014.
FIELD OF THE INVENTION
[0002] The object of the present invention is a boat according to the preamble of the main claim. EP2305553 presents the characteristics of the invention described in said preamble.
BACKGROUND OF THE INVENTION
[0003] Boats having a stern compartment provided with at least one closing stern hatch of its own are known for a long time. Such a compartment is used, for instance, to house a small boat or a tender. It is also known that in the stern portion, many prestigious boats have a stern platform determined by a projecting plane suitable for operating as a “small beach” for the boat's passengers.
[0004] With reference to said hatch, it can be moved with the purpose of freeing or closing an aperture to access the stern compartment (from the sea or from the stern platform). For this purpose, actuating members are usually provided, usually in the form of telescopic members which constrain the body of the hatch to side walls of the stern compartment. This solution implies that, irrespective of whether the hatch is closed or open, such telescopic (pneumatic or hydraulic) members limit the internal space of the stern compartment. The hatch being open, conversely, they can be hitted against by those who occupy the craft, who might hurt themselves or in any case cause even non negligible physical damages to themselves.
[0005] Also, the presence of said telescopic actuating members makes the mounting of the hatch onto the aperture of the stern compartment a rather complex operation, in that it shall be performed through a number of successive steps, which include positioning the hatch and the actuating members locally, constraining the latter to the wall of the stern compartment and to the hatch body, and correctly adjusting the position of the latter with respect to the aperture of the stern compartment so as to allow an optimum closing.
[0006] Also add to this the fact that in the known solutions mentioned above the hatch and the walls of the compartment shall comprise hinge means and countermeans to allow the rotary motion (around said hinges) to open and close the hatch onto the compartment. Consequently, a need arises for associating hinge pins with the opposed sides of the hatch or with the walls of the compartment, such pins being suitable for being housed within seats provided for this purpose in said walls and sides. All of this requires non negligible times or difficulties, also considering that a hatch of the type under examination possibly features a surface of several square meters.
[0007] EP2305553, which forms the preamble of claim 1 , describes a side service door for boats comprising shaped shutters applied at a boat compartment. Operation means are operatively connected to each shutter and are coupled with the hull of the boat; the above operation means are suitable to move each shutter between a rest position wherein the shutters close the compartment and a working position in which each shutter protrudes from the hull.
[0008] The operation means are externally located to each shutter at least when the shutter is in its working position.
SUMMARY OF THE INVENTION
[0009] The purpose of the present invention is to offer a boat that is enhanced with respect to the known boats.
[0010] Specifically, a purpose of the present invention is to offer a boat provided with a stern compartment on which a corresponding stern hatch not rigidly connected to the boat, is located.
[0011] More specifically, a purpose of the invention is to offer a boat provided with a stern compartment on an aperture of which a corresponding stern hatch is located which is moved by means that do not limit the amplitude of the compartment either when the hatch is closed or it is open.
[0012] Another purpose is to offer a boat of the type mentioned above, in which the hatch can be assembled onto the stern compartment with reduced times and costs with respect to those requested to assemble hatches onto their corresponding compartments in boats according to the present status of the art.
[0013] A further purpose is to offer a boat in which the hatch is not provided with any hinge means suitable for cooperating with their corresponding countermeans associated with the stern compartment, this allowing to reduce the costs and times necessary to assemble the hatch onto the boat.
[0014] A further purpose is to offer a boat in which one and the same hatch, if properly configured, can be alternatively hinged so as to open toward the stern platform and far away therefrom, being it possible to take said decision even at the last moment just upon finishing the craft.
[0015] A further purpose of the invention is to offer a boat in which one and the same stern hatch is capable of performing a dual function, i.e. closing the stern compartment and operating as a plane to stay on or rear small beach defined by a surface lacking in projecting members, said hatch being obviously movable so as to allow the opening of and the access to the stern compartment.
[0016] Another purpose is to offer a boat of the mentioned type in which the stern hatch can be used reliably in each of its positions assumed with respect to the craft.
[0017] These purposes and others which will be apparent to those expert in the art are achieved by a boat according to the attached claims.
BRIEF DESCRIPTION OF THE DRAWING
[0018] For a better understanding of the present invention the following drawings are attached for purely explanatory, not exhaustive, purposes, of which:
[0019] FIG. 1 shows the stern of a boat according to the invention, its stern hatch being closed;
[0020] FIG. 2 shows the stern of the boat depicted in FIG. 1 , its hatch being open downwards;
[0021] FIG. 3 shows the stern of the boat depicted in FIG. 1 , the hatch being further opened downwards;
[0022] FIG. 4 shows the stern of the boat, the hatch being in the closed position and partially cross-sectioned showing the hatch opening and closing actuating means;
[0023] FIG. 5 shows an enlarged, transparent view of the hatch highlighting the detail identified by A in FIG. 4 ;
[0024] FIG. 6 shows a cross-sectional view according to the line 6 - 6 of FIG. 5 ;
[0025] FIG. 7 shows a side view of the hatch actuating means;
[0026] FIG. 8 shows an enlarged, transparent perspective view of the hatch in its open configuration according to FIG. 2 ; and
[0027] FIG. 9 shows a cross-sectional view according to the line 9 - 9 of FIG. 2 .
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0028] With reference to the mentioned figures, a boat 1 is (partially, in its stern portion only) shown as comprising a hull 2 having a stern hatch 3 suitable for enclosing a stern compartment 4 , for instance suitable for housing a small boat like a dinghy or a tender (not shown in the figures). Such compartment 4 comprises an aperture 5 , opposed side walls 6 , an upper part 7 , and a lower part 8 .
[0029] The stern hatch 3 comprises an outer wall 10 , an inner wall 11 (generally made of fiberglass, for instance like the hull 2 ) spaced from each other by sides 12 and 13 , upper and lower edges 14 and 15 ; such walls 10 and 11 , said sides 12 and 13 , and the upper and lower edges 14 and 15 determine a body 20 of the hatch.
[0030] In the embodiment depicted in the figures, the hatch 3 is capable of opening toward a stern platform 21 of the hull 2 , i.e. it is capable of opening downwards with respect to the compartment 4 . Should such platform 21 feature a central portion 21 A lowered toward the water (on which the boat floats) with respect to the side portions 21 B and 21 C, the hatch 3 might reach, when open, a position in which its inner wall 11 is coplanar with the lower wall 8 of the compartment 4 , as shown in FIG. 3 . Obviously, the same coplanarity can be obtained, the wall 8 being realized in such a way as to fit in with the wall 11 , even in the case of a hatch according to FIG. 1 .
[0031] The outer wall 10 of the hatch is suitable for arranging itself in correspondence with a stern wall 26 of the boat 1 when the hatch is closed, said wall 26 delimiting the aperture 5 of the compartment 4 .
[0032] According to the invention, the stern hatch 3 is associated with actuating means 30 completely and totally located inside its body 20 only, in a cavity 31 present between the inner wall 11 and the outer one 10 ; such actuating means 30 make it possible the movement of the hatch with respect to the aperture 5 of the compartment 4 during the opening and closing operations and at the same time constrain said hatch to the latter, so as not to limit the amplitude of said compartment. In this way, the hatch is not provided with any hinge members or further connections to the hull 2 . It follows that mainly the side walls 6 , but also the walls 7 and 8 of the compartment 4 do not support any hatch actuating member and the hatch is perfectly smooth on all of its side. All of this to the advantage of safety for the people on board the boat 1 , who can freely move inside the compartment 4 without any risks of hitting against parts projecting from its walls and also to the advantage of an ease operation in loading means or goods inside such compartment.
[0033] For this purpose, in correspondence with at least one side 12 , 13 and preferably both of them, should the dimensions and the weight of the hatch be non negligible, within the cavity 31 there is a pair of gearings 40 and 41 whose toothed surfaces 40 A and 41 A are suitable for cooperating with each other so as to allow a relative movement between said gearings. More specifically, the gearing or gear wheel 40 is fixed to a beveled shaft 43 which is constrained, via an extremal flange 44 arranged in correspondence with a hole 45 present in said side 12 , 13 , to a support constrained to the craft 2 . In particular, such support is a panel 47 which can be connected to the stern wall 26 or its corresponding side wall 6 of the compartment 4 ; alternatively it can be fixed to the stern platform 21 . The shaft 43 is connected to the hatch 3 via other constraint elements, like flanges 430 .
[0034] The gear wheel 40 is fixed whereas the gear wheel or gearing 41 can move along its toothed surface. Such a movement is generated by a pneumatically, hydraulically, or hydropneumatically movable telescopic member 50 comprising a stem 51 movable in a sleeve 52 ; the sleeve 52 is fixed, via a support or bracket 59 to a wall, for instance the outer one 10 (from the inside of the cavity 31 ), of the hatch, whereas the stem 51 features a head 53 supporting a pin 54 (via an eyelet 55 ) eccentrically fixed to a body or connecting rod 56 integral with the gearing or gear wheel 41 . Activating the telescopic member results in lowering or lifting the hatch.
[0035] Such telescopic member 50 is controlled by a control unit (not shown in the figures) outside the hatch, indicatively installed in the engine room and which the oil (or air) ducts originate from to subsequently reach the sleeve 52 , for instance via the shaft 43 of the first gearing 40 .
[0036] Such member can be electrically operated indeed.
[0037] More specifically, starting from the position depicted in FIGS. 1 and 7 , if the stem 51 is retracted into the sleeve 52 , then the connecting rod 56 rotates (clockwise in FIG. 7 , see arrow F) the gearing 41 onto the gearing 40 , which results in lowering the hatch down. Vice versa, taking the stem 51 out of the sleeve 52 results in a rotation of the gearing 41 onto the gearing 40 that is reversed (with respect to the previous one, i.e. counterclockwise), which results in lifting the hatch 3 up to its closing positioning on the aperture 5 of the compartment 4 .
[0038] The gearing 41 is rotatable via a bearing or an equivalent member 58 and is put on a shaft 60 projecting from a support 46 and integral therewith. Such support is put on the shaft 43 and can rotate around it thanks to appropriate mechanical decoupling members or bearings.
[0039] In particular, such support 46 is located in a hollow 66 created outside the adjacent side 12 , 13 of the hatch 3 and is blocked therein by a shape coupling with the hollow itself. In this way, the movement of the gearing 41 on the gearing 40 forces the shaft 60 , hence its support 46 and the complete hatch 3 , to rotate around such gearing 40 , which subsequently operates as a hinge for the hatch.
[0040] Thanks to the invention, the possibility is achieved of constraining the hatch to the hull of the boat without using any specially conceived hinge members and at the same time a hatch movement mode is offered which is fully encased therein, which leads to the advantages indicated above. Also, the complete actuating mechanisms defined by the actuating means 30 can be pre-assembled in the hatch and constrained to the panel 47 upon its final mounting on the boat 1 . This reduces the mounting time as referred to that necessary with the known solutions. Therefore, the hatch according to the invention is not rigidly connected to the boat.
[0041] A specific embodiment of the invention has been described. However, others can be obtained (for instance one that comprises an electric motor, for instance a stepping motor, instead of the telescopic member 50 ) in the light of the previous description and shall be deemed to fall within the scope of the following claims.
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A boat includes a hull provided with a rear stern hatch located in correspondence with an internal stern compartment of the hull and suitable for opening and closing in correspondence with an aperture of the compartment, the hatch having a body with opposed side located in correspondence with side walls of the compartment and a upper edge and a lower edge. The hatch includes an actuator to open and close the compartment arranged inside its own body. The actuator rotatably constraining at least one of the sides of the hatch to the hull. The body being not provided with any further connections of the sides to the hull.
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This is a continuation of co-pending application Ser. No. 478,843, filed on Mar. 25, 1983 now abandoned.
The present invention relates to novel palladium complexes and pharmaceutical compositions containing certain palladium complexes adapted for the treatment of tumors and therapeutic methods for the treatment of tumors involving the use of certain palladium complexes.
BACKGROUND OF THE INVENTION
Recently, a number of platinum complexes have been shown by Rosenberg and co-workers to be highly active anti-tumor agents. [U.S. Pat. Nos. 4,177,263 and 4,140,707.] The complex, cis-dichlorodiammine-platinum-II, is the chemotherapeutic agent of choice in the treatment of many and varied tumors.
There are several drawbacks associated with the use of the platinum complexes to treat tumors, however. Generally, the platinum complexes have a relatively low solubility in water thereby rendering it difficult to formulate a composition which can effectively deliver the reagent to the site of the tumor in the body.
Moreover, many of the platinum complexes are highly nephrotoxic thereby further restricting their use in the absence of precautionary measures to avoid damage to the kidneys when administered to animals afflicted with tumors.
Additionally, platinum complexes and cis-dichlorodiammine-platinum-II in particular are relatively inactive against gastro-intestinal tumors, presumably because of an inability to aquate in the presence of the high chloride concentrations present in this region of the body.
It is an object of the present invention to provide certain novel palladium complexes, pharmaceutical compositions comprising certain palladium complexes and methods for the treatment of tumors with certain palladium complexes which do not share the disadvantages associated with the platinum complexes of the prior art.
SUMMARY OF THE INVENTION
According to the present invention there are provided certain novel palladium complexes having the formulas:
cis-Pd(II)A.sub.m X.sub.n (I)
wherein:
m is 1 or 2;
n is 1 or 2;
A is selected from the group consisting of bidentate amine ligands excluding ethylenediamine when m is 1 and is a monodentate amine ligand when m is 2; and
X is selected from the group consisting of monovalent anionic ligands excluding chloride when n is 2 and is a divalent anionic ligand when n is 1,
provided that the sum of the valencies of A m and X n is four;
cis-Pd(II)(NH.sub.3).sub.2 X (II)
wherein:
X is selected from the group consisting of divalent anionic ligands excluding oxalate and malonate;
cis-[Pd(II)A.sub.m (OH)].sub.x X (III)
wherein:
m is 1 or 2;
x is 2, 3 or 4;
A is selected from the group consisting of bidentate amine ligands excluding ethylenediamine when m is 1 and is a monodentate amine ligand when m is 2; and
X represents two monovalent anionic ligands or one divalent anionic ligand when x is 2, three monovalent anionic ligands or one trivalent anionic ligand when x is 3, and four monovalent anionic ligands or two divalent ligands when x is 4; or
cis-or-trans-Pd(IV)A.sub.m X.sub.n L (IV)
wherein:
m is 1 or 2;
n is 1, 2 or 4;
A is a bidentate amine ligand when m is 1, and two monodentate amine ligands when m is 2;
X is a trivalent anionic ligand when n is 1, a divalent anionic ligand when n is 2 and a monovalent anionic ligand when n is 4;
L represents two monovalent anionic ligands when x is a divalent anionic ligand and one monovalent anionic ligand when x is a trivalent anionic ligand,
provided that the sum of the valencies of A m ,X n and L is six.
The present invention also provides, in unit dosage form, a pharmaceutical composition adapted for the treatment of animal tumor cells sensitive to the compounds represented by formulas V, VI and VII comprising an anti-tumor effective amount of a pharmaceutically acceptable carrier and a complex having the formula:
cis-Pd(II)A.sub.m X.sub.n (V)
wherein:
m is 1 or 2;
n is 1 or 2;
A is a bidentate amine ligand when m is 1 and NH 3 or a monodentate amine ligand when m is 2; and
X is a monovalent anionic ligand when n is 2 and a divalent anionic ligand when n is 1,
provided that the sum of the valencies of A m and X n is four;
cis-[Pd(II)A.sub.m (OH)].sub.x X (VI)
wherein:
m is 1 or 2;
x is 2, 3, or 4;
A is a bidentate amine ligand when m is 1 and NH 3 or a monodentate amine ligand when m is 2, and
X represents two monovalent anionic ligands or one divalent anionic ligand when x is 2, three monovalent anionic ligands or one trivalent anionic ligand when x is 3 and four monovalent anionic ligands or two divalent anionic ligands when x is 4; or
cis- or trans-Pd(IV)A.sub.m X.sub.n L (VII)
wherein:
m is 1 or 2;
n is 1, 2 or 4;
A is a bidentate amine ligand when m is 1, and two monodentate amine ligands when m is 2;
X is a trivalent anionic ligand when n is 1, a divalent anionic ligand when n is 2 and a monovalent anionic ligand when n is 4;
L represents two monovalent anionic ligands when X is a divalent anionic ligand and one monovalent anionic ligand when X is a trivalent anionic ligand,
provided that the sum of the valencies of A m X n and L is six.
There is also provided by the present invention a method for the treatment of animal tumor cells sensitive to complexes of the formulas (V), (VI) or (VII) comprising the administration to an animal afflicted with said tumor cells an amount of a complex of formula (V), (VI) or (VII) effective to cause regression of the tumor.
DETAILED DESCRIPTION OF THE INVENTION
It has previously been suggested to employ certain palladium complexes as anti-tumor agents in chemotherapy. However, in all instances reported in the literature the complexes tested had either little or marginal anti-tumor activity. The low activity of the palladium complexes tested heretofore as compared with the related platinum complexes has been attributed to the fast equation of the leaving groups which dissociate from the metal in vivo. See Connors, Cancer Treatment Reports, Vol. 63, Sept.-Oct., 1979, pages 1499-1502; Lim et al, J. Inorg. Nucl. Chem., Vol. 38, pages 1911-1914 ( 1976); Connors, Platinum Coordination Complexes in Cancer Chemotherapy, pages 13-37 (Springer-Verlag Berlin, 1974); Cleare, Bioinorganic Chemistry, Vol. 2, pages 187-210 (1973); Graham et al, J. Inorg. Nucl. Chem., Vol. 41, pages 1245-1249 (1979); Kirschner et al, J. Med. Chem. Vol. 9, pages 369-372 (1966); Kirschner et al, 168th Annual Meet. ACS (Sept. 1974) (Abstract); Kirschner et al, Adv. Exp. Med. Biol., Vol. 91, 151 (1977); Kirschner et al, Inorganic and Nutritional Aspects of Cancer, pages 151-160, Plenum, N.Y. (1978); Kirschner et al, J. Clin. Hema. and Onc., Vol. 7, page 190 (1977).
The novel palladium complexes of the invention and certain other palladium complexes known in the art have been found, however, to have an anit-tumor activity comparable to and, in some instances, greater than the platinum complexes currently in widespread use in cancer chemotherapy.
The palladium complexes of the present invention also find utility as catalysts in methods for the homogeneous hydrogenation, isomerization, hydroformylation and oxidative hydrolysis of olefins; the carboxylation of methanol and the activation of alkanes. The palladium complexes of optically active amines also find utility in stoichiometric and catalytic asymmetric syntheses from prochiral substrates.
In the palladium complexes of the present invention of formulas I, II, III and IV above, and in the known palladium complexes employed in the pharmaceutical composition and therapeutic methods of the invention, the bidentate amine ligands are preferably selected from the group consisting of alkylene diamines (excluding ethylene diamine where indicated), of the formula:
R.sub.1 RN--Alk--NRR.sub.1
wherein:
R and R 1 may be the same of different, and are H, lower alkyl, hydroxy alkyl, lower alkoxy, aryl, arloweralkyl, cycloalkyl, cycloalkenyl and substituted derivatives thereof, and alk is lower alkylene having from 2 to 12 carbon atoms, unsubstituted or substituted by hydroxoalkyl, lower alkoxy, aryl or arloweralkyl; cycloalkanes (which may be substituted by the above groups) having from 3 to 12 carbon atoms, and heterocyclic diamines which may be saturated, unsaturated and unsubstituted or substituted by the above groups.
Suitable bidentate amine ligands include 1,2-diaminopropane, 1,3-diaminopropane, 1,2-diaminocyclohexane, 2,2'-bipyridine, 1,10-phenanthroline; 1,2-diamino-ethane; 1,2-diaminobenzene; imidazole; pyrimidine; 3-aminopyridine; 1,4-diaminobutane; 1,2-diaminocyclopentane; o-phenylenediamine; 5,6-diaminopyrimidine; 2,3-diaminonaphthalene; 1,2-diaminocycloheptane; 1,2-diaminocyclooctane; 1,2-diamino-b 2-methyl propane; nitrophenylenediamine; 1,3-diamino-2-propanol; 2,3-diaminopyridine; 3,4-diaminotoluene; 1,2-dianilino-ethane; 4-carboxyphenylene diamine; 2-amino-4 picoline; 3-aminoquinoline; 1,5-diaminopentane.
The monodentate amine ligands are preferably selected from the group consisting of: lower alkyl amines; lower alkyl amines substituted in said alkyl group or on said nitrogen atom by an aryl group, a hydroxyloweralkyl group, hydroxy or a lower alkoxy group; aryl amines; heterocyclic amines or amino acids.
Suitable monodentate amine ligands include the lower alkyl amines, e.g., methyl-, ethyl-, n-propyl-isopropyl-, n-butyl amines, etc.; aryl amines, e.g., aniline, etc.; or arloweralkyl amines, e.g., benzyl-amine, etc.; hydroxy lower alkyl amines, e.g., ethanolamine, propanolamine, etc.; lower alkoxyl amines, e.g., methoxylamine, etc.; lower alkoxy, lower alkylamines, e.g.; methoxymethylamine; heterocyclic amines such as pyridine, aziridine, etc.; all amino acids of the formula R--CHNH 2 --COOH wherein R is H, lower alkyl (e.g., methyl, isopropyl, etc.), hydroxy lower alkyl (e.g., hydroxymethyl, hydroxyethyl, etc.), or arloweralkyl (e.g., benzyl, etc.).
Suitable monodentate anionic ligands include chloride (except where expressly excluded), bromide, iodide, nitrite, hydroxide, nitrate, lactate, alkoxy, aryloxy hydride, fluoride, acetate, trifluoroacetate, chloroacetate, cyanide, cyanate, thiocyanate, ozonide, azide, chlorite, hypochlorite, hypophosphite.
Suitable bidentate anionic ligands include malonates and oxalates (except where expressly excluded), pyrophosphite, dithiooxalate, phthalate, carboxyphthalate, gluconate, glucuronate, carbonate, sulphite, selenite, pyrosulphite, dithionite, sulphate.
Suitable trivalent anionic ligands include phosphate, arsenite, orthoarsenate, ferricyanide.
Particularly preferred novel palladium complexes are those of formula (I) having the formulae:
Pd(II)(1,2-diaminocyclohexane)(NO 3 ) 2 ,
Pd(II)(1,2-diaminopropane)(NO 3 ) 2 ,
Pd(II)(1,3-diaminopropane)(NO 3 ) 2 ,
Pd(II)(2,2'-bipyridine)(NO 3 ) 2 , and
Pd(II)(1,2-diaminoethane)(NO 3 ) 2 .
and those of the formula III having the formulae: ##STR1## wherein: n=2, 3 or 4. ##STR2## wherein: n=2, 3 or 4.
It will be understood that all references herein to "lower alkyl" or "lower alkylene" are to alkyl or alkylene groups containing from 2 to 6 carbon atoms, unless otherwise indicated.
The novel palladium complexes of the invention are readily prepared by first forming the chloroaminepalladium complex by reacting a suitable palladium chloride (e.g., sodium tetrachloropalladate (II) in water with a suitable amine. The chloroamine-palladium complex is then reacted with the silver salt of the appropriate anionic ligand. Alternatively, they are prepared from the diaquo complex by the addition of the sodium salt of the anionic ligand in water. The oligomeric complexes are isolated from the monomeric complexes at different pH's. The dicarboxylate complexes were prepared by adding the sodium salt of the dicarboxylic acid to the solution of the anionic complex whereby the dicarboxylate complexes crystallize out of the solution.
The following non-limiting examples are illustrative of methods of preparing the palladium complexes of the invention:
EXAMPLE 1
Preparation of Dichloro(cis-1,2-diaminocyclohexane)palladium
1,2-Diaminocyclohexane (hereinafter-dach) as an isomeric mixture of trans- and cis-dach, respectively, was separated into trans-dach dihydrochloride, and cis-dach sulphate by the method of Saito et al, Chem. Lett., Vol. 123 (1976).
To a solution containing 5.0 g (0.017 mole) of sodium tetrachloropalladate (II) in 200 ml of water buffered with sodium hydroxide (3.604 g (0.017 mole) of cis-dach dihydrochloride was added. The mixture was stirred at room temperature. Within 10 minutes, a yellow precipitate was obtained. The mixture was stirred for another 12 hours. The yellow precipitate was removed by filtration, washed with 0.01N HCl, cold water, hot water, alcohol and ether to give a quantitative yield of the product. This was further purified by treatment with silver nitrate in water and precipitation of the dichloro complex with 1N HCl. Elemental analysis gave: H, 4.84; C, 24.63; N, 9.60; Cl, 24.67; Pd, 36.43. Calculated for H 14 C 6 N 2 Cl 2 Pd: H, 4.81; C, 24.7; N, 9.61; Cl, 24.4; Pd, 36.51.
EXAMPLE 2
Preparation of Dinitrato (cis-1,2-diaminocyclohexane)palladium
A mixture of Pd(cis-dach)Cl 2 5.828 g (0.02 mole) prepared according to Example 1 and silver nitrate 6.664 g (0.0196 mole) in 100 ml of water, acidified to pH 1.5 with nitric acid, was stirred for 24 hours in a low actinic glass flask. Silver chloride was removed by filtration and the pale yellow solution was removed by filtration. The pale yellow solution was concentrated on a flash evaporator and allowed to crystallize. This was crystallized again from acidified nitric acid. Elemental analysis gave: H, 4.13; C, 20.87; N, 16.13; Pd, 30.67. Calculated for H 14 C 6 N 4 O 6 Pd: H, 4.06; C, 20.90; N, 16.26; Pd, 30.89.
EXAMPLE 3
Preparation of oligomeric [(1,2-diaminocyclohexane)palladium] Nitrate
Pd(dach)(NO 3 ) 2 (5.0 g) was dissolved in 70 ml water. The pH of the solution was raised to 6.45 by dropwise addition of 1.5N NaOH. The flask was stoppered and allowed to stand at room temperature for 30 minutes. The volume of the solution was reduced to 30 ml on a flash evaporator at 30° C. and the solution was allowed to stand at 5° C. for a week. During this time, the obligomer crystallized out of the solution as a yellow colored complex. The pH of the filtrate was raised to 6.45 again and the above procedure repeated to get more of the trimer. The overall yield of the complex was 60%. The complex analysed as: H, 5.08; C, 23.95; O, 21.42; N, 13.98; Pd, 35.35. Calculated for H 45 C 18 N 9 O 12 Pd 3 : H, 5.01; C, 24.05; O, 21.38; N, 14.03; Pd, 35.54.
EXAMPLE 4
Preparation of Tartronato(1,2-diaminocyclohexane)palladium
To a solution containing 1.0332 g (0.003 mole) of dinitratro(dach) palladium was added tartronic acid (1.0 g, 0.0096 mole), neutralized with 2N NaOH. A yellow crystalline precipitate was obtained. This was filtered, washed with ethanol, acetone and dried at room temperature and reduced pressure. The yield was 90%. The complex analyzed as H, 4.79; C, 31.95; N, 8.23; O, 23.54; Pd, 31.28. Calculated for C 9 H 16 N 2 O 5 Pd: H, 4.73; C, 31.91; N, 8.27; O, 23.64; Pd, 31.44.
EXAMPLE 5
Preparation of Dichloro(1,2-diaminoethane)palladium
To a solution, containing 5.0 g of sodium tetrachloropalladate (II), in 200 ml of water, 2.5 g of ethylenediamine hydrochloride was added. The solution was buffered with sodium hydroxide. The mixture was stirred at room temperature and a yellow precipitate was obtained in 10 minutes. Stirring was continued overnight to ensure the completion of the reaction. The yellow precipitate was removed by filtration, washed with 0.1N HCl, cold water alcohol and ether to give a quantitative yield of the product. The complex was further purified by treatment with silver nitrate in water and precipitation of the dichloro complex with hydrochloric acid.
EXAMPLE 6
Preparation of Dinitrato(1,2-diaminoethane)palladium
A mixture of dichloro(1,2-diaminoethane)palladium 3.0 g and silver nitrate 4.2 g in 60 ml of water was stirred for 24 hours in a flask covered with aluminum foil. Silver chloride was removed by filtration and the pale yellow solution was concentrated on a flash evaporator and allowed to crystallize. The complex analyzed as C, 8.33; H, 2.78; N, 19.10; Pd, 36.31. Calculated for C 2 H 8 N 4 O 6 Pd: C, 8.26; H, 2.75; N, 19.28; Pd; 36.40.
EXAMPLE 7
Preparation of Malonato(1,2-diaminoethane)palladium
Dichloro(1,2-diaminoethane)palladium (1.0 g), silver nitrate (1.4 g) and water (20 ml) were stirred together in a stoppered flask, covered with aluminum foil for a period of 20 hours. Solid silver chloride was removed by filtration and to the filtrate malonic acid (1.0 g in 10 ml of water) neutralized with 2N KOH was added. The mixture was carefully warmed until crystals of the product began to form in greater quantity. The mixture was then cooled to room temperature, allowed to sit overnight at 5° C. and filtered. The filtrate was reheated for 5-10 minutes and cooled at 0° C. to collect a further crop. The product was further crystallized from hot water. Yield: 80%.
EXAMPLE 8
Preparation of Dichloro(1,2-diaminocyclohexane)palladium
To a solution containing 4.0 g of sodium tetrachloropallidate (II) in 160 ml of water, 2.54 g of (mix-dach) dihydrochloride (70:30, trans:cis) was added. The solution was buffered with sodium hydroxide and the mixture was stirred at room temperature for 20 hours. The yellow precipitate was removed by filtration, washed with 0.01N HCl, cold water, hot water, alcohol and ether to give a quantitative yield of the product. The complex was further purified by treatment of the dichloro complex with silver nitrate in water and precipitation of the dichloro complex with hydrochloric acid.
EXAMPLE 9
Preparation of Dinitrato(1,2-diaminocyclohexane)palladium
A mixture of Pd(mix-dach)Cl 2 5.828 g (0.02 mole) and silver nitrate 6.664 g (0.0196 L mole) in 100 ml of water was stirred for 24 hours in a low-actinic flask. Silver chloride was removed by filtration. The pale yellow solution was concentrated on a flash evaporator and allowed to crystallize.
EXAMPLE 10
Preparation of Dichloro(cis-1,2-diaminocyclohexane)palladium
A mixture of sodium tetrachloropalladite (5.0 g) and (cis-dach) H 2 SO 4 (1.39 g) in 160 ml of water was stirred at room temperature for 20 hours. The dichloro complex was removed by filtration; washed with water and acetone and dried. The yield was quantitative.
EXAMPLE 11
Preparation of Dinitrato(cis-1,2-diaminocyclohexane)palladium
A mixture of Pd(cis-dach)Cl 2 5.828 g (0.02 mole) and silver nitrate 6.664 g (0.0106 mole) in 100 ml of water was stirred for 24 hours. Silver chloride was removed by filtration. The yellow solution was concentrated on a flash evaporator and allowed to crystallize. The yield was 75%.
EXAMPLE 12
Preparation of Oxalato(trans-1,2-diaminocyclohexane)palladium
Pd(trans-dach)(NO 3 ) 2 (0.55 g) in 40 ml of water and potassium oxalate (0.6 g) in 10 ml of water were mixed together. The mixture was heated to 70° C. to obtain crystals. It was cooled, filtered and dried. Yield: 75%.
EXAMPLE 13
Preparation of Dinitrato(2,2'-bipyridyl)palladium
A mixture of dichloro(2,2'-bipyridyl)palladium (4.0 g) and silver nitrate (3.729 g) in 50 ml of water was stirred for 20 hours. Silver chloride was removed by filtration and the solvent was concentrated to give 92% yield of the complex. It was further crystallized from hot water.
EXAMPLE 14
Preparation of Sulphato(1,2-diaminopropane)palladium
A mixture of silver sulphate (1.684 g) and dichloro(1,2-diaminopropane)palladium (2.0 g) in 30 ml of water was stirred for 20 hours. Silver sulphate was removed by filtration and the filtrate dried under reduced pressure to give 85% yield of the sulphato complex.
EXAMPLE 15
Preparation of Oxalato-bis(cyclohexylamine)palladium
A mixture of K 2 PdOX 2 · 2H 2 O (5.52 g, 0.01394 moles) and cyclohexylamine hydrochloride (3.8355 g, 0.02788 mole) was dissolved in 900 ml of water. The mixture was heated to 40° C. and 1.12 g (0.02788 mole) of sodium hydroxide dissolved in 100 ml of water was added dropwise. A pale yellow precipitate of the complex was obtained. It was cooled overnight at 5° C., filtered, washed with water, ethanol and dried.
EXAMPLE 16
Preparation of 1,1-cyclobutanedicarboxylato(trans-1,2-diaminocyclohexane)palladium
Dichloro(trans-dach)Pd (1.0 g) was dissolved in 40 ml of water and was added to 1,1-cyclobutanedicarboxylic acid (1.0 g in 10 ml of water); pH of the solution was raised to 5.6 and within five minutes, pale yellow precipitate was obtained which was removed by filtration, washed with alcohol and dried. Yield: 90%.
EXAMPLE 17
Preparation of Dichloro(1,3-diaminopropane)palladium
A mixture of sodium tetrachloropalladite (6.0 g) and 1,2-diaminopropane dihydrochloride (3.0 g) in 150 ml of water was buffered with sodium hydroxide and stirred for 20 hours at room temperature. This gave quantitative yield of the dichloro complex.
EXAMPLE 18
Preparation of Dinitrato(1,3-diaminopropane)palladium
A mixture of the dichloro(1,3-diaminopropane) palladium 3.0 g and silver nitrate 3.976 g in 50 ml of water was stirred for 24 hours. Silver chloride was removed by filtration and the solution was concentrated to give 85% yield of the dinitrato complex.
EXAMPLE 19
Preparation of Dichloro(1,2-diaminopropane)palladium
A mixture of sodium tetrachloropallidate (6.0 g) and 1,2-diaminopropane dihydrochloride (3.0 g) in 150 ml of water, buffered with NaOH, was stirred for 20 hours to give the quantitative yield of the dichloro complex. This was further purified by reaction with silver nitrate in water and precipitation with hydrochloric acid.
EXAMPLE 20
Preparation of Dinitrato(1,2-diaminopropane)palladium
A mixture of the dichloro(1,2-diaminopropane) palladium 3.0 g and silver nitrate 3.976 g in 40 ml of water was stirred for 20 hours. Silver chloride was removed by filtration and the solution was concentrated to give 80% yield of the product. This was further crystallized from water, acidified with nitric acid to prevent hydrolysis. The complex analyzed as: C, 12.38; H, 3.44; N, 17.28; Pd, 34.91. Calculated for C 3 H 11 N 4 O 6 Pd: C, 11.8; 3.6; N, 18.34; Pd, 34.84.
The complexes of the invention as well as those known in the prior art and which possess anti-tumor activity are preferably administered intravenously or intraarterially to those afflicted with tumor cells sensitive to the complexes in solution in suitable i.v. administrable media such as water, 5% dextrose solution, saline solution (varying in NaCl concentrations from 0% to 5× normal saline).
The pharmaceutical compositions may be prepared according to conventional methods well known in the prior art. The appropriate palladium complex may, for example, be dissolved in water at appropriate pH's, filtered, sterilized, dispensed into ampoules, freeze dried and capped with hyperdermic penetrable seals.
The amount of complex included in the pharmaceutical composition of the invention will vary depending in each case upon the anti-tumor activity of the complex, the toxicity and solubility characteristics thereof, etc. Generally, however, an amount of palladium complex ranging from about 10 to 20,000 mg, preferably from about 100 to about 2,000 mg per unit dosage form of the composition may be incorporated therein.
The palladium complexes are preferably administered intravenously or intraarterially, either as a push injection or by a slow drip over a period of hours. This treatment may be repeated each day for a few consecutive days, or given on one day every month. This is repeated for a number of months at dosages in the range of from about 1 to about 200 mg/kg of body weight, preferably from about 1 to about 50 mg/kg of body weight. Again, the particular dosage will depend upon the therapeutic and chemical and physical characteristics of the complex and the nature of the tumor treated as well as the health of the individual afflicted with the tumor.
The following examples illustrate the anti-tumor activity of the palladium complexes.
EXAMPLE 21
Measurements of Anti-Tumor Activity of Palladium Complexes
Animal tests for evaluating anti-tumor activities of palladium complexes were performed on ICR random-bred, white, female, 4-5 week old (18-20 g) mice. Ascites Sarcoma-180 J cells (4×10 6 ) were injected intraperitoneally into animals on day 0 and the compounds (6 animals/dose level) were injected as solutions of slurries, on day 1. Evaluations were made on 2× the average day of death of the negative control. 7 mg/kg of cis-Pt(NH 3 ) 2 Cl 2 is injected as a positive control of the testing situation. The % increase Life Span (ILS) is computed as follows: the average day of death of test animals minus the average day of death of the negative controls, divided by the average day of death of controls ×100.
Individual tests of representative complexes are listed in Table 1 below, with the concentration of the drug and % increased life span (% ILS expressed in days).
TABLE 1______________________________________Complex mg/kg % ILS______________________________________Pd(dach)(NO.sub.3).sub.2 20 27 40 27 60 35 80 65[Pd(dach)(OH)].sub.n (NO.sub.3).sub.n 20 2 30 53 50 48 80 75Pd(dach)malonate 50 62 100 51 150 76 200 46Pd(trans-dach)(NO.sub.3).sub.2 30 60 60 84 120 44 140 -63Pd(cis-dach)(NO.sub.3).sub.2 30 56 60 44 120 56 140 -62Pd(1,2-propylenedi- 50 19amine)(NO.sub.3).sub.2 100 72 150 54 200 70Pd(1,3-diamino- 40 48propane)(NO.sub.3).sub.2 60 81 80 55 100 74Pd(1,2-diamino- 40 61ethane)(NO.sub.3).sub.2 60 55 80 94 100 68Pd(2,2'-bipyridyl) 40 57(NO.sub.3).sub.2 60 55 80 70 100 61Pd(NH.sub.3).sub.2 (NO.sub.3).sub.2 10 -23 20 14 40 4Pd(dach)Cl.sub.2 12.5 19 25 -4 50 20 100 32Pd(ethylenediamine)Cl.sub.2 12.5 -1 25 -5 50 -12 100 2Pd(NH.sub.3).sub.2 Cl.sub.2 12.5 -7 25 6 50 4 100 11______________________________________ Cis-dichlorodiammineplatinum (II) gives a % ILS 65-80.
The results set forth in Table 1 unequivocally establish the anti-tumor activity of the palladium complexes described herein.
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Palladium complexes and pharmaceutical compositions containing palladium complexes adapted for the treatment of tumors cells sensitive to the palladium complexes and methods of treating tumor cells using the palladium complexes are disclosed.
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FIELD OF THE INVENTION
[0001] The invention relates to a collagen-containing sheet material used as a wound dressing, in particular for surgical procedures.
BACKGROUND OF THE INVENTION
[0002] Collagen-containing sheet materials are known. For example, published patent application EP 2 098 255 A2 (AAP Biomaterials GmbH) discloses a method for producing collagen material. As a starting material, porcine skin is used, which is purified by an alkaline, oxidative, and acidic treatment to remove grease and other foreign matter.
[0003] The porcine skin is comminuted mechanically, and subsequently an aqueous suspension is produced from the porcine skin, which is adjusted to a neutral to slightly alkaline pH by addition of a phosphate buffer.
[0004] Thereby, a three-dimensional network of collagen fibrils is formed. The suspension containing this network is lyophilized. The resulting sponge-like or non-woven sheet material is highly porous, very flexible, and does not adhere to surgical instruments, in both its dry and wet states.
[0005] For some applications, a drawback of the material is that it can be badly cut in the rehydrated state, due to its very high flexibility. Further, the material swells in the wet state.
[0006] In some applications it is particularly disadvantageous that the sheet material is opaque. So the surgeon cannot look through the sheet material, which would strongly facilitate accurate placement of the sheet material in many cases.
SUMMARY OF THE INVENTION
[0007] The invention is therefore based on the object to at least mitigate the drawbacks of the prior art mentioned above.
[0008] A particular object of the invention is to provide a flexible sheet material which at the same time is transparent to a certain extent, so that at least in its applied state the tissue below is discernable.
[0009] The object of the invention is already achieved by a method for producing a collagen-containing sheet material and by a transparent collagen-containing sheet material in accordance with the illustrative embodiment of the present invention.
[0010] The invention relates to a method for producing a collagen-containing sheet material. A collagen-containing sheet material in particular refers to a material which comprises more than 70%, preferably more than 90% of collagen.
[0011] The manufacturing method comprises wet-chemical preparation of a starting material from mammalian skins.
[0012] Preferably, porcine skin is used as a starting material. However, it is also conceivable to use equine or bovine starting materials.
[0013] The alkaline, oxidative, and acidic treatment may be performed, for example, by alternately dipping and rinsing in bases, peroxides, and acids. In particular sodium hydroxide, hydrogen peroxide, and phosphoric acid may be used.
[0014] The wet-chemical preparation is performed in order to remove undesired foreign material, such as grease, cell components, and pyrogens, and to eliminate microbial organisms.
[0015] Following the wet-chemical treatment, the starting material is preferably acidified.
[0016] For producing a collagen-containing suspension, the starting material is comminuted. Comminuting is preferably performed mechanically, especially by mincing and/or in a rotor-stator type mill.
[0017] Comminuting is preferably performed following the wet-chemical preparation. However, it is also conceivable, to first comminute the starting material and to subsequently perform the wet-chemical treatment.
[0018] In particular by mechanical comminution of the starting material a suspension is provided which includes a native collagen in which the telopeptides are largely preserved.
[0019] According to the invention, the suspension is then dried, wherein in contrast to the procedure described in published patent application EP 2 098 255 A2 the drying is performed in a manner so that the collagen at least partially settles before or during the drying and forms a transparent skin.
[0020] So the material produced is not highly porous, but has a dense film-like structure which is at least partially transparent.
[0021] Transparent in the sense of the invention does not mean that the material is completely transparent like a clear transparent glass pane or film, but that the material is translucent to an extent that at least in its applied state the underlying tissue is visible. It will be understood that the material may contain air bubbles and haziness.
[0022] The drying may be performed by first waiting until most of the collagen has settled.
[0023] Further, the drying may be performed in particular at temperatures above the freezing point of the suspension. This causes the collagen material to sag together during drying to form a film-like sheet material. It is also conceivable to perform drying under reduced pressure.
[0024] Surprisingly, the sheet material so produced is bendable and flexible. Previously it was assumed that a porous three-dimensional structure would be necessary in order to provide a material which is not brittle and fragile.
[0025] Surprisingly, however, the invention enabled to provide a material which is translucent and flexible. Furthermore, in contrast to a highly porous non-woven or spongy material, the material can be easily cut in the rehydrated state, so that the user may easily adjust the shape and size of the material.
[0026] In a further embodiment of the invention, metal particles, in particular silver particles, are added to the suspension.
[0027] The addition of an elemental metal makes it possible to functionalize the material with further properties. Silver is preferably used to provide antibacterial properties.
[0028] It has been found that the film-like material of the invention releases metal ions more slowly as compared to a porous material, so that the effect lasts longer and toxic concentrations directly after application can largely be avoided.
[0029] A further advantage of the use of elemental silver as compared to the use of metal salts is that dark staining will only occur to a slight extent, if any.
[0030] In order to provide a long lasting antibacterial effect, or for other purposes, is also conceivable to add other active substances, such as bacteriostatic or bactericidal agents or antifungal agents, such as gentamicin or guanidines.
[0031] The metal particles are preferably added in form of a suspension.
[0032] In particular, particles with an average particle size from 10 nm to 10 μm may be used. Preferably nanoparticles are used, especially nanoparticles with a particle size of less than 50 nm.
[0033] In fact, agglomeration phenomena may arise with such nanomaterials in the manufacturing of the sheet material, so that the metal in the sheet material is mainly present in agglomerates. However, this does not affect the positive properties of the material according to the invention.
[0034] In a preferred embodiment of the invention, the metal is dosed such that the sheet material produced has a metal content from 10 to 10,000 ppm, preferably from 100 to 10,000 ppm.
[0035] In a preferred embodiment of the invention, before drying the pH of the suspension is adjusted to a value between 3 and 9, preferably between 5.5 and 8.
[0036] It is especially contemplated adjust the suspension to a neutral to slightly alkaline pH.
[0037] To avoid a reaction of the silver with chlorine, the suspension should not be acidified using hydrochloric acid. Preferably, a substantially chloride-free suspension is used.
[0038] The material of the invention may be produced without the use of a crosslinking agent. However, the invention does not exclude the use of a crosslinking agent.
[0039] The invention further allowed to simplify the drying.
[0040] Lyophilization is not necessary, but may yet be performed when the collagen has settled. Preferably, the material is dried under reduced pressure at a temperature above the freezing point of the suspension.
[0041] The invention permits to provide an at least partially transparent collagen-containing sheet material.
[0042] This sheet material preferably has a closed porosity of less than 50%, more preferably less than 20%.
[0043] The material has a film-like structure and is thinner than similarly stable non-woven or sponge-like collagens. In particular, the sheet material has a thickness from 0.05 to 2.00 mm, preferably between 0.1 and 1.00 mm.
[0044] The material may take various shapes, in particular round, square, and oval shapes.
[0045] It will be understood that typically a sterile material will be prepared. Sterilization may be accomplished by ionizing radiation, e.g. y- and/or p-irradiation.
[0046] Preferably, sterilization is performed using ethylene oxide, since as a result thereof the stability of the sheet material is increased, whereas at least strong ionizing radiation weakens the stability of the sheet material.
[0047] Possibly, the ethylene oxide causes additional crosslinks to be formed.
[0048] To obtain antibacterial properties, in particular a nano-silver containing suspension is used, which contains an emulsifier.
[0049] A method for producing such a stable silver containing suspension is known from published patent application DE 10 2009 059 276 A1 (Rent-a-Scientist GmbH). The disclosure of this document is fully incorporated herein by reference.
[0050] The inventive material has hemostatic properties, and due to its antibacterial properties it is especially suitable for use in conjunction with poorly healing wounds, in particular in case of diabetes and for burn injuries. Also dental applications are conceivable.
DESCRIPTION OF THE DRAWINGS
[0051] FIG. 1 shows a flowchart of a method for producing a collagen-containing sheet material.
DETAILED DESCRIPTION
[0052] First, porcine skin is prepared by an alkaline, oxidative, and acidic treatment.
[0053] For this purpose, hydrogen peroxide, sodium hydroxide, and phosphoric acid may be used, for example, in which the starting material is alternately dipped and is then rinsed.
[0054] Through this wet-chemical preparation, a starting material is provided which comprises more than 70%, preferably more than 80% of collagen.
[0055] Then, the wet-chemically purified porcine skin is acidified. Preferably, phosphoric acid is used for this purpose.
[0056] To prepare a suspension, the porcine skin is first comminuted mechanically by mincing, and then an aqueous suspension is produced from the slurry resulting from further comminuting steps. This suspension in particular has a solids content from 0.5 to 5%.
[0057] Then, the aqueous suspension is adjusted to a neutral to slightly alkaline pH from 6.5 to 8.5 by adding a phosphate buffer.
[0058] Subsequently, a nano-silver containing aqueous suspension may be added. For this purpose, a suspension should be used which is stable over a longer period. The metal is not added as a salt, but as elemental silver.
[0059] To achieve a good distribution, the addition of the nano-silver containing suspension may be accomplished using suitable dispersion promoting means, for example in an ultrasonic bath, or a suitable rotor-stator type mill.
[0060] Subsequently, the suspension is dried in trays at a temperature above 20° C. under reduced pressure.
[0061] The collagen will thereby mostly settle on the bottom of the tray as a film-like structure, with a large part of the silver particles trapped in the material being formed.
[0062] Subsequently, the dried sheet material can be packaged and sterilized.
[0063] Sterilization may be accomplished using ethylene oxide, for example.
[0064] Also, sterilization of the already packaged material is possible by irradiation.
[0065] The produced material rehydrates very fast, has a good hemostatic effect, and is bendable, rollable and can be cut easily, even in its dry state.
[0066] Additionally, the material is translucent at least to an extent so that the applied material permits to perceive the underlying tissue. Complications such as inflammation arising under the sheet material can be easily identified.
[0067] Furthermore, the material is less prone to sticking and can be easily removed.
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A method for producing a collagen-containing sheet material, wherein a collagen-containing suspension is dried in such a manner that the collagen settles during drying and forms a transparent skin.
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BACKGROUND OF THE INVENTION
[0001] The art of playing drums is well known and consists of holding a drumstick and striking a drum. A drumstick is a device used to hit the drums to make a percussive noise. A drummer is the person who plays the drums. A drum consist of at least one membrane, called a “drumhead” or “drumskin”, that is stretched over a shell and struck, either directly with parts of a player's body, or with some sort of implement such as a drumstick, to produce sound.
[0002] Drumsticks typically have a smooth surface that allows the drumstick to slip through the hands of the drummer. Also, sweat on the drummer's hands increases the risk of losing the drumstick. In certain situations the release of the drumstick can be disadvantageous, for example, during a parade when the drummer is moving and cannot retrieve the drumstick.
[0003] Also, the lack of a drumstick restraint can be dangerous to other individuals. For example, during the vigorous playing of the drums, a player can accidentally release the drumstick resulting in a flying projectile that may injure others.
[0004] Many beginners have found it challenging to learn how to play the drums. It can take up to a year for a beginner to learn how to hold the drumsticks in the proper position and at a proper angle. A positioning device attached to the finger and the drumstick may be set such that there is a proper offset between the finger and the drumstick that replicates the proper playing position.
[0005] The prior art depicts three devices that use a ring design to affix a finger to the drumstick. The first such device is U.S. Pat. No. 3,365,108 (Jan. 23, 1968) to Giba which uses a two ring structure with a three hundred and sixty degree swivel between the two rings. The '108 patent does not position the drumstick at the proper playing angle rather allows it to spin a complete 360 degrees. Another such device is U.S. Pat. No. 5,370,030 (Dec. 6, 1994) to Horne which uses a flexible ring inserted into the drumstick. The '030 device has the drawback of requiring the finger to be pressed up against the drumstick. Another such device is US Pub No. 2006/0090629 (May 4, 2006) to Nybye uses a rigid ring inserted into the drumstick.
[0006] Other devices use a much bulkier apparatus to accomplish the same goal of connecting the hands of the drummer to the stick. The U.S. Pat. No. 5,581,031 (Dec. 3, 1993) to Blankenship, Jr., describes a pistol-type grip with grooves that receive the fingers of the drummer. U.S. Pat. No. 6,810,531 (Nov. 2, 2004) to Lento on uses an entire glove structure to properly align the drumstick to the player hand.
[0007] Another device with the US Publication No. 2002/0002895 (Jan. 10, 2002) to Zbrzezny on published on changes the cylindrical portion that is used to grip the drumstick to a hexagonal shape. The article in the '895 publication depicts a device that increases the friction on the drumstick thereby decreasing the slippage of the drumstick from the hand of the musician, but, the device does not prevent the drumstick from being ejected from the hand of the musician.
[0008] Lastly, another device is shown in US Publication No. 2006/0027076 (Feb. 9, 2006) to Barke. The device shown in the '076 publication utilizes a spacer with straps to hold the stick in the proper alignment with the hand. The device shown in the '076 publication, like the device shown in the '895 does not prevent the drumstick from being ejected from the hand of the musician.
SUMMARY OF THE INVENTION
[0009] While describing the invention and its embodiments various terms will be used for the sake of clarity. These terms are intended to not only include the recited embodiments, but also all equivalents that perform substantially the same function, in substantially the same manner to achieve the same result.
[0010] The device is directed at the drum band apparatus and the method of using the same. The device is useful for attaching a generic cylindrical drumstick to a drummer's hand, keeping the drumstick at a proper angle to the hand, allowing the drummer to have greater control over the drumstick, and allows the drummer to never drop the drumstick. The device also allows a quick change of drumsticks if the drumstick shatters. The device also provides support to the drumstick to prevent shattering. Also, the device accomplishes the previously mentioned objectives while being inconspicuous. Lastly, no modification of a cylindrical drumstick is required.
[0011] It is an object of this invention to provide a drum band that attaches on the finger of the drummer and on a part of the stick.
[0012] It is another object of this invention to provide a drum band that positions the stick in the palm of the drummer in a manner that is most likely to aid the proper holding of the drumstick.
[0013] The apparatus and method of this device has several features, no single one of which is solely responsible for its desirable attributes. Without limiting the scope of this invention as expressed by the claims that follow, its more prominent features will now be discussed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIG. 1 : shows the side view of the drum band apparatus.
[0015] FIG. 2 : show the side view of the drum band apparatus.
[0016] FIG. 3 : shows the isometric view of the drum band apparatus.
[0017] FIG. 4 a: shows the drum band apparatus attached to a right hand and attached to a generic drumstick from a palm up view.
[0018] FIG. 4 b: shows the drum band apparatus attached to a right hand from the side view.
[0019] FIG. 5 a: shows the drum band apparatus attached to a right hand and attached to a generic drumstick from a palm up view.
[0020] FIG. 5 b: shows the drum band apparatus attached to a right hand from the side view.
[0021] FIG. 5 c shows the drum band apparatus laid palm up and affixed to the middle finger.
[0022] FIG. 5 d shows the drum band apparatus with the palm downwards and the index finger and thumb holding the drumstick.
[0023] FIG. 5 e shows a palm down view of the drum band apparatus attached with the drumstick held between the thumb and index finger.
[0024] FIG. 6 a: Shows the bottom view of the drum band for the left hand.
[0025] FIG. 6 b: Shows the bottom view of the drum band for the right hand.
DETAILED DESCRIPTION
[0026] Now referring to FIG. 1 . FIG. 1 shows a frontal view of the drumstick band 100 . The drumstick band 100 consists of a finger ring 101 and a drumstick ring 103 . The finger ring 101 is connected to the drumstick ring 103 using a flexible member 102 . The finger ring 101 is sized so that the inner diameter of the finger ring 104 of the finger ring 101 is sized to comfortably fit on a drum player's finger.
[0027] Now referring to FIG. 2 . FIG. 2 is a side view of the drumstick band 100 . As shown, the finger ring 101 and the drumstick ring 103 are connected with a flexible member 102 . For the purposes of orientation a finger plane 104 slices through the finger ring 101 and a drumstick plane 105 intersects the drumstick ring 103 . The finger plane 104 and the drumstick plane 105 are offset by an angle 106 .
[0028] Now referring to FIG. 3 . FIG. 3 is a close up view of the drumstick band 100 . As shown the finger ring 101 may have an elongated section 107 on the top of the finger ring 101 for the purposes of ornamentation.
[0029] Now referring to FIG. 4 a. FIG. 4 a depicts a view of the drumstick band 100 as held by a hand 110 with the left-hand palm facing upwards. The finger ring 101 is slipped through the middle finger 115 and the drumstick 120 is inserted through the drumstick ring 103 . As shown the drumstick 120 is at an angle to the finger 115 as set by the angle between the finger ring 101 and the drumstick ring 103 .
[0030] Now referring to FIG. 4 b. FIG. 4 b shows a side view of the drumstick band 100 where the hand is left hand palm down. As shown the finger ring 101 is looped around the middle finger 115 , the flexible member 102 is connected to the finger ring 101 and the drumstick ring 103 is connected to the flexible member 102 . The flexible member 102 is of such a length to allow a gap between the palm of the hand and the drumstick 120 .
[0031] Now referring to FIG. 5 a. FIG. 5 a depicts a view of the drumstick band 100 ′ as held by a hand 110 ′ with the right hand palm facing upwards. The finger ring 101 ′ is slipped through the middle finger 115 ′ and the drumstick 120 ′ is inserted through the drumstick ring 103 . As shown the drumstick 120 ′ is at an angle to the finger 115 ′ as set by the angle between the finger ring 101 ′ and the drumstick ring 103 ′.
[0032] Now referring to FIG. 5 b. FIG. 5 b shows a side view of the drumstick band 100 ′ where the hand is right hand palm down. As shown the finger ring 101 ′ is looped around the middle finger 115 ′, the flexible member 102 ′ is connected to the finger ring 101 ′ and the drumstick ring 103 ′ is connected to the flexible member 102 ′. The flexible member 102 ′ is of such a length to allow a gap between the palm of the hand and the drumstick 120 ′.
[0033] Now referring to FIG. 5 c. FIG. 5 c shows a palm up view of the drumstick band 100 ′. As shown the finger ring 101 ′ is looped around the middle finger 115 ′, the flexible member (not shown) is connected to the finger ring 101 ′ and the drumstick ring 103 ′ is connected to the flexible member 102 ′.
[0034] Now referring to FIG. 5 d. FIG. 5 d shows a palm down view of the drumstick band 100 ′. As shown the finger ring 101 ′ is looped around the middle finger 115 ′, the flexible member (not shown) is connected to the finger ring 101 ′ and the drumstick ring 103 ′ is connected to the flexible member 102 ′. The flexible member 102 ′ is set at an angle so that the index finger 140 ′ and the thumb 130 ′ hold the drumstick 120 ′ in the proper position for playing the drums.
[0035] Now referring to FIG. 5 e. FIG. 5 e shows another palm down view of the drumstick band 100 ′. As in FIG. 5 d, the index finger 140 ′ and the thumb 130 ′ grasp the drumstick at an angle set by the flexible member 102 ′. This flexible member 102 ′ is set at an angle that is the proper holding position for a drumstick.
[0036] The difference between FIGS. 4 and 5 being the right hand and left hand orientation of the drumstick bands 100 , 100 ′.
[0037] Now referring to FIGS. 6 a and 6 b, the orientation of the bands 100 and 100 ′ is shown in detail. The finger band 101 , 101 ′ and the drumstick band 103 , 103 ′ are oriented in such a way to hold the drumsticks at a natural playing angle.
[0038] Other embodiments of the device allow for the flexible member to be detached from the finger ring. This allows the finger ring to be worn ornamentally and also providing for the connection of the flexible member with ease.
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A musical apparatus comprising, a first ring, a second ring, and a flexible member. The first ring is position on the finger of a drummer, the second ring encircles a drumstick and the flexible member connects the two rings. The flexible member is configured so that the first ring and second ring are offset at an angle that allows the drumstick to properly rest on the hand of the drummer.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims priority under 35 U.S.C. §119(e) to Chinese Patent Application Nos. CN201210055616.X, filed Mar. 5, 2012, and CN201210055620.6, filed Mar. 5, 2012.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a resin article, particularly to a composite formulation for a recycled EVA (ethylene-vinyl acetate copolymer), a recycled PP (chlorinated polypropylene), a recycled PVC (polyvinyl chloride), and a recycled PE (polyethylene), as well as to a process for the heat-pressing of a recycled plastic composite.
[0004] 2. Background Information
[0005] Currently the problem in the resin article and the related art is the high cost of the raw material, the blank will be modified by the repairing, low production efficiency, the repeated usage of the corresponding mold being limited (about 300 times), and the lower surface smoothness, heat resistance, and toughness of the resin article.
SUMMARY OF THE INVENTION
[0006] The present invention provides a formulation for a recycled plastic composite comprising in the terms of weight percent: recycled EVA plastic from 30% to 80%, a stone powder from 20% to 70%. Preferably, said formulation comprises in the terms of weight percent: the recycled EVA plastic greater than 70% and less than or equal to 80%, the stone powder greater than or equal to 20% and less than 30%. The recycled plastic comprises a recycled EVA (ethylene-vinyl acetate copolymer), a recycled PP (chlorinated polypropylene), a recycled PVC (polyvinyl chloride), and a recycled PE (polyethylene). The formulation for the recycled plastic composite of the present invention can improve the toughness, strength, surface smoothness, heat resistance, and electroplating performance of various products obtained, can be pressed through hydraulic press, results in the increased production, lowered labor, cost for producing various products and decreased pollution.
[0007] The present invention further provides a process for the heat-pressing of a recycled plastic composite comprising sufficiently mixing the pellet of the recycled plastic and the heavy calcium carbonate according to the formulations to get the composite, the composite is fed to a screw melting machine with electric heating, heated and further mixed, the thick composite after being heated is conveyed to the outlet by the screw; the thick composite is obtained at the outlet, conveyed to the steel mold of the hydraulic press according to the volume of the mold to be molded and pressed strong; said thick composite is cooled in the steel mold for 5 minute to 15 minute with the recirculation of the cooling water to de-mold the thick composite, and the thick composite is completely immersed in the water to be cooled completely to finish the heat-pressing of the composite. The process of heat-pressing the composite of the present invention can improve production efficiency, the surface smoothness, the toughness of the product, the saving of the raw material, improving the heat resistance from −40° C. to −80° C., improve the electroplating performance of various products obtained, results in the decreased pollution.
[0008] More specifically, the present invention provides a formulation for the recycled plastic composite which can improve the toughness, strength, surface smoothness, heat resistance, and electroplating performance of various products obtained, results in the increased production, lowered labor, cost for producing various products and decreased pollution. In order to achieve the subject of the present invention, there is provided the following embodiments: a formulation for a recycled plastic composite comprising in the terms of weight percent: a recycled plastic from 30% to 80%, a heavy calcium carbonate from 20% to 70%.
[0009] Preferably, the recycled plastic is one or mixture of more in any ratio of a recycled EVA (ethylene-vinyl acetate copolymer), a recycled PP (chlorinate polypropylene), a recycled PVC (polyvinyl chloride), and a recycled PE (polyethylene). In one embodiment, said formulation comprises in the terms of weight percent: the recycled plastic greater than 70% and less than or equal to 80%, the heavy calcium carbonate greater than or equal to 20% and less than 30%. In one embodiment, said formulation comprises in the terms of weight percent: the recycled plastic greater than 60% and less than or equal to 70%, the heavy calcium carbonate greater than or equal to 30% and than 40%. In one embodiment, said formulation comprises in the terms of weight percent: the recycled plastic greater than 50% and less than or equal to 60%, the heavy calcium carbonate greater than or equal to 40% and less than 50%. In one embodiment, said formulation comprises in the terms of weight percent: the recycled plastic greater than 40% and less than or equal to 50%, the heavy calcium carbonate greater than or equal to 50% and less than 60%. In one embodiment, said formulation comprises in the terms of weight percent: the recycled plastic greater than 30% and less than or equal to 40%, the heavy calcium carbonate greater than or equal to 60% and less than 70%. In one embodiment, the talc can be added to any of the formulation in an amount from 1% to 15%.
[0010] The technical effects achieved in the present invention through the above mentioned embodiments include improving the toughness, strength, surface smoothness, heat resistance, and electroplating performance of various products obtained, can be pressed through hydraulic press, results in the increased production, lowered labor, cost for producing various products and decreased pollution.
[0011] Further, the present invention provides a process of heat-pressing the composite which can improve production efficiency, the surface smoothness, the toughness of the product, the saving of the raw material, improving the heat resistance from −40° C. to −80° C. improve the electroplating performance of various products obtained, results in the decreased pollution. In order to achieve the subject of the present invention, there is provided a process for the heat-pressing of a recycled plastic composite comprising the steps of:
A. sufficiently mixing the pellet of the recycled plastic and the heavy calcium carbonate according to the formulations to get the composite; B. the composite id fed to a screw melting machine with electric heating, heated and further mixed, the thick composite after being heated is conveyed to the outlet by the screw; C. the thick composite is obtained at the outlet, conveyed to the steel mold of the hydraulic press according to the volume of the mold to be molded and pressed strongly; D. said thick composite is cooled in the steel mold for 5 minute to 15 minute with the recirculation of the cooling water to de-mold the thick composite, and the thick composite is completely immersed in the water to be cooled completely to finish the heat-pressing of the composite.
Preferably, the size of the heavy calcium carbonate is from 600 mesh to 1200 mesh. Preferably, the temperature in the screw melting machine with electric heating is controlled to be from 160° C. to 240° C.
[0016] The technical effects achieved in the present invention through the above mentioned embodiments include improving production efficiency, the surface smoothness, the toughness of the product, the saving of the raw material, improving the heat resistance from −40° C. to −80° C., improving the electroplating performance of various products obtained, resulting in the decreased pollution. The product of the process of the present invention is the resin article such as flowerpot, frame for the image, lamp bracket and lamp socket fence of the garden, guard of the garden, gift, furniture decoration, construction decoration, graving, article, graving of emulation, and the raw materials for emulation animal and plant graving.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0017] The present invention provides a formulation for a recycled plastic composite comprising in the terms of weight percent: a recycled EVA plastic from 30% to 80%, a heavy calcium carbonate from 20% to 70%.
[0018] Preferably, the recycled plastic is one or mixture of more in any ratio of a recycled EVA (ethylene-vinyl acetate copolymer), a recycled PP (chlorinated polypropylene), a recycled PVC (polyvinyl chloride), and a recycled PE (polyethylene). Specifically the formulation for the high toughness recycled plastic composite comprises in the terms of weight percent: the recycled plastic greater than 70% and less than or equal to 80%, heavy calcium carbonate greater than or equal to 20% and less then 30%.
[0019] Formulation 1: the recycled plastic 80%, the heavy calcium carbonate 20%.
[0020] Formulation 2: the recycled plastic 71%, the heavy calcium carbonate 29%.
[0021] Formulation 3: the recycled plastic 75%, the heavy calcium carbonate 25%.
[0022] More specifically the formulation for the less high toughness recycled plastic composite comprises in the terms of weight percent: the recycled plastic greater than 60% and less than or equal to 70%, the heavy calcium carbonate greater than or equal to 30% and less than 40%.
[0023] Formulation 4: the recycled EVA plastic 70%, the heavy calcium carbonate 30%.
[0024] Formulation 5: the recycled EVA plastic 65%, the heavy calcium carbonate 35%.
[0025] Formulation 6: the recycled EVA plastic 61%, the heavy calcium carbonate 39%.
[0026] Still more specifically the formulation for the medium toughness recycled plastic composite comprises in the terms of weight percent: the recycled plastic greater than 50% and less than or equal to 60%, the heavy calcium carbonate greater than or equal to 40% and less than 50%.
[0027] Formulation 7: the recycled EVA plastic 60%, the heavy calcium carbonate 40%.
[0028] Formulation 8: the recycled EVA plastic 55%, the heavy calcium carbonate 45%.
[0029] Formulation 9: the recycled EVA plastic 51%, the heavy calcium carbonate 49%.
[0030] Still more specifically the formulation for the less medium toughness recycled plastic composite comprises in the terms of weight percent: the recycled plastic greater than 40% and less than or equal to 50%, the heavy calcium carbonate greater than or equal to 50% and less than 60%.
[0031] Formulation 10: the recycled EVA plastic 50%, the heavy calcium carbonate 50%.
[0032] Formulation 11: the recycled EVA plastic 45%, the heavy calcium carbonate 55%.
[0033] Formulation 12: the recycled EVA plastic 39%, the heavy calcium carbonate 61%.
[0034] Still more specifically the formulation for the low toughness recycled plastic composite comprises in the terms of weight percent: the recycled plastic greater than 30% and less than or equal to 40%, the heavy calcium carbonate greater than or equal to 60% and less than 70%.
[0035] Formulation 13: the recycled EVA plastic 40%, the heavy calcium carbonate 60%.
[0036] Formulation 14: the recycled EVA plastic 35%, the heavy calcium carbonate 65%.
[0037] Formulation 15: the recycled EVA plastic 31%, the heavy calcium carbonate 69%.
[0038] Preferably, the talc can be added to any of the formulation in an amount from 1% to 15% in order to improve the surface smoothness of the article.
[0039] The method for producing the composite comprises sufficiently mixing the pellet of the recycled plastic and the heavy calcium carbonate according to any abovementioned formulations to get the composite, the composite is fed to a screw melting machine with electric heating, heated and further mixed, the thick composite after being heated is conveyed to the outlet by the screw; the thick composite is obtained at the outlet, conveyed to the steel mold of the hydraulic press according to the volume of the mold to be molded, the thick composite is completely immersed in the water after cooling the temperature thereof to complete the heat-pressing of the composite. The formulation of the present invention is useful in the resin article such as for the manufacturing of flowerpot, frame for the image, lamp bracket and lamp socket, fence of the garden, guard of the garden, unsaturated resin article, gift, furniture decoration, construction decoration, graving article, graving of emulation, and the raw materials for various products.
[0040] The present invention provides a process for the heat-pressing of a recycled plastic composite comprising the steps of:
[0041] A. sufficiently mixing the pellet of the recycled plastic and the heavy calcium carbonate according to the formulations to get the composite wherein the mixing can be carried out through a manual or mechanical means. The recycled plastic is one or mixture of more in any ratio of a recycled EVA (ethylene-vinyl acetate copolymer), a recycled PP (chlorinated polypropylene), a recycled PVC (polyvinyl chloride), and a recycled PE (polyethylene). The formulation is as follows:
[0042] The formulation for the high toughness recycled plastic composite: the recycled plastic from 70% to 80%, the heavy calcium carbonate from 20% to 30%; the formulation for the less high toughness recycled plastic: the recycled plastic from 60% to 70%, the heavy calcium carbonate from 30% to 40%; the formulation for the medium toughness recycled plastic: the recycled plastic from 50% to 60%, the heavy calcium carbonate from 40% to 50%; the formulation for the less medium toughness recycled plastic: the recycled plastic from 40% to 50%, the heavy calcium carbonate from 50% to 60%; the formulation for the low toughness recycled plastic: the recycled plastic from 30% to 40%, the heavy calcium carbonate from 60% to 70%.
[0043] B. the composite is fed to a screw melting machine with electric heating, heated and further mixed, the thick composite after being heated is conveyed to the outlet by the screw; in the step B, the feeding of the composite to the screw melting machine with electric heating can be carried out through a manual or mechanical means;
[0044] C. the thick composite is obtained at the outlet, conveyed to the steel mold of the hydraulic press according to the volume of the mold to be molded and pressed strongly; in the step C, the obtaining of the thick composite can be carried out through a manual or mechanical means; or the conveying of the thick composite to the steel mold of the hydraulic press can be carried out through a manual or mechanical means;
[0045] D. said thick composite is cooled in the steel mold for 5 minute to 15 minute with the recirculation of the cooling water to de-mold the thick composite, and the thick composite is completely immersed in the water to be cooled completely to finish the heat-passing of the composite.
[0046] Preferably in the example described above, the size of the heavy calcium carbonate is from 600 mesh to 1200 mesh. Preferably in the example described above, the temperature in the screw melting machine with electric heating is controlled to be from 160° C. to 240° C.
[0047] While specific embodiments of the invention have been described in detail, it will be appreciated by those skilled in the art that various modifications and alternatives to those details could be developed in light of the overall teachings of the disclosure. Accordingly, the particular arrangements disclosed are meant to be illustrative only an not limiting as to the scope of invention which is to be give the full breadth of the claims appended and any and all equivalents thereof.
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A formulation for a recycled plastic composite composition, and a method of making the composite composition, is provided. The composite composition includes recycled EVA plastic from 3 to 80%, a stone powder from 20% to 70%; percentages by weight.
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RELATED APPLICATIONS
[0001] This application is based on, and claims priority under 35 U.S.C. §120 to U.S. Provisional Application No. 61/334,937, filed on May 14, 2010, and which is incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present invention relates to aromatic compounds processes for preparing them, pharmaceutical compositions containing them and their use as pharmaceuticals as modulators of sphingosine-1-phosphate receptors. The invention relates specifically to the use of these compounds and their pharmaceutical compositions to treat disorders associated with sphingosine-1-phosphate (S1P) receptor modulation.
BACKGROUND OF THE INVENTION
[0003] Sphingosine-1 phosphate is stored in relatively high concentrations in human platelets, which lack the enzymes responsible for its catabolism, and it is released into the blood stream upon activation of physiological stimuli, such as growth factors, cytokines, and receptor agonists and antigens. It may also have a critical role in platelet aggregation and thrombosis and could aggravate cardiovascular diseases. On the other hand the relatively high concentration of the metabolite in high-density lipoproteins (HDL) may have beneficial implications for atherogenesis. For example, there are recent suggestions that sphingosine-1-phosphate, together with other lysolipids such as sphingosylphosphorylcholine and lysosulfatide, are responsible for the beneficial clinical effects of HDL by stimulating the production of the potent antiatherogenic signaling molecule nitric oxide by the vascular endothelium. In addition, like lysophosphatidic acid, it is a marker for certain types of cancer, and there is evidence that its role in cell division or proliferation may have an influence on the development of cancers. These are currently topics that are attracting great interest amongst medical researchers, and the potential for therapeutic intervention in sphingosine-1-phosphate metabolism is under active investigation.
[0004] Published International Patent Application No. WO 2008030843 describes heterocyclic aminophosphonates and oxyphosphonates having sphingosine-1-phosphate receptor biological activity.
[0005] Published International Patent Application No. WO 2008030838 describes heteroaromatic derivatives as sphingosine-1-phosphate receptor agonists and theft preparation and use in the treatment of diseases.
[0006] Published International Patent Application No. WO 2008141013 describes Sphingosine-1-phosphate 3 receptor inhibitors for the treatment of pain.
[0007] Published International Patent Application No. WO 9202513 describes the preparation of diphenylazines as antithrombotics vasodilators, antihypertensives, and antiinflammatories.
[0008] Granted U.S. Pat. No. 7,728,014 discloses heteroaromatic compounds having biological activity at the sphingosine-1-phosphate 3 receptor.
SUMMARY OF THE INVENTION
[0009] We have now discovered a group of novel compounds which are potent and selective sphingosine-1-phosphate modulators. As such, the compounds described herein are useful in treating a wide variety of disorders associated with modulation of sphingosine-1-phosphate receptors. The term “modulator” as used herein, includes but is not limited to: receptor agonist, antagonist, inverse agonist, inverse antagonist, partial agonist, partial antagonist.
[0010] This invention describes compounds of Formula I, which have sphingosine-1-phosphate receptor biological activity. The compounds in accordance with the present invention are thus of use in medicine, for example in the treatment of humans with diseases and conditions that are alleviated by S1P modulation.
[0011] In one aspect, the invention provides a compound having Formula I or a pharmaceutically acceptable salt thereof or stereoisomeric forms thereof, or the geometrical isomers, enantiomers, diastereoisomers, tautomers, zwitterions and pharmaceutically acceptable salts thereof:
[0000]
[0012] wherein:
[0013] R 1 is Me, CF 3 or aryl;
[0014] R 2 is H, C 1-10 alkyl, or together with R 3 forms a 5 or 6 membered heterocycle ring;
[0015] R 3 is H, C 1-10 alkyl, or together with R 2 forms a 5 or 6 membered heterocycle ring;
[0016] R 4 is OPO 3 H 2 , carboxylic acid, C 1-6 alkyl, —S(O) 2 H, —P(O)(OH)(OR 10 ), —P(O)(H)OH or OR 9 ;
[0017] X is CR 5 or N;
[0018] Y is CR 6 or N;
[0019] Z is CR 7 or N;
[0020] A is O, CH 2 or NR 8 ;
[0021] L 1 is C 2-10 alkylene;
[0022] R 5 is H, C 1-10 alkyl, C 2-6 alkenyl or C 3-10 cycloalkyl;
[0023] R 6 is H, C 1-10 alkyl, C 2-6 alkenyl or C 3-10 cycloalkyl;
[0024] R 7 is H, C 1-10 alkyl, C 2-6 alkenyl or C 3-10 cycloalkyl;
[0025] R 8 is H, C 3-10 cycloalkyl or C 1-6 alkyl;
[0026] R 9 is H or C 1-10 alkyl;
[0027] R 10 is H or C 1-10 alkyl;
[0028] Q is C 3-10 cycloalkyl, heterocycle or aryl; and
[0029] a is 0, 1, 2, 3 or 4.
[0030] The term “alkyl”, as used herein, refers to saturated, monovalent hydrocarbon moieties having linear or branched moieties or combinations thereof and containing 1 to 10 carbon atoms. One methylene (—CH 2 —) group, of the alkyl can be replaced by oxygen, sulfur, sulfoxide, nitrogen, carbonyl, carboxyl, sulfonyl, or by a divalent C 3-10 cycloalkyl. Alkyl groups can be substituted by halogen, hydroxyl, cycloalkyl, amino, heterocycles, carboxylic acid, phosphonic acid groups, sulphonic acid groups, phosphoric acid. Usually, in the present case, alkyl groups are methyl, n-butyl, n-propyl, hexafluoropropyl, trifluoromethyl.
[0031] The term “alkylene”, as used herein, refers to saturated, divalent hydrocarbon moieties having linear or branched moieties or combinations thereof and containing 2 to 10 carbon atoms. One methylene (—CH 2 —) group, of the alkylene can be replaced by oxygen, sulfur, sulfoxide, nitrogen, carbonyl, carboxyl, sulfonyl, or by a divalent C 3-10 cycloalkyl. Alkylene groups can be substituted by halogen, hydroxyl, cycloalkyl, amino, heterocycles, carboxylic acid, phosphonic acid groups, sulphonic acid groups, phosphoric acid. Usually, in the present case, alkylene groups are ethylene, n-butylene, n-propylene, hexafluoropropylene.
[0032] The term “cycloalkyl”, as used herein, refers to a monovalent or divalent group of 3 to 10 carbon atoms, preferably 3 to 5 carbon atoms derived from a saturated cyclic hydrocarbon. Cycloalkyl groups can be monocyclic or polycyclic. Cycloalkyl can be substituted by C 1-6 alkyl groups or halogens.
[0033] The term “alkenyl”, as used herein, refers to a monovalent or divalent hydrocarbon radical having 2 to 6 carbon atoms, derived from a saturated alkyl, having at least one double bond. C 2-6 alkenyl can be in the E or Z configuration. Alkenyl groups can be substituted by C 1-6 alkyl, as defined above, or by halogen.
[0034] The term “halogen”, as used herein, refers to an atom of chlorine, bromine, fluorine, iodine. Usually, in the present case, halogen group is fluoro.
[0035] The term “heterocycle” as used herein, refers to a 3 to 10 membered ring, which can be aromatic or non-aromatic, saturated or non-saturated, containing at least one heteroatom selected form O or N or S or combinations of at least two thereof, interrupting the carbocyclic ring structure. The heterocyclic ring can be saturated or non-saturated. The heterocyclic ring can be interrupted by a C═O; the S heteroatom can be oxidized. Heterocycles can be monocyclic or polycyclic. Heterocyclic ring moieties can be substituted by hydroxyl, C 1-6 alkyl or halogens. Usually, in the present case, heterocyclic groups are pyridine, thiopene, furan, thiazol, oxazol, pyrroline, 5-fluoro-thiophen-2-yl.
[0036] The term “aryl” as used herein, refers to an organic moiety derived from an aromatic hydrocarbon consisting of a ring containing 6 to 10 carbon atoms by removal of one hydrogen, which can be substituted by halogen atoms, —OC 1-3 alkyl, C 1-3 alkyl, nitrile, C(O)C 1-3 alkyl, amino or hydroxyl groups. Usually, in the present case, aryl is phenyl, 3-fluorophenyl, 4-fluorophenyl, 3-hydroxylphenyl.
[0037] The term “hydroxyl” as used herein, represents a group of formula “—OH”.
[0038] The formula “H”, as used herein, represents a hydrogen atom.
[0039] The formula “O”, as used herein, represents an oxygen atom.
[0040] The formula “N”, as used herein, represents a nitrogen atom.
[0041] The formula “S”, as used herein, represents a sulfur atom.
[0042] The term “nitrile”, as used herein, represents a group of formula “—CN”.
[0043] The term “sulfoxide” as used herein, represents a group of formula “—S(O)”.
[0044] The term “carbonyl” as used herein, represents a group of formula “—C(O)”.
[0045] The term “carboxyl” as used herein, represents a group of formula “—(CO)O—”.
[0046] The term “sulfonyl” as used herein, represents a group of formula —SO 2 ”.
[0047] The term “carboxylic acid” as used herein, represents a group of formula “—COOH”.
[0048] The term “CF 3 ” as used herein, represents a trifluoromethyl group.
[0049] The term “amino” as used herein, represents a group of formula “—NH 2 ” or “—NH(C 1-6 alkyl)” or “—N(C 1-6 alkyl)(C 1-6 alkyl)”.
[0050] The term “phosphonic acid” as used herein, represents a group of formula “—P(O)(OH) 2 ”.
[0051] The term “sulphonic acid” as used herein, represents a group of formula “—SO 2 (OH)”.
[0052] The term “phosphoric acid” as used herein, represents a group of formula “—OP(O)(OH) 2 ”.
[0053] The term “Me”, as used herein represents a methyl group.
[0054] Generally, R 1 is selected from Me, CF 3 or aryl. Usually R 1 is Me, CF 3 , or phenyl.
[0055] Generally, R 2 is selected from H, C 1-10 alkyl, or together with R 3 forms a 5 or 6 membered heterocycle ring. Usually R 2 is H or form together with R 3 a pyrrolidine ring.
[0056] Generally, R 3 is selected from H, C 1-10 alkyl, or together with R 2 forms a 5 or 6 membered heterocycle ring. Usually R 3 is H or form together with R 2 a pyrrolidine ring.
[0057] Generally, R 4 is selected from OPO 3 H 2 , carboxylic acid, C 1-6 alkyl, —S(O) 2 H, —P(O)(OH)(OR 10 ), —P(O)(H)OH or OR 9 . Usually, R 4 is P(O)(OH)(OR 10 ).
[0058] Generally, X is CR 5 or N. Usually X is CH, N or C—C 1-6 alkyl.
[0059] Generally, Y is CR 6 or N. Usually, Y is CH or N.
[0060] Generally, Z is CR 7 or N. Usually, Z is CH or N.
[0061] Generally, A is O, CH 2 or NR 8 . Usually, A is O or CH 2 .
[0062] Generally, L 1 is C 2-10 alkylene. Usually, L 1 is ethylene, n-butylene, n-propylene, hexafluoropropylene.
[0063] Generally, R 5 is H, C 1-10 alkyl, C 2-6 alkenyl or C 3-10 cycloalkyl. Usually, R 5 is H or propyl.
[0064] Generally, R 6 is H, C 1-10 alkyl, C 2-6 alkenyl or C 3-10 cycloalkyl. Usually, R 6 is H.
[0065] Generally, R 7 is H, C 1-10 alkyl, C 2-6 alkenyl or C 3-10 cycloalkyl. Usually, R 7 is H.
[0066] Generally, R 8 is H, C 3-10 cycloalkyl or C 1-6 alkyl.
[0067] Generally, R 9 is H or C 1-10 alkyl.
[0068] Generally, R 10 is H or C 1-10 alkyl. Usually, R 10 is H or ethyl.
[0069] Generally, Q is C 3-10 cycloalkyl, heterocycle or aryl. Usually, Q is phenyl, pyridinyl, thiopene, oxazole, thiazole, 3-fluorophenyl, 4-fluorophenyl, 3-hydroxylphenyl, 5-fluoro-thiophen-2-yl.
[0070] Generally, a is 0, 1, 2, 3 or 4. Usually, a is 0 or 1.
[0071] In one embodiment of the invention
[0072] R 1 is Me, CF 3 , phenyl; and
[0073] R 2 is H, or together with R 3 forms a 5 membered heterocycle ring; and
[0074] R 3 is H, or together with R 2 forms a 5 membered heterocycle ring; and
[0075] R 4 is —P(O)(OH)(OR 10 ); and
[0076] X is CR 5 or N; and
[0077] Y is CR 6 or N; and
[0078] Z is CR 7 or N; and
[0079] A is O or CH 2 ; and
[0080] L 1 is C 2-5 alkylene; and
[0081] R 5 is H or C 1-6 alkyl; and
[0082] R 6 is H; and
[0083] R 7 is H; and
[0084] R 10 is H or C 1-6 alkyl; and
[0085] Q is heterocycle or aryl; and
[0086] a is 0 or 1.
[0087] In a preferred embodiment of the invention
[0088] R 1 is Me or phenyl; and
[0089] R 2 is H; and
[0090] R 3 is H; and
[0091] R 4 is —P(O)(OH)(OR 10 ); and
[0092] X is CR 5 ; and
[0093] Y is CR 6 or N; and
[0094] Z is N; and
[0095] A is CH 2 ; and
[0096] L 1 is C 2-5 alkylene; and
[0097] R 5 is H or C 1-6 alkyl; and
[0098] R 6 is H; and
[0099] R 10 is H; and
[0100] Q is heterocycle or aryl; and
[0101] a is 1.
[0102] Compounds of the invention are:
(3-{[6-(5-Hexyl-pyridin-2-yl)-biphenyl-3-ylmethyl]-amino}-propyl)-phosphonic acid; (3-{[6-(6-Hexyl-pyridin-3-yl)-biphenyl-3-ylmethyl]-amino}-propyl)-phosphonic acid; (3-{[5-(4-Hexyl-phenyl)-6-phenyl-pyridin-2-ylmethyl]-amino}-propyl)-phosphonic acid; [1-(4-Hexyl-[1,1′;2′,1″]terphenyl-4′-ylmethyl)-pyrrolidin-3-yl]-phosphonic acid monoethyl ester; [1-(4-Hexyl-[1,1′;2′,1″]terphenyl-4′-ylmethyl)-pyrrolidin-3-yl]-phosphonic acid; (3-{[6-(6-Octyl-pyridin-3-yl)-biphenyl-3-ylmethyl]-amino}-propyl)-phosphonic acid; (3-{[5-(4-Pentyloxy-phenyl)-6-phenyl-pyridin-2-ylmethyl]-amino}-propyl)-phosphonic acid; (3-{[6-(4-Fluoro-phenyl)-5-(4-pentyloxy-phenyl)-pyridin-2-ylmethyl]-amino}-propyl)-phosphonic acid; (3-{[6-(3-Fluoro-phenyl)-5-(4-pentyloxy-phenyl)-pyridin-2-ylmethyl]-amino}-propyl)-phosphonic acid; (3-{[4-(3-Phenyl-propyl)-[1,1′;2′,1″]terphenyl-4′-ylmethyl]-amino}-propyl)-phosphonic acid; (3-{[4-(3,3,4,4,5,5,6,6,6-Nonafluoro-hexyl)-[1,1′;2′,1″]terphenyl-4′-ylmethyl]-amino}-propyl)-phosphonic acid; (3-{[5-(4-Hexyl-3-propyl-phenyl)-6-phenyl-pyridin-2-ylmethyl]-amino}-propyl)-phosphonic acid; (3-{[6-(3-Chloro-phenyl)-5-(4-hexyl-3-propyl-phenyl)-pyridin-2-ylmethyl]-amino}-propyl)-phosphonic acid; [3-({6-Phenyl-5-[4-(3-phenyl-propyl)-phenyl]-pyridin-2-ylmethyl}-amino)-propyl]-phosphonic acid; [3-({6-(3-Chloro-phenyl)-5-[4-(3-phenyl-propyl)-phenyl]-pyridin-2-ylmethyl}-amino)-propyl]-phosphonic acid; (3-{[5-(4-Hexyl-phenyl)-6-(3-hydroxy-phenyl)-pyridin-2-ylmethyl]-amino}-propyl)-phosphonic acid; (3-{[5-(4-Hexyl-phenyl)-6-thiophen-2-yl-pyridin-2-ylmethyl]-amino}-propyl)-phosphonic acid; (3-{[5-(4-Hexyl-phenyl)-6-thiophen-3-yl-pyridin-2-ylmethyl]-amino}-propyl)-phosphonic acid; (3-{[6-Furan-2-yl-5-(4-hexyl-phenyl)-pyridin-2-ylmethyl]-amino}-propyl)-phosphonic acid; (3-{[5-(4-Hexyl-phenyl)-6-oxazol-4-yl-pyridin-2-ylmethyl]-amino}-propyl)-phosphonic acid; (3-{[5-(4-Hexyl-phenyl)-6-thiazol-2-yl-pyridin-2-ylmethyl]-amino}-propyl)-phosphonic acid; [3-({5-[4-(3-Phenyl-propyl)-phenyl]-6-thiophen-2-yl-pyridin-2-ylmethyl}-amino)-propyl]-phosphonic acid; (3-{[5-(4-Hexyl-3-propyl-phenyl)-6-thiophen-2-yl-pyridin-2-ylmethyl]-amino}-propyl)-phosphonic acid; (3-{[3-(4-Hexyl-phenyl)-[2,3′]bipyridinyl-6-ylmethyl]-amino}-propyl)-phosphonic acid; (3-{[6-(5-Fluoro-thiophen-2-yl)-5-(4-hexyl-phenyl)-pyridin-2-ylmethyl]-amino}-propyl)-phosphonic acid.
[0128] Preferred compounds of the invention are:
(3-{[5-(4-Hexyl-3-propyl-phenyl)-6-phenyl-pyridin-2-ylmethyl]-amino}-propyl)-phosphonic acid; [3-({6-Phenyl-5-[4-(3-phenyl-propyl)-phenyl]-pyridin-2-ylmethyl}-amino)-propyl]-phosphonic acid; (3-{[5-(4-Hexyl-phenyl)-6-thiophen-2-yl-pyridin-2-ylmethyl]-amino}-propyl)-phosphonic acid; (3-{[5-(4-Hexyl-phenyl)-6-thiophen-3-yl-pyridin-2-ylmethyl]-amino}-propyl)-phosphonic acid; (3-{[6-Furan-2-yl-5-(4-hexyl-phenyl)-pyridin-2-ylmethyl]-amino}-propyl)-phosphonic acid; (3-{[5-(4-Hexyl-phenyl)-6-oxazol-4-yl-pyridin-2-ylmethyl]-amino}-propyl)-phosphonic acid; (3-{[5-(4-Hexyl-phenyl)-6-thiazol-2-yl-pyridin-2-ylmethyl]-amino}-propyl)-phosphonic acid; [3-({5-[4-(3-Phenyl-propyl)-phenyl]-6-thiophen-2-yl-pyridin-2-ylmethyl}-amino)-propyl]-phosphonic acid; (3-{[5-(4-Hexyl-3-propyl-phenyl)-6-thiophen-2-yl-pyridin-2-ylmethyl]-amino}-propyl)-phosphonic acid; (3-{[6-(5-Fluoro-thiophen-2-yl)-5-(4-hexyl-phenyl)-pyridin-2-ylmethyl]-amino}-propyl)-phosphonic acid.
[0139] Some compounds of Formula I and some of their intermediates have at least one stereogenic center in their structure. This stereogenic center may be present in an R or S configuration, said R and S notation is used in correspondence with the rules described in Pure Appli. Chem. (1976), 45, 11-13.
[0140] The term “pharmaceutically acceptable salts” refers to salts or complexes that retain the desired biological activity of the above identified compounds and exhibit minimal or no undesired toxicological effects. The “pharmaceutically acceptable salts” according to the invention include therapeutically active, non-toxic base or acid salt forms, which the compounds of Formula I are able to form.
[0141] The acid addition salt form of a compound of Formula I that occurs in its free form as a base can be obtained by treating the free base with an appropriate acid such as an inorganic, for example, a hydrohalic such as hydrochloric acid, hydrobromic acid, sulfuric acid, phosphoric acid, nitric acid and the like; or an organic acid such as for example, acetic, hydroxyacetic, propanoic, lactic, pyruvic, malonic, fumaric acid, maleic acid, oxalic acid, tartaric acid, succinic acid, malic acid, ascorbic acid, benzoic acid, tannic acid, pamoic acid, citric, methylsulfonic, ethanesulfonic, benzenesulfonic, formic and the like (Handbook of Pharmaceutical Salts, P. Heinrich Stahal & Camille G. Wermuth (Eds), Verlag Helvetica Chemica Acta-Zürich, 2002, 329-345).
[0142] Compounds of Formula I and their salts can be in the form of a solvate, which is included within the scope of the present invention. Such solvates include for example hydrates, alcoholates and the like.
[0143] With respect to the present invention reference to a compound or compounds, is intended to encompass that compound in each of its possible isomeric forms and mixtures thereof unless the particular isomeric form is referred to specifically.
[0144] Compounds according to the present invention may exist in different polymorphic forms. Although not explicitly indicated in the above formula, such forms are intended to be included within the scope of the present invention.
[0145] The compounds of the invention are indicated for use in treating or preventing conditions in which there is likely to be a component involving the sphingosine-1-phosphate receptors.
[0146] In another embodiment, there are provided pharmaceutical compositions including at least one compound of the invention in a pharmaceutically acceptable carrier.
[0147] In a further embodiment of the invention, there are provided methods for treating disorders associated with modulation of sphingosine-1-phosphate receptors. Such methods can be performed, for example, by administering to a subject in need thereof a pharmaceutical composition containing a therapeutically effective amount of at least one compound of the invention.
[0148] These compounds are useful for the treatment of mammals, including humans, with a range of conditions and diseases that are alleviated by S1P modulation: not limited to the treatment of diabetic retinopathy, other retinal degenerative conditions, dry eye, angiogenesis and wounds.
[0149] Therapeutic utilities of S1P modulators are ocular diseases, such as but not limited to: wet and dry age-related macular degeneration, diabetic retinopathy, retinopathy of prematurity, retinal edema, geographic atrophy, glaucomatous optic neuropathy, chorioretinopathy, hypertensive retinopathy, ocular ischemic syndrome, prevention of inflammation-induced fibrosis in the back of the eye, various ocular inflammatory diseases including uveitis, scleritis, keratitis, and retinal vasculitis; or systemic vascular barrier related diseases such as but not limited to: various inflammatory diseases, including acute lung injury, its prevention, sepsis, tumor metastasis, atherosclerosis, pulmonary edemas, and ventilation-induced lung injury; or autoimmune diseases and immunosuppression such as but not limited to: rheumatoid arthritis, Crohn's disease, Graves' disease, inflammatory bowel disease, multiple sclerosis, Myasthenia gravis, Psoriasis, ulcerative colitis, antoimmune uveitis, renal ischemia/perfusion injury, contact hypersensitivity, atopic dermititis, and organ transplantation; or allergies and other inflammatory diseases such as but not limited to: urticaria, bronchial asthma, and other airway inflammations including pulmonary emphysema and chronic obstructive pulmonary diseases; or cardiac protection such as but not limited to: ischemia reperfusion injury and atherosclerosis; or wound healing such as but not limited to: scar-free healing of wounds from cosmetic skin surgery, ocular surgery, GI surgery, general surgery, oral injuries, various mechanical, heat and burn injuries, prevention and treatment of photoaging and skin ageing, and prevention of radiation-induced injuries; or bone formation such as but not limited to: treatment of osteoporosis and various bone fractures including hip and ankles; or anti-nociceptive activity such as but not limited to: visceral pain, pain associated with diabetic neuropathy, rheumatoid arthritis, chronic knee and joint pain, tendonitis, osteoarthritis, neuropathic pains; or central nervous system neuronal activity in Alzheimer's disease, age-related neuronal injuries; or in organ transplant such as renal, corneal, cardiac or adipose tissue transplant.
[0150] In still another embodiment of the invention, there are provided methods for treating disorders associated with modulation of sphingosine-1-phosphate receptors. Such methods can be performed, for example, by administering to a subject in need thereof a therapeutically effective amount of at least one compound of the invention, or any combination thereof, or pharmaceutically acceptable salts, hydrates, solvates, crystal forms and individual isomers, enantiomers, and diastereomers thereof.
[0151] The present invention concerns the use of a compound of Formula I or a pharmaceutically acceptable salt thereof, for the manufacture of a medicament for the treatment of ocular disease, wet and dry age-related macular degeneration, diabetic retinopathy, retinopathy of prematurity, retinal edema, geographic atrophy, glaucomatous optic neuropathy, chorioretinopathy, hypertensive retinopathy, ocular ischemic syndrome, prevention of inflammation-induced fibrosis in the back of the eye, various ocular inflammatory diseases including uveitis, scleritis, keratitis, and retinal vasculitis; or systemic vascular barrier related diseases, various inflammatory diseases, including acute lung injury, its prevention, sepsis, tumor metastasis, atherosclerosis, pulmonary edemas, and ventilation-induced lung injury; or autoimmune diseases and immunosuppression, rheumatoid arthritis, Crohn's disease, Graves' disease, inflammatory bowel disease, multiple sclerosis, Myasthenia gravis, Psoriasis, ulcerative colitis, antoimmune uveitis, renal ischemia/perfusion injury, contact hypersensitivity, atopic dermititis, and organ transplantation; or allergies and other inflammatory diseases, urticaria, bronchial asthma, and other airway inflammations including pulmonary emphysema and chronic obstructive pulmonary diseases; or cardiac protection, ischemia reperfusion injury and atherosclerosis; or wound healing, scar-free healing of wounds from cosmetic skin surgery, ocular surgery, GI surgery, general surgery, oral injuries, various mechanical, heat and burn injuries, prevention and treatment of photoaging and skin ageing, and prevention of radiation-induced injuries; or bone formation, treatment of osteoporosis and various bone fractures including hip and ankles; or anti-nociceptive activity, visceral pain, pain associated with diabetic neuropathy, rheumatoid arthritis, chronic knee and joint pain, tendonitis, osteoarthritis, neuropathic pains; or central nervous system neuronal activity in Alzheimer's disease, age-related neuronal injuries; or in organ transplant such as renal, corneal, cardiac or adipose tissue transplant.
[0152] The actual amount of the compound to be administered in any given case will be determined by a physician taking into account the relevant circumstances, such as the severity of the condition, the age and weight of the patient, the patient's general physical condition, the cause of the condition, and the route of administration.
[0153] The patient will be administered the compound orally in any acceptable form, such as a tablet, liquid, capsule, powder and the like, or other routes may be desirable or necessary, particularly if the patient suffers from nausea. Such other routes may include, without exception, transdermal, parenteral, subcutaneous, intranasal, via an implant stent, intrathecal, intravitreal, topical to the eye, back to the eye, intramuscular, intravenous, and intrarectal modes of delivery. Additionally, the formulations may be designed to delay release of the active compound over a given period of time, or to carefully control the amount of drug released at a given time during the course of therapy.
[0154] In another embodiment of the invention, there are provided pharmaceutical compositions including at least one compound of the invention in a pharmaceutically acceptable carrier therefor. The phrase “pharmaceutically acceptable” means the carrier, diluent or excipient must be compatible with the other ingredients of the formulation and not deleterious to the recipient thereof.
[0155] Pharmaceutical compositions of the present invention can be used in the form of a solid, a solution, an emulsion, a dispersion, a micelle, a liposome, and the like, wherein the resulting composition contains one or more compounds of the present invention, as an active ingredient, in admixture with an organic or inorganic carrier or excipient suitable for enteral or parenteral applications. Invention compounds may be combined, for example, with the usual non-toxic, pharmaceutically acceptable carriers for tablets, pellets, capsules, suppositories, solutions, emulsions, suspensions, and any other form suitable for use. The carriers which can be used include glucose, lactose, gum acacia, gelatin, mannitol, starch paste, magnesium trisilicate, talc, corn starch, keratin, colloidal silica, potato starch, urea, medium chain length triglycerides, dextrans, and other carriers suitable for use in manufacturing preparations, in solid, semisolid, or liquid form. In addition auxiliary, stabilizing, thickening and coloring agents and perfumes may be used. Invention compounds are included in the pharmaceutical composition in an amount sufficient to produce the desired effect upon the process or disease condition.
[0156] Pharmaceutical compositions containing invention compounds may be in a form suitable for oral use, for example, as tablets, troches, lozenges, aqueous or oily suspensions, dispersible powders or granules, emulsions, hard or soft capsules, or syrups or elixirs. Compositions intended for oral use may be prepared according to any method known to the art for the manufacture of pharmaceutical compositions and such compositions may contain one or more agents selected from the group consisting of a sweetening agent such as sucrose, lactose, or saccharin, flavoring agents such as peppermint, oil of wintergreen or cherry, coloring agents and preserving agents in order to provide pharmaceutically elegant and palatable preparations. Tablets containing invention compounds in admixture with non-toxic pharmaceutically acceptable excipients may also be manufactured by known methods. The excipients used may be, for example, (1) inert diluents such as calcium carbonate, lactose, calcium phosphate or sodium phosphate; (2) granulating and disintegrating agents such as corn starch, potato starch or alginic acid; (3) binding agents such as gum tragacanth, corn starch, gelatin or acacia, and (4) lubricating agents such as magnesium stearate, stearic acid or talc. The tablets may be uncoated or they may be coated by known techniques to delay disintegration and absorption in the gastrointestinal tract and thereby provide a sustained action over a longer period. For example, a time delay material such as glyceryl monostearate or glyceryl distearate may be employed.
[0157] In some cases, formulations for oral use may be in the form of hard gelatin capsules wherein the invention compounds are mixed with an inert solid diluent, for example, calcium carbonate, calcium phosphate or kaolin. They may also be in the form of soft gelatin capsules wherein the invention compounds are mixed with water or an oil medium, for example, peanut oil, liquid paraffin, or olive oil.
[0158] The pharmaceutical compositions may be in the form of a sterile injectable suspension. This suspension may be formulated according to known methods using suitable dispersing or wetting agents and suspending agents. The sterile injectable preparation may also be a sterile injectable solution or suspension in a non-toxic parenterally-acceptable diluent or solvent, for example, as a solution in 1,3-butanediol. Sterile, fixed oils are conventionally employed as a solvent or suspending medium. For this purpose any bland fixed oil may be employed including synthetic mono- or diglycerides, fatty acids (including oleic acid), naturally occurring vegetable oils like sesame oil, coconut oil, peanut oil, cottonseed oil, etc., or synthetic fatty vehicles like ethyl oleate or the like. Buffers, preservatives, antioxidants, and the like can be incorporated as required.
[0159] Invention compounds may also be administered in the form of suppositories for rectal administration of the drug. These compositions may be prepared by mixing the invention compounds with a suitable non-irritating excipient, such as cocoa butter, synthetic glyceride esters of polyethylene glycols, which are solid at ordinary temperatures, but liquify and/or dissolve in the rectal cavity to release the drug.
[0160] Since individual subjects may present a wide variation in severity of symptoms and each drug has its unique therapeutic characteristics, the precise mode of administration and dosage employed for each subject is left to the discretion of the practitioner.
[0161] The compounds and pharmaceutical compositions described herein are useful as medicaments in mammals, including humans, for treatment of diseases and or alleviations of conditions which are responsive to treatment by agonists or functional antagonists of sphingosine-1-phosphate receptors. Thus, in further embodiments of the invention, there are provided methods for treating a disorder associated with modulation of sphingosine-1-phosphate receptors. Such methods can be performed, for example, by administering to a subject in need thereof a pharmaceutical composition containing a therapeutically effective amount of at least one invention compound. As used herein, the term “therapeutically effective amount” means the amount of the pharmaceutical composition that will elicit the biological or medical response of a subject in need thereof that is being sought by the researcher, veterinarian, medical doctor or other clinician. In some embodiments, the subject in need thereof is a mammal. In some embodiments, the mammal is human.
[0162] The present invention concerns also processes for preparing the compounds of Formula I. The compounds of formula I according to the invention can be prepared analogously to conventional methods as understood by the person skilled in the art of synthetic organic chemistry. The synthetic scheme set forth below, illustrates how compounds according to the invention can be made. Those skilled in the art will be able to routinely modify and/or adapt the following scheme to synthesize any compounds of the invention covered by Formula I.
[0000]
[0163] In Scheme 1, the commercially available carboxylic acid was esterified followed by a Suzuki coupling with available aryl boronic acids to give rise to the biaryl methoxy ester. Demethylation and re-esterification resulted in the corresponding phenolic ester, which was converted to a triflate.
[0000]
[0164] In Scheme 2, Sonogashira coupling followed by reduction of the resulting alkyne afforded the substituted aryl halide. Conversion to the boronic acid followed Suzuki coupling with the resulting aryl triflate from Scheme 1 afforded the desired triaryl ester.
[0000]
[0165] In Scheme 3, the desired final compound of Formula I, was afforded in three final steps from the triaryl ester. Reduction of the ester to the alcohol and subsequent oxidation afforded the corresponding aldehyde. Reductive amination of this aldehyde yielded the final product.
DETAILED DESCRIPTION OF THE INVENTION
[0166] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory only and are not restrictive of the invention claimed. As used herein, the use of the singular includes the plural unless specifically stated otherwise.
[0167] It will be readily apparent to those skilled in the art that some of the compounds of the invention may contain one or more asymmetric centers, such that the compounds may exist in enantiomeric as well as in diastereomeric forms. Unless it is specifically noted otherwise, the scope of the present invention includes all enantiomers, diastereomers and racemic mixtures. Some of the compounds of the invention may form salts with pharmaceutically acceptable acids or bases, and such pharmaceutically acceptable salts of the compounds described herein are also within the scope of the invention.
[0168] The present invention includes all pharmaceutically acceptable isotopically enriched compounds. Any compound of the invention may contain one or more isotopic atoms enriched or different than the natural ratio such as deuterium 2 H (or D) in place of hydrogen 1 H (or H) or use of 13 C enriched material in place of 12 C and the like. Similar substitutions can be employed for N, O and S. The use of isotopes may assist in analytical as well as therapeutic aspects of the invention. For example, use of deuterium may increase the in vivo half-life by altering the metabolism (rate) of the compounds of the invention. These compounds can be prepared in accord with the preparations described by use of isotopically enriched reagents.
[0169] The following examples are for illustrative purposes only and are not intended, nor should they be construed as limiting the invention in any manner. Those skilled in the art will appreciate that variations and modifications of the following examples can be made without exceeding the spirit or scope of the invention.
[0170] As will be evident to those skilled in the art, individual isomeric forms can be obtained by separation of mixtures thereof in conventional manner. For example, in the case of diasteroisomeric isomers, chromatographic separation may be employed.
[0171] The IUPAC names of the compounds mentioned in the examples were generated with ACD version 8.
[0172] Unless specified otherwise in the examples, characterization of the compounds is performed according to the following methods:
[0173] NMR spectra are recorded on 300 or 600 MHz Varian and acquired at room temperature. Chemical shifts are given in ppm referenced either to internal trimethylsilyl or to the residual solvent signal.
[0174] All the reagents, solvents, catalysts for which the synthesis is not described are purchased from chemical vendors such as Sigma Aldrich, Fluka, Bio-Blocks, Ryan Scientific, Syn Chem, Chem-Impex, Aces Pharma, however some known intermediates, for which the CAS registry number [CAS #] are mentioned, were prepared in-house following known procedures.
[0175] Usually the compounds of the invention were purified by flash column chromatography using a gradient solvent system of methanol/dichloromethane unless otherwise reported.
[0176] The following abbreviations are used in the examples:
[0177] DMF N,N-dimethylformamide
[0178] NaOH sodium hydroxide
[0179] CD 3 OD deuterated methanol
[0180] HCl hydrochloric acid
[0181] CDCl 3 deuterated chloroform
[0182] DMSO-d 6 deuterated dimethyl sulfoxide
[0183] CDl 1,1′-carbonyldiimidazole
[0184] Et 2 Zn diethylzinc
[0185] NH 4 Cl ammonium chloride
[0186] CH 2 Cl 2 dichloromethane
[0187] K 2 CO 3 potassium carbonate
[0188] MPLC medium pressure liquid chromatography
[0189] THF tetrahydrofuran
[0190] [IrCl(cod)] 2 di-μ-chlorobis(1,5-cyclooctadiene)diiridium(I)
[0191] ClCH 2 I chloroiodomethane
[0192] RT room temperature
[0193] MeOH methanol
[0194] DMAP 4-Dimethylaminopyridine
[0195] MgSO 4 magnesium sulfate
[0196] LiCl lithium chloride
[0197] DIBAL-H Diisobutylaluminium hydride
[0198] NMO N-Methylmorpholine-N-Oxide
[0199] LDA Lithium diisopropylamide
[0200] MTBE Methyl tert-butyl ether
[0201] Na 2 SO 4 sodium sulfate
[0202] dppp 1,3-Bis(diphenylphosphino)propane
[0203] Those skilled in the art will be able to routinely modify and/or adapt the following schemes to synthesize any compound of the invention covered by Formula I.
[0204] Some compounds of this invention can generally be prepared in one step from commercially available literature starting materials.
Example 1
Intermediate 1
Methyl 6-methoxybiphenyl-3-carboxylate
[0205] To a solution of methyl 3-bromo-4-methoxybenzoate (13 g, 53 mmol) in toluene (500 mL), methanol (65 mL), and water (106 mL) was added phenyl boronic acid (7.8 g, 63.6 mmol) and potassium carbonate (14.6 g, 106 mmol) and bubbled with argon for 6 min. Tetrakis(triphenylphosphine)palladium(0) (370 mg) was added and bubbled with argon for another 2 min. The reaction mixture was then heated to 95° C. for 20 h with stirring. After cooling to RT, the two phases were separated and the aqueous layer was extracted with ether, dried with magnesium sulfate, and concentrated. Purification by MPLC (5% ethyl acetate in hexanes) gave 12.2 g of the desired product as an off white solid.
Example 2
Intermediate 2
Methyl 6-{[(trifluoromethyl)sulfonyl]oxy}biphenyl-3-carboxylate
[0206] To a solution of Intermediate 1 (12.2 g, 50.4 mmol) in dichloromethane (200 mL) at −78° C. was added boron tribromide (100 mL, 1M in dichloromethane) dropwise with stirring. The reaction mixture was warmed to RT and stirred for 16 h, after which time, the reaction mixture was cooled to −78° C. and boron tribromide (20 mL, 1M in dichloromethane) was added and stirred at RT for another 6 h. Cooling to −10° C., the reaction mixture was quenched with a saturated solution of sodium bicarbonate. The layers were separated and the aqueous layer was acidified with 1N HCl. Extraction of the aqueous layer with ethyl acetate followed by combination of the organic layers, washed with brine, dried with magnesium sulfate, and concentrated to afford 6 g corresponding phenolic acid as colorless foam.
[0207] A solution of the resulting carboxylic acid (6 g, 26.3 mmol) in MeOH (80 mL) was added and fuming sulfuric acid (3 mL) dropwise. After heating to 80° C. for 16 h, the reaction mixture was cooled to RT and concentrated under reduced pressure. The residue was diluted with water and extracted with ethyl acetate, dried over magnesium sulfate and concentrated under reduced pressure to give 5.17 g desired phenolic ester.
[0208] To a solution of the resulting phenolic ester (5.17 g, 22.6 mmol) in dichloromethane (500 mL) was added N-(5-chloro-2-pyridyl)bis(trifluoromethanesulfonimide) (13.3 g, 34 mmol) and DMAP (5.5 g, 45.2 mmol) with stirring. After 16 h at RT, the reaction mixture was quenched with water. The aqueous layer was extracted with ethyl acetate, dried (MgSO 4 ), and concentrated under reduced pressure. Purification by MPLC (5% ethyl acetate in hexanes) gave rise to 6.67 g of the title compound as a colorless oil.
[0209] 1 H NMR (300 MHz, CDCl 3 ) δ 8.19 (d, J=2.05 Hz, 1H), 8.11 (dd, J=2.20, 8.64 Hz, 1H), 7.46-7.50 (m, 6H), 3.96 (s, 3H).
Example 3
Intermediate 3
Methyl 4-hexyl-1,1′:2′,1″-terphenyl-4′-carboxylate
[0210] To a solution of aryl bromide (2.8 g, 11.6 mmol) in THF (100 mL) at −78° C. was added t-butyllithium (1.7 M in pentane, 13.8 mL) slowly dropwise. After stirring at −78° C. for 1 h, trimethyl borate (2.63 mL, 23.56 mmol) was added. The reaction mixture was warmed to RT over 2 h. After stirring at RT for 15 min, the reaction mixture was quenched with saturated solution of ammonium chloride and extracted with ethyl acetate. The combined organic layers were washed with HCl (10% solution), brine, and dried (MgSO 4 ), filtered, and concentrated under reduce pressure to give 2.22 g boronic acid. A solution of the resulting boronic acid (2.22 g) and Intermediate 2 (3.8 g, 10.7 mmol) in toluene (200 mL) were added potassium carbonate (2.95 g, 21.4 mmol) and LiCl (454 mg) with stirring. After bubbling with Ar for 10 min, tetrakis(triphenylphosphine) palladium(0) (370 mg) was added and heated to 95° C. for 16 h. After the reaction mixture was cooled to RT, it was diluted with water and extracted with ethyl acetate. The combined organic layers were washed with brine, and dried (MgSO 4 ), filtered, and concentrated under reduce pressure. The residue was purified by MPLC (0-10% ethyl acetate in hexanes) gave 2.32 g of ester as a colorless oil.
[0211] 1 H NMR (300 MHz, CDCl 3 ) δ 8.09 (d, J=1.76 Hz, 1H), 8.05 (dd, J=1.76, 7.91 Hz, 1H), 7.50 (d, J=7.91 Hz, 1H), 7.20-7.24 (m, 3H), 7.13-7.17 (m, 2H), 7.04 (s, 4H), 3.94 (s, 3H), 2.56 (t, J=7.62 Hz, 2H), 1.53-1.63 (m, 2H), 1.25-1.33 (m, 6H), 0.88 (t, J=6.45 Hz, 3H)
[0212] Intermediates 4-8 were prepared from Intermediate 2 and the corresponding aryl bromide derivatives, in a similar manner to the method described in Example 3 for Intermediate 3. The results are described below in Table 1.
[0000]
TABLE 1
Interm.
number
IUPAC name
1 H NMR δ (ppm) for Intermediate
4
Methyl-4-octyl-1,1′:2′,1″-
1 H NMR (300 MHz, CDCl 3 ) δ 8.10 (d, J = 1.76 Hz,
terphenyl-4′-carboxylate
1H), 8.05 (dd, J = 1.76, 7.91 Hz, 1H),
7.49 (d, J = 7.91 Hz, 1H), 7.20-7.25 (m, 3H),
7.12-7.17 (m, 3H), 7.03 (s, 4H), 3.94 (s, 3H),
2.52-2.58 (m, 2H), 1.53-1.62 (m, 2H), 1.28 (d, J = 5.57 Hz,
10H), 0.88 (t, J = 6.45 Hz, 3H)
5
Methyl-6-(6-hexylpyridin-
1 H NMR (300 MHz, CDCl 3 ) δ 8.34-8.40 (m, J = 0.59,
3-yl)biphenyl-3-
2.34 Hz, 1H), 8.12 (d, J = 1.47 Hz, 1H),
carboxylate
8.09 (dd, J = 1.76, 7.91 Hz, 1H), 7.49 (d, J = 7.91 Hz,
2H), 7.11-7.29 (m, 5H), 6.97 (d, J = 8.20 Hz,
1H), 3.95 (s, 3H), 2.75 (t, J = 7.62 Hz,
2H), 1.64-1.74 (m, 2H), 1.26-1.36 (m, 6H),
0.87 (t, J = 6.74 Hz, 3H)
6
Methyl-6-(6-octylpyridin-
1 H NMR (300 MHz, CDCl 3 ) δ 8.37 (dd, J = 0.88,
3-yl)biphenyl-3-
2.34 Hz, 3H), 8.08-8.13 (m, 2H), 7.49 (d, J = 7.91 Hz,
carboxylate
1H), 7.22-7.29 (m, 4H),
7.12-7.15 (m, 2H), 6.97 (dd, J = 0.59, 7.91 Hz, 1H),
3.95 (s, 3H), 2.74 (dd, J = 7.60 Hz, 2H),
1.64-1.74 (m, 2H), 1.23-1.35 (m, 10H), 0.88 (t, J = 6.45 Hz,
3H)
7
Methyl-4-
1 H NMR (300 MHz, CDCl 3 ) δ 8.04-8.11 (m,
(3,3,4,4,5,5,6,6,6-
2H), 7.48 (d, J = 7.91 Hz, 2H), 7.21-7.25 (m,
nonafluorohexyl)-
3H), 7.11-7.17 (m, 2H), 7.09 (s, 3H), 3.94 (s,
1,1′:2′,1″-terphenyl-4′-
3H), 2.85-2.91 (m, 2H), 2.26-2.44 (m, 2H)
carboxylate
8
Methyl-4-(3-
1 H NMR (300 MHz, CDCl 3 ) δ 8.10 (d, J = 1.47 Hz,
phenylpropyl)-1,1′:2′,1″-
1H), 8.05 (dd, J = 1.76, 7.91 Hz, 1H),
terphenyl-4′-carboxylate
7.46-7.51 (m, 2H), 7.13-7.31 (m, 9H), 7.04 (s, 4H),
3.94 (s, 3H), 2.61 (t, J = 7.62 Hz, 4H),
1.88-1.98 (m, 2H)
Example 4
Intermediate 9
Ethyl 6-(2-furyl)-5-(4-hexylphenyl)pyridine-2-carboxylate
[0213] To a solution of methyl 3-propyl-4-{[(trifluoromethyl)sulfonyl]oxy}benzoate (2.09 g, 7.11 mmol) and 1-hexyne (1.12 mL) in DMF (17.5 mL) and triethyl amine (3.5 mL) was added dppp (100 mg, 0.14 mmol). After heating to 95° C. with stirring for 16 h, the reaction mixture was cooled to RT, diluted with diethyl ether and washed with water. The ethereal layer was washed with brine, and dried (MgSO 4 ), filtered, and concentrated under reduce pressure. The residue was purified by MPLC (3% ethyl acetate in hexanes) to give 11.9 g ethyl 6-(2-furyl)-5-(4-hexylphenyl)pyridine-2-carboxylate as a brown oil.
[0214] 1 H NMR (300 MHz, CDCl 3 ) δ 7.84 (d, J=1.76 Hz, 1H), 7.77 (dd, J=1.61, 8.06 Hz, 1H), 7.41 (d, J=7.91 Hz, 1H), 3.90 (s, 3H), 2.77 (t, J=7.91 Hz, 2H), 2.47 (t, J=6.70 Hz, 2H), 1.44-1.74 (m, 6H), 0.96 (t, J=7.33 Hz, 6H).
Example 5
Intermediate 10
Methyl 4-hexyl-3-propylbenzoate
[0215] To a solution of Intermediate 9 (2.5 g, 9.7 mmol) in ethanol (110 mL) was added palladium hydroxide on carbon (20% wt on carbon, 700 mg). After stirring at RT under hydrogen balloon atmosphere for 16 h, the reaction mixture was filtered through celite and concentrated under reduced pressure. Filtration through a short plug of silica gel afforded 4.7 g of methyl 4-hexyl-3-propylbenzoate as a brown oil.
[0216] 1 H NMR (300 MHz, CDCl 3 ) δ 7.82 (d, J=1.47 Hz, 1H), 7.78 (dd, J=1.76, 7.91 Hz, 1H), 7.20 (d, J=7.91 Hz, 1H), 3.89 (s, 3H), 2.59-2.67 (m, 4H), 1.52-1.69 (m, 4H), 1.22-1.41 (m, 6H), 0.99 (t, J=7.33 Hz, 3H), 0.89 (t, J=6.45 Hz, 3H)
Example 6
Intermediate 11
(4-hexyl-3-propylphenyl)methanol
[0217] To a solution of Intermediate 10 6.4 g, 24.4 mmol) in dichloromethane (230 mL) at −78° C. was added DIBAL-H (1.0 M in dichloromethane, 58.6 mL, 58.6 mmol). The reaction was warmed to RT over for 20 h with stirring and was quenched at −10° C. with methanol and 10% solution of HCl. The mixture was diluted with water and the aqueous layer was extracted with ethyl acetate. The combined organic layers were washed with brine, dried over MgSO 4 , and concentrated under reduced pressure to afford 5.4 g of (4-hexyl-3-propylphenyl)methanol as a yellow oil.
[0218] 1 H NMR (300 MHz, CDCl 3 ) δ 7.11-7.18 (m, 3H), 4.63 (s, 2H), 2.59 (td, J=1.32, 7.84 Hz, 4H), 1.50-1.68 (m, 4H), 1.22-1.40 (m, 6H), 0.99 (t, J=7.33 Hz, 3H), 0.89 (t, J=6.74 Hz, 3H)
Example 7
Intermediate 12
4-hexyl-3-propylbenzaldehyde
[0219] To a solution of Intermediate 11 (4.1 g, 17.5 mmol), NMO (5.1 g, 43 mmol), and 4 A molecular sieves (4 g) in dichloromethane (170 mL) and acetonitrile (22 mL) was added tetrapropylammonium perruthenate (TPAP, 320 mg). After stirring at RT for 2 h, the reaction mixture was filtered through a short column of silica gel, eluted with ethyl acetate and concentrated under reduced pressure. Purification by MPLC (0-20% ethyl acetate in hexanes) gave rise to 2.96 g 4-hexyl-3-propylbenzaldehyde as a yellow oil.
[0220] 1 H NMR (300 MHz, CDCl 3 ) δ 9.95 (s, 1H), 7.66 (d, J=1.47 Hz, 1H), 7.63 (dd, J=1.80, 7.62 Hz, 1H), 7.30 (d, J=7.62 Hz, 1H), 2.63-2.70 (m, 4H), 1.54-1.71 (m, 4H), 1.26-1.43 (m, 6H), 1.00 (t, J=7.33 Hz, 3H), 0.90 (t, J=6.70 Hz, 3H)
Example 8
Intermediate 13
(2E)-3-(4-hexyl-3-propylphenyl)acrylaldehyde
[0221] To a solution of LDA (1.5M in cyclohexane, 9 mL, 13.5 mmol) in THF (28 mL) at 0° C., was added a solution of 2-methyl-N-[2-(triethylsilyl)ethylidene]-2-propanamine (2.9 g, 13.5 mmol) in THF (6 mL) dropwise and stirred for 30 min. The reaction mixture was cooled to −78° C. and a solution of Intermediate 12 (2.6 g, 12.3 mmol) in THF (6 mL) was added dropwise. After warming to RT over 3.5 h, the reaction mixture was quenched with citric acid (20% solution, 40 mL) and stirred for another 16 h. The mixture was washed with brine, extracted with diethyl ether, dried over MgSO 4 , and concentrated under reduced pressure. Purification of the crude product by MPLC (10% ethyl acetate in hexanes) afforded 3.8 g (2E)-3-(4-hexyl-3-propylphenyl)acrylaldehyde
[0222] 1 H NMR (300 MHz, CDCl 3 ) δ 9.68 (d, J=7.91 Hz, 1H), 7.44 (d, J=16.12 Hz, 1H), 7.31-7.36 (m, 2H), 7.20 (d, J=8.50 Hz, 1H), 6.69 (dd, J=7.62, 15.82 Hz, 1H), 2.59-2.66 (m, 4H), 1.52-1.69 (m, 4H), 1.28-1.43 (m, 6H), 1.00 (t, J=7.33 Hz, 3H), 0.90 (t, J=6.74 Hz, 3H)
Example 9
Intermediate 14
(2E)-3-[4-(3-phenylpropyl)phenyl]acrylaldehyde
[0223] To a solution of 1-bromo-4-(3-phenylpropyl)-benzene (684 mg, 2.48 mmol) in DMF (10 mL) were added acrolein diethyl acetal (1.7 mL, 11.1 mmol), tetrabutylammonium acetate (1.87 g, 6.2 mmol), potassium carbonate (514 mg, 3.72 mmol), potassium chloride (185 mg, 2.48 mmol), and palladium(II) acetate (50 mg, 0.22 mmol). After stirring at 90° C. for 4 h, the reaction mixture was cooled to RT and HCl (2M, 15 mL) was added. After stirring for 10 min at RT, the mixture was extracted with MTBE and washed with water and brine, dried over MgSO 4 and concentrated under reduced pressure. Purification by MPLC (20% ethyl acetate in hexanes) gave 390 mg (2E)-3-[4-(3-phenylpropyl)phenyl]acrylaldehyde as a yellow oil.
[0224] 1 H NMR (300 MHz, CDCl 3 ) δ 9.69 (d, J=7.62 Hz, 1H), 7.42-7.51 (m, 3H), 7.16-7.32 (m, 7H), 6.69 (dd, J=7.62, 15.82 Hz, 1H), 2.67 (q, J=8.20 Hz, 4H), 1.91-2.03 (m, 2H)
Example 10
Intermediate 15
ethyl (2Z,4E)-2-azido-5-(4-hexyl-3-propylphenyl)penta-2,4-dienoate
[0225] To a freshly prepared solution of sodium ethoxide (76 mmol) at −10° C. was added a solution of ethyl azidoacetate (25% in ethanol, 39.2 mL, 76 mmol) followed by a solution of Intermediate 13 (3.25 g, 12.6 ml) in ethanol (45 mL). After stirring for 1 h at −10° C., the reaction mixture was quenched with water and brine and extracted with ethyl acetate. The combined organic layers were washed with water and brine, dried over MgSO4, and concentrated under reduced pressure. Purification by MPLC (10% ethyl acetate in hexanes) gave rise to 1.65 g ethyl (2Z,4E)-2-azido-5-(4-hexyl-3-propylphenyl)penta-2,4-dienoate as a yellow oil.
[0226] 1 H NMR (300 MHz, CDCl 3 ) δ 7.23-7.26 (m, 2H), 7.11 (s, 2H), 6.73-6.81 (m, 2H), 4.33 (q, J=7.13 Hz, 2H), 2.59 (t, J=7.91 Hz, 2H), 2.59 (t, J=7.91 Hz, 2H), 1.51-1.68 (m, 4H), 1.37 (t, J=7.18 Hz, 3H), 1.24-1.43 (m, 6H), 1.00 (t, J=7.33 Hz, 3H), 0.90 (t, J=7.00 Hz, 3H).
[0227] Intermediates 16-18 were prepared from the corresponding starting materials, in a similar manner to the method described in Example 10 for Intermediate 15. The starting materials used and the results are described below in Table 2.
[0000]
TABLE 2
Interm.
Starting
1 H NMR δ (ppm) for
number
IUPAC name
Materials
Intermediate
16
ethyl (2Z,4E)-2-azido-
2-Propenal,
1 H NMR (300 MHz, CDCl 3 ) δ
5-(4-
3-(4-hexyl
7.40 (d, J = 7.91 Hz, 2H), 7.07-7.18 (m,
hexylphenyl)penta-
phenyl)-
3H), 6.80 (d, J = 15.53 Hz, 1H),
2,4-dienoate
CAS313690-31-2
6.75 (dd, J = 1.17, 11.14 Hz, 1H),
4.33 (q, J = 7.23 Hz, 2H), 2.60 (t, J = 7.60 Hz,
2H), 1.57-1.65 (m, 2H),
1.37 (t, J = 7.18 Hz, 3H),
1.24-1.38 (m, 6H), 0.88 (t, J = 7.03 Hz,
3H)
17
ethyl (2Z,4E)-2-azido-
Intermediate 14
1 H NMR (300 MHz, CDCl 3 ) δ
5-(4-(3-
7.40 (d, J = 8.21 Hz, 2H), 7.25-7.32 (m,
phenylpropyl)phenyl)penta-
2H), 7.08-7.22 (m, 6H),
2,4-dienoate
6.73-6.82 (m, 2H), 4.33 (q, J = 7.13 Hz,
2H), 2.65 (t, J = 7.62 Hz, 4H),
1.90-2.01 (m, 2H), 1.37 (t, J = 7.18 Hz,
3H)
18
ethyl (2Z,4E)-2-azido-
2-Propenal,
1 H NMR (300 MHz, CDCl 3 ) δ
5-(4-
3-[4-(pentyloxy)phenyl]-
7.39-7.44 (m, 2H), 7.02 (dd, J = 11.70,
pentyloxyphenyl)penta-
CAS 66049-89-6
14.94 Hz, 1H), 6.84-6.89 (m, 2H),
2,4-dienoate
6.73-6.79 (m, 2H), 4.32 (q, J = 7.13 Hz,
2H), 3.97 (t, J = 6.59 Hz,
2H), 1.74-1.84 (m, 2H),
1.36-1.48 (m, 4H), 1.38 (t, J = 7.20 Hz,
3H), 0.93 (t, J = 7.00 Hz, 3H)
Example 11
Intermediate 19
Ethyl(2Z,4E)-5-(4-hexyl-3-propylphenyl)-2-[(triphenylphosphoranylidene)amino]penta-2,4-dienoate
[0228] To a solution of Intermediate 15 (1.65 g, 4.47 mmol) in diethyl ether (22 mL) at 0° C. was added a solution of triphenylphosphine (1.17 g) in diethyl ether (11 mL). After stirring for 16 h at RT, the reaction mixture was concentrated under reduced pressure. Purification by MPLC (20% ethyl acetate in hexanes) gave 2.2 g ethyl (2Z,4E)-5-(4-hexyl-3-propylphenyl)-2-[(triphenylphosphoranylidene)amino]penta-2,4-dienoate as a yellow foam.
[0229] 1 H NMR (300 MHz, CDCl 3 ) δ 7.64-7.80 (m, 7H), 7.39-7.51 (m, 9H), 7.23 (s, 1H), 7.13 (d, J=7.91 Hz, 1H), 7.05 (d, J=8.20 Hz, 1H), 6.73 (dd, J=3.81, 11.14 Hz, 1H), 6.60 (d, J=15.82 Hz, 1H), 3.89 (q, J=7.13 Hz, 2H), 2.57 (t, J=7.91 Hz, 4H), 1.51-1.70 (m, 4H), 1.26-1.43 (m, 6H), 0.96-1.06 (m, 6H), 0.85-0.92 (m, 3H).
[0230] Intermediates 20-22 were prepared from the corresponding starting materials, in a similar manner to the method described in Example 11 for Intermediate 19. The starting materials and the results are described below in Table 3.
[0000]
TABLE 3
Interm.
Starting
1 H NMR δ (ppm) for
number
IUPAC name
materials
Intermediate
20
ethyl (2Z,4E)-5-[4-(3-
Intermediate 17
1 H NMR (300 MHz,
phenylpropyl)phenyl]-2-
CDCl 3 ) δ 7.40 (d, J = 7.91 Hz,
[(triphenylphosphoranylidene)amino]penta-
2H), 7.07-7.18 (m,
2,4-
3H), 6.80 (d, J = 15.53 Hz,
dienoate
1H), 6.75 (dd, J = 1.17,
11.14 Hz, 1H), 4.33 (q, J = 7.23 Hz,
2H), 2.60 (t, J = 7.60 Hz,
2H),
1.57-1.65 (m, 2H), 1.37 (t, J = 7.18 Hz,
3H), 1.24-1.38 (m,
6H), 0.88 (t, J = 7.03 Hz,
3H)
21
ethyl (2Z,4E)-5-(4-
Intermediate 16
1 H NMR (300 MHz,
hexylphenyl)-2-
CDCl 3 ) δ 7.71-7.80 (m,
[(triphenylphosphoranylidene)amino]penta-
6H), 7.66 (dd, J = 11.14,
2,4-
15.82 Hz, 1H),
dienoate
7.39-7.53 (m, 9H), 7.29 (d, J = 8.21 Hz,
2H), 7.10 (s, 2H),
6.72 (dd, J = 3.66, 10.70 Hz,
1H), 6.62 (d, J = 15.82 Hz,
1H), 3.90 (q, J = 7.13 Hz,
2H), 2.57 (t, J = 7.60 Hz,
2H), 1.54-1.65 (m, 2H),
1.25-1.37 (m, 6H),
1.04 (t, J = 7.18 Hz, 3H),
0.88 (t, J = 7.00 Hz, 3H)
22
ethyl(2Z,4E)-5-(4-pentyloxyphenyl)-
Intermediate 18
1 H NMR (300 MHz,
2-[(triphenylphosphoranylidene)amino]penta-
CDCl 3 ) δ 7.71-7.80 (m,
2,4-dienoate
6H), 7.39-7.60 (m, 10H),
7.29 (d, J = 8.50 Hz, 2H),
6.81 (d, J = 8.79 Hz, 2H),
6.72 (dd, J = 3.37,
10.99 Hz, 1H), 6.59 (d, J = 15.82 Hz,
1H), 3.96 (d, J = 13.19 Hz,
2H), 3.90 (q, J = 7.00 Hz,
2H), 1.73-1.83 (m,
2H), 1.32-1.50 (m, 4H),
1.04 (t, J = 7.18 Hz, 3H),
0.94 (t, J = 6.74 Hz, 3H)
Example 12
Intermediate 23
Ethyl 5-(4-hexylphenyl)-6-(3-thienyl)pyridine-2-carboxylate
[0231] To a solution of Intermediate 21 (766 mg, 1.36 mmol) in acetonitrile (20 mL) was added thiophene-3-carbaldehyde (0.12 mL, 1.36 mmol). After stirring at 65° C. for 16 h, the reaction mixture was concentrated under reduced pressure and purified by MPLC (10% ethyl acetate in hexanes) to afford 350 mg of ethyl 5-(4-hexylphenyl)-6-(3-thienyl)pyridine-2-carboxylate as a yellow oil.
[0232] 1 H NMR (300 MHz, CDCl 3 ) δ 7.97 (d, J=7.91 Hz, 1H), 7.67 (d, J=7.91 Hz, 1H), 7.06-7.14 (m, 5H), 7.00-7.05 (m, 2H), 4.41 (q, J=7.03 Hz, 2H), 2.56 (t, J=7.91 Hz, 2H), 1.45-1.66 (m, 2H), 1.38 (t, J=7.03 Hz, 3H), 1.17-1.32 (m, 6H), 0.77-0.84 (m, 3H).
[0233] Intermediates 24-39 were prepared from the corresponding starting materials, in a similar manner to the method described in Example 12 for Intermediate 23. The starting materials and the results are described below in Table 4.
[0000]
TABLE 4
1 H NMR δ (ppm) for
Interm. number
IUPAC name
Starting material
Intermediate
24
Ethyl-5-(4-hexylphenyl)-
Intermediate 21
1 H NMR (300 MHz, CDCl 3 )
6-phenylpyridine-2-
Benzaldehyde
δ 8.10 (d, J = 8.20 Hz, 1H),
carboxylate
CAS 100-52-7
7.83 (d, J = 7.91 Hz, 1H),
7.38-7.42 (m, 2H),
7.20-7.26 (m, 2H), 7.08 (s, 5H),
4.49 (q, J = 7.23 Hz, 2H),
2.56-2.61 (m, 2H),
1.54-1.64 (m, 2H), 1.45 (t, J = 7.18 Hz,
3H),
1.25-1.35 (m, 6H), 0.88 (t, J = 6.70 Hz,
3H)
25
Ethyl-5-(4-hexyl-3-
Intermediate 19
1 H NMR (300 MHz, CDCl 3 )
propylphenyl)-6-
Benzaldehyde
δ 8.09 (d, J = 7.91 Hz, 1H),
phenylpyridine-2-
CAS 100-52-7
7.83 (d, J = 7.91 Hz, 1H),
carboxylate
7.38-7.42 (m, 2H),
7.19-7.24 (m, 3H), 7.07 (d, J = 7.91 Hz,
1H), 6.97 (dd, J = 2.05,
7.62 Hz, 1H), 6.89 (s,
1H), 4.48 (q, J = 7.23 Hz,
2H), 2.57 (t, J = 7.60 Hz,
2H), 2.45 (t, J = 7.80 Hz,
2H), 1.50-1.65 (m, 2H),
1.40-1.48 (m, J = 7.18,
7.18 Hz, 3H),
1.24-1.48 (m, 8H), 0.89 (t, J = 6.45 Hz,
3H), 0.82 (t, J = 7.33 Hz,
3H)
26
Ethyl-6-(3-chlorophenyl)-
Intermediate 19
1 H NMR (300 MHz, CDCl 3 )
5-(4-hexyl-3-propyl
3-chloro-
δ 8.12 (d, J = 8.20 Hz, 1H),
phenyl)pyridine-2-
benzaldehyde
7.85 (d, J = 7.91 Hz, 1H),
carboxylate
CAS 587-04-2
7.45-7.47 (m, 1H),
7.19-7.24 (m, 2H), 7.13 (d, J = 7.33 Hz,
1H), 7.10 (d, J = 7.91 Hz,
1H), 6.96 (dd, J = 1.76,
7.91 Hz, 1H), 6.89 (d,
J = 1.47 Hz, 1H), 4.50 (q, J = 7.13 Hz,
2H), 2.59 (t, J = 7.60 Hz,
2H), 2.49 (t, J = 7.60 Hz,
2H),
1.51-1.61 (m, 2H), 1.45 (d, J = 14.07 Hz,
3H), 1.26-1.48 (m,
8H), 0.86-0.92 (m, J = 6.70,
6.70 Hz, 3H), 0.85 (t, J = 7.00 Hz,
3H)
27
Ethyl-6-phenyl-5-[4-(3-
Intermediate 20
1 H NMR (300 MHz, CDCl 3 )
phenylpropyl)phenyl]pyridine-
Benzaldehyde
δ 8.11 (d, J = 7.91 Hz, 1H),
2-carboxylate
CAS 100-52-7
7.83 (d, J = 7.91 Hz, 1H),
7.38-7.42 (m, 2H),
7.15-7.31 (m, 8H), 7.09 (s, 4H),
4.49 (q, J = 7.23 Hz, 2H),
2.60-2.66 (m, 4H),
1.89-2.00 (m, 2H), 1.45 (t, J = 7.03 Hz,
3H)
28
Ethyl-6-(3-chlorophenyl)-
Intermediate 20
1 H NMR (300 MHz, CDCl 3 )
5-[4-(3-phenylpropyl)phenyl]pyridine-
3-chloro-
δ 8.13 (d, J = 7.91 Hz, 1H),
2-
benzaldehyde
7.85 (d, J = 7.91 Hz, 1H),
carboxylate
CAS 587-04-2
7.49 (t, J = 1.76 Hz, 1H),
7.07-7.31 (m, 12H),
4.50 (q, J = 7.23 Hz, 2H),
2.61-2.68 (m, 4H),
1.90-2.01 (m, 2H), 1.46 (t, J = 7.03 Hz,
3H)
29
Ethyl-5-(4-hexylphenyl)-
Intermediate 21
1 H NMR (300 MHz, CDCl 3 )
6-(3-hydroxyphenyl)
3-hydroxy-
δ 8.14 (d, J = 7.91 Hz, 1H),
pyridine-2-carboxylate
benzaldehyde
7.87 (d, J = 7.91 Hz, 1H),
CAS 100-83-4
7.20 (s, 1H), 7.06-7.13 (m,
4H), 6.92 (t, J = 7.62 Hz,
1H), 6.74 (br. s., 1H),
6.58-6.64 (m, 2H), 4.47 (q, J = 7.23 Hz,
2H), 2.58 (t, J = 7.91 Hz,
2H),
1.54-1.63 (m, 2H), 1.40 (t, J = 7.03 Hz,
3H), 1.24-1.34 (m,
6H), 0.88 (t, J = 6.74 Hz,
3H)
30
Ethyl-5-[4-
Intermediate 22
1 H NMR (300 MHz, CDCl 3 )
(pentyloxy)phenyl]-6-
Benzaldehyde
δ 8.10 (d, J = 7.91 Hz, 1H),
phenylpyridine-2-
CAS 100-52-7
7.81 (d, J = 7.91 Hz, 1H),
carboxylate
7.40-7.44 (m, 2H),
7.22-7.27 (m, 3H),
7.06-7.11 (m, 2H), 6.78-6.83 (m, 2H),
4.49 (q, J = 7.00 Hz, 2H),
3.93 (t, J = 6.59 Hz, 2H),
1.73-1.83 (m, 2H), 1.45 (t,
J = 7.03 Hz, 3H),
1.31-1.49 (m, 4H), 0.93 (t, J = 7.33 Hz,
3H)
31
Ethyl-6-(4-fluorophenyl)-
Intermediate 22
1 H NMR (300 MHz, CDCl 3 )
5-[4-
4-fluoro-
δ 8.09 (d, J = 7.91 Hz, 1H),
(pentyloxy)phenyl]pyridine-
benzaldehyde
7.81 (d, J = 7.91 Hz, 1H),
2-carboxylate
CAS 459-57-4
7.40 (dd, J = 5.42, 8.94 Hz,
2H), 7.05-7.11 (m, 2H),
6.90-6.98 (m, 2H),
6.80-6.85 (m, 2H), 4.49 (q, J = 7.03 Hz,
2H), 3.95 (t, J = 6.59 Hz,
2H),
1.73-1.84 (m, 2H), 1.45 (t, J = 7.18 Hz,
3H), 1.34-1.47 (m,
4H), 0.94 (t, J = 7.30 Hz,
3H)
32
Ethyl-6-(3-fluorophenyl)-
Intermediate 22
1 H NMR (300 MHz, CDCl 3 )
5-[4-(pentyloxy)
3-fluoro-
δ 8.12 (d, J = 7.91 Hz, 1H),
phenyl]pyridine-2-
benzaldehyde
7.83 (d, J = 8.20 Hz, 1H),
carboxylate
CAS 456-48-4
7.11-7.24 (m, 3H), 7.09 (d,
J = 8.79 Hz, 1H), 7.09 (q, J = 4.98 Hz,
1H),
6.92-7.00 (m, 1H), 6.80-6.85 (m, 2H),
4.49 (q, J = 7.13 Hz, 2H),
3.95 (t, J = 6.59 Hz, 2H),
1.74-1.84 (m, 2H), 1.46 (t,
J = 7.00 Hz, 3H),
1.32-1.50 (m, 4H), 0.93 (t, J = 6.70 Hz,
3H)
33
Ethyl-5-(4-hexylphenyl)-
Intermediate 21
1 H NMR (300 MHz, CDCl 3 )
6-(2-thienyl)pyridine-2-
2-Thiophene
δ 7.56 (d, J = 7.91 Hz, 1H),
carboxylate
carboxaldehyde
7.27 (d, J = 5.86 Hz, 1H),
CAS 98-03-3
7.23 (s, 4H), 7.11 (d, J = 7.62 Hz,
1H),
6.76-6.86 (m, 1H), 6.62 (d, J = 3.81 Hz,
1H), 4.81 (s, 2H),
3.92-4.07 (m, 1H), 2.68 (t, J = 7.77 Hz,
2H),
1.62-1.72 (m, 2H), 1.27-1.42 (m, 6H),
0.90 (t, J = 6.74 Hz, 3H)
34
Ethyl-6-(5-fluoro-2-
Intermediate 21
1 H NMR (300 MHz, CDCl 3 )
thienyl)-5-(4-
5-fluoro-2-
δ 7.02-7.09 (m, 5H),
hexylphenyl)pyridine-2-
Thiophenecarboxaldehyde
6.98 (t, J = 3.96 Hz, 1H),
carboxylate
CAS 29669-49-6
6.60 (dd, J = 2.78, 6.59 Hz, 1H),
6.36 (dd, J = 1.47, 4.10 Hz,
1H), 4.31 (q, J = 7.33 Hz,
2H), 2.53 (dd, J = 7.62, 8.20 Hz,
2H), 1.50-1.59 (m,
2H), 1.36 (t, J = 7.18 Hz,
3H), 1.23-1.33 (m, 6H),
0.83-0.91 (m, 3H)
35
Ethyl-5-(4-hexyl-3-
Intermediate 19
1 H NMR (300 MHz, CDCl 3 )
propylphenyl)-6-(2-
2-
δ 7.98 (d, J = 7.62 Hz, 1H),
thienyl)pyridine-2-
Thiophenecarboxaldehyde
7.69 (d, J = 7.91 Hz, 1H),
carboxylate
CAS 98-03-3
7.28 (d, J = 4.98 Hz, 1H),
7.21 (d, J = 7.33 Hz, 1H),
7.06-7.12 (m, 2H),
6.81 (dd, J = 3.81, 4.98 Hz, 1H),
6.75 (d, J = 3.52 Hz, 1H),
4.49 (q, J = 7.23 Hz, 2H),
2.68 (t, J = 7.62 Hz, 1H),
2.60 (dd, J = 7.33, 7.91 Hz,
2H), 1.48 (t, J = 7.03 Hz,
3H), 1.32-1.69 (m, 10H),
0.89-0.99 (m, 6H)\
36
Ethyl-5-[4-(3-
Intermediate 20
1 H NMR (300 MHz, CDCl 3 )
phenylpropyl)phenyl]-6-
2-Thiophenecarboxaldehyde
δ 7.99 (d, J = 7.91 Hz, 1H),
(2-thienyl)pyridine-2-
CAS 98-03-3
7.67 (s, 1H), 7.17-7.33 (m,
carboxylate
10H), 6.81 (t, J = 4.40 Hz,
1H), 6.72 (dd, J = 1.03, 3.66 Hz,
1H), 4.49 (q, J = 7.23 Hz,
2H), 2.71 (dt, J = 7.76,
11.13 Hz, 4H), 2.01 (quin, J = 7.69 Hz,
2H), 1.47 (t, J = 7.03 Hz,
3H)
37
Ethyl-5-(4-hexylphenyl)-
Intermediate 21
1 H NMR (300 MHz, CDCl 3 )
6-(1,3-oxazol-4-
4-Oxazolecarboxaldehyde
δ 8.11 (d, J = 7.91 Hz, 1H),
yl)pyridine-2-carboxylate
CAS 118994-84-6
7.83 (s, 1H), 7.78 (d, J = 7.91 Hz,
1H), 7.31 (s, 1H),
7.17-7.27 (m, 4H), 4.51 (q,
J = 7.23 Hz, 2H), 2.66 (t, J = 7.77 Hz,
2H),
1.60-1.70 (m, 2H), 1.47 (t, J = 7.18 Hz,
3H), 1.33 (br. s., 6H),
0.90 (t, J = 6.74 Hz, 3H)
38
Ethyl-5-(4-hexylphenyl)-
Intermediate 21
1 H NMR (300 MHz, CDCl 3 )
6-(1,3-thiazol-2-
2-Thiazole
δ 8.15 (d, J = 7.91 Hz, 1H),
yl)pyridine-2-carboxylate
carboxaldehyde
7.86 (d, J = 7.91 Hz, 1H),
CAS 10200-59-6
7.69 (d, J = 3.22 Hz, 1H),
7.37 (d, J = 3.22 Hz, 1H),
7.15-7.25 (m, 4H), 4.51 (q,
J = 7.23 Hz, 2H), 2.65 (t, J = 7.77 Hz,
2H),
1.59-1.69 (m, 2H), 1.47 (t, J = 7.03 Hz,
3H), 1.22-1.39 (m,
6H), 0.89 (t, J = 6.30 Hz,
3H)
39
Ethyl-6-(2-furyl)-5-(4-
Intermediate 21
1 H NMR (300 MHz, CDCl 3 )
hexylphenyl)pyridine-2-
2-Furancarboxaldehyde
δ 8.03 (d, J = 7.91 Hz, 1H),
carboxylate
CAS 98-01-1
7.72 (d, J = 7.91 Hz, 1H),
7.42 (s, 1H), 7.18-7.26 (m,
4H), 6.28 (dd, J = 1.76, 3.22 Hz,
1H), 6.09 (d, J = 3.52 Hz,
1H), 4.51 (q, J = 7.03 Hz,
2H), 2.68 (t, J = 7.77 Hz,
2H), 1.58-1.72 (m,
2H), 1.48 (t, J = 7.18 Hz,
3H), 1.29-1.39 (m, 6H),
0.87-0.94 (m, 3H)
Example 13
Intermediate 40
[5-(4-hexylphenyl)-6-(3-thienyl)pyridin-2-yl]methanol
[0234] To a solution of Intermediate 23 (350 mg, 0.89 mmol) in dichloromethane (10 mL) at −78° C. was added DIBAL-H (1.0 M in dichloromethane, 4.5 mL). The reaction was warmed to RT over for 3 h with stirring and was quenched at −10° C. with ethyl acetate methanol, and 10% solution of HCl. The mixture was diluted with water. The aqueous layer was washed with ethyl acetate. The combined organic layers were washed with brine, dried over Na 2 SO 4 , and concentrated under reduced pressure. The residue was purified by MPLC (40% ethyl acetate in hexanes) to give 227 mg of the desired alcohol as colorless oil. 1 H NMR (300 MHz, CDCl 3 ) δ 7.64 (d, J=7.91 Hz, 1H), 7.25 (dd, J=1.32, 2.78 Hz, 1H), 7.11-7.19 (m, 5H), 7.13 (d, J=2.93 Hz, 1H), 7.09 (dd, J=1.17, 4.98 Hz, 1H), 4.82 (s, 2H), 2.64 (t, J=7.62 Hz, 2H), 1.58-1.69 (m, 2H), 1.32 (br. s., 6H), 0.90 (t, J=6.45 Hz, 3H)
[0235] Intermediates 41-61 were prepared from the corresponding starting materials, in a similar manner to the method described in Example 13 for Intermediate 40. The starting materials and the results are described below in Table 5.
[0000]
TABLE 5
Interm.
1 H NMR δ (ppm) for
number
IUPAC name
starting material
Intermediate
41
(4-octyl-1,1′:2′,1″-terphenyl-
Intermediate 4
1 H NMR (300 MHz,
4′-yl)methanol
CDCl 3 ) δ 7.39-7.46 (m,
3H), 7.14-7.24 (m, 5H),
7.04 (s, 4H), 4.77 (s, 2H),
2.57 (t, J = 7.62 Hz, 2H),
1.55-1.64 (m, 2H),
1.25-1.36 (m, 10H),
0.88-0.95 (m, 3H)
42
[6-(6-hexylpyridin-3-
Intermediate 5
1 H NMR (300 MHz,
yl)biphenyl-3-yl]methanol
CDCl 3 ) δ 8.03-8.06 (m, J = 0.59,
2.30 Hz, 1H),
7.42 (s, 2H), 7.35 (d, J = 7.91 Hz,
1H), 7.17-7.24 (m,
4H), 7.04-7.08 (m, 2H),
6.93 (d, J = 7.91 Hz, 1H),
4.77 (s, 2H), 2.73 (t, J = 7.30 Hz,
2H),
1.62-1.73 (m, 2H), 1.25-1.34 (m,
6H), 0.87 (t, J = 6.74 Hz,
3H)
43
[4-(3,3,4,4,5,5,6,6,6-
Intermediate 7
1 H NMR (300 MHz,
nonafluorohexyl)-1,1′:2′,1″-
CDCl 3 ) δ 7.42 (s, 3H),
terphenyl-4′-yl]methanol
7.19-7.24 (m, 3H),
7.10-7.16 (m, 2H),
7.04-7.09 (m, 4H), 4.78 (s, 2H),
2.84-2.90 (m, 2H),
2.25-2.44 (m, 2H), 1.70 (br. s., 1H)
44
[5-(4-hexylphenyl)-6-
Intermediate 24
1 H NMR (300 MHz,
phenylpyridin-2-yl]methanol
CDCl 3 ) δ 7.71 (d, J = 7.62 Hz,
1H), 7.35-7.39 (m,
2H), 7.21-7.26 (m, 3H),
7.07 (s, 5H), 4.83 (s, 2H),
2.55-2.61 (m, 2H),
1.53-1.64 (m, 2H), 1.31 (s, 6H),
0.88 (t, J = 6.15 Hz, 3H)
45
4-(3-phenylpropyl)-1,1′:2′,1″-
Intermediate 8
1 H NMR (300 MHz,
terphenyl-4′-methanol
CDCl 3 ) δ 7.37-7.44 (m,
3H), 7.24-7.30 (m, 2H),
7.11-7.20 (m, 7H),
6.99-7.05 (m, 4H), 4.75 (s, 2H),
2.60 (td, J = 3.81, 7.62 Hz,
4H), 1.87-1.98 (m, 2H),
1.76 (s, OH)
46
[5-(4-hexyl-3-propylphenyl)-6-
Intermediate 25
1 H NMR (300 MHz,
phenylpyridin-2-yl]methanol
CDCl 3 ) δ 7.72 (d, J = 7.91 Hz,
1H), 7.34-7.38 (m,
2H), 7.20-7.25 (m, 4H),
7.06 (d, J = 7.62 Hz, 1H),
6.95 (dd, J = 2.05, 7.33 Hz,
1H), 6.87 (d, J = 1.76 Hz,
1H), 4.82 (s, 2H),
2.57 (t, J = 7.90 Hz, 2H),
2.45 (t, J = 7.60 Hz, 2H),
1.50-1.61 (m, 2H),
1.26-1.44 (m, 8H), 0.89 (t, J = 6.40 Hz,
3H), 0.82 (t, J = 7.33 Hz,
3H)
47
[6-(6-octylpyridin-3-
Intermediate 6
1 H NMR (300 MHz,
yl)biphenyl-3-yl]methanol
CDCl 3 ) δ 8.14 (dd, J = 0.59,
2.34 Hz, 1H),
7.36-7.45 (m, 3H),
7.18-7.26 (m, 4H), 7.06-7.11 (m,
2H), 6.94 (d, J = 7.91 Hz,
1H), 4.78 (s, 2H), 2.84 (br.
s., 1H), 2.73 (t, J = 7.60 Hz,
2H), 1.63-1.73 (m,
2H), 1.23-1.34 (m, 10H),
0.87 (t, J = 7.00 Hz, 3H)
48
[6-(3-chlorophenyl)-5-(4-
Intermediate 26
1 H NMR (300 MHz,
hexyl-3-propylphenyl)pyridin-
CDCl 3 ) δ 7.73 (d, J = 7.91 Hz,
2-yl]methanol
1H), 7.41 (t, J = 1.76 Hz,
1H), 7.27 (d, J = 7.91 Hz,
1H), 7.20 (tt, J = 2.10,
7.60 Hz, 2H), 7.13 (d, J = 7.62 Hz,
1H), 7.08 (d, J = 7.91 Hz,
1H), 6.94 (dd, J = 1.90,
7.77 Hz, 1H),
6.87 (d, J = 1.76 Hz, 1H),
4.83 (s, 2H), 2.59 (t, J = 7.60 Hz,
2H), 2.48 (t, J = 7.60 Hz,
2H), 1.50-1.61 (m,
2H), 1.25-1.48 (m, 8H),
0.86-0.93 (m, J = 6.40,
6.40 Hz, 3H), 0.84 (t, J = 7.30 Hz,
3H)
49
{6-(3-chlorophenyl)-5-[4-(3-
Intermediate 28
1 H NMR (300 MHz,
phenylpropyl)phenyl]pyridin-
CDCl 3 ) δ 7.74 (d, J = 7.91 Hz,
2-yl}methanol
1H), 7.45 (s, 1H),
7.06-7.31 (m, 13H), 4.85 (s,
2H), 2.61-2.68 (m, 4H),
1.90-2.01 (m, 2H)
50
3-[3-(4-hexylphenyl)-6-
Intermediate 29
1 H NMR (300 MHz,
(hydroxymethyl)pyridin-2-
CDCl 3 ) δ 7.72 (d, J = 7.91 Hz,
yl]phenol
1H), 7.27 (d, J = 7.91 Hz,
1H), 6.97-7.09 (m,
6H), 6.74 (d, J = 7.62 Hz,
2H), 4.83 (s, 2H), 2.58 (t, J = 7.77 Hz,
2H),
1.54-1.64 (m, 2H), 1.23-1.34 (m,
6H), 0.88 (t, J = 6.59 Hz,
3H)
51
6-phenyl-5-[4-(3-
Intermediate 27
1 H NMR (300 MHz,
phenylpropyl)phenyl]pyridine-
CDCl 3 ) 7.72 (d, J = 7.62 Hz,
2-methanol
1H), 7.36-7.39 (m,
2H), 7.15-7.31 (m, 9H),
7.08 (s, 4H), 4.84 (s, 2H),
2.63 (t, J = 7.60 Hz, 4H),
1.94 (t, J = 7.62 Hz, 2H)
52
{5-[4-(pentyloxy)phenyl]-6-
Intermediate 30
1 H NMR (300 MHz,
phenylpyridin-2-yl}methanol
CDCl 3 ) δ 7.69 (d, J = 7.91 Hz,
1H), 7.35-7.41 (m,
2H), 7.21-7.27 (m, 4H),
7.03-7.09 (m, 2H),
6.76-6.82 (m, 2H), 4.82 (s, 2H),
3.92 (t, J = 6.59 Hz, 2H),
1.72-1.82 (m, 2H),
1.31-1.49 (m, 4H), 0.93 (t, J = 7.00 Hz,
3H)
53
{6-(4-fluorophenyl)-5-[4-
Intermediate 31
1 H NMR (300 MHz,
(pentyloxy)phenyl]pyridin-2-
CDCl 3 ) δ 7.69 (d, J = 7.91 Hz,
yl}methanol
1H), 7.33-7.40 (m,
2H), 7.24 (d, J = 7.91 Hz,
1H), 7.03-7.09 (m, 2H),
6.90-6.98 (m, 2H),
6.78-6.84 (m, 2H), 4.82 (s, 2H),
3.94 (t, J = 6.59 Hz, 2H),
1.74-1.84 (m, 2H),
1.35-1.50 (m, 4H), 0.94 (t, J = 7.00 Hz,
3H)
54
{6-(3-fluorophenyl)-5-[4-
Intermediate 32
1 H NMR (300 MHz,
(pentyloxy)phenyl]pyridin-2-
CDCl 3 ) δ 7.71 (d, J = 7.91 Hz,
yl}methanol
1H), 7.27 (d, J = 8.20 Hz,
1H), 7.09-7.24 (m,
3H), 7.07 (d, J = 8.79 Hz,
1H), 7.07 (q, J = 4.98 Hz,
1H), 6.96 (d, J = 1.17 Hz,
1H), 6.81 (d, J = 8.79 Hz,
1H), 6.81 (q, J = 5.00 Hz,
1H), 4.84 (s, 2H), 3.94 (t, J = 6.59 Hz,
2H), 3.86 (br.
s., 1H), 1.74-1.84 (m,
2H), 1.32-1.50 (m, 4H),
0.93 (t, J = 7.00 Hz, 3H)
55
[5-(4-hexylphenyl)-6-(2-
Intermediate 33
1 H NMR (300 MHz,
thienyl)pyridin-2-yl]methanol
CDCl 3 ) δ 7.56 (d, J = 7.91 Hz,
1H), 7.27 (d, J = 5.86 Hz,
1H), 7.23 (s, 4H),
7.11 (d, J = 7.62 Hz, 1H),
6.76-6.86 (m, 1H), 6.62 (d, J = 3.81 Hz,
1H), 4.81 (s, 2H),
3.92-4.07 (m, 1H),
2.68 (t, J = 7.77 Hz, 2H),
1.62-1.72 (m, 2H),
1.27-1.42 (m, 6H), 0.90 (t, J = 6.74 Hz,
3H)
56
[6-(5-fluoro-2-thienyl)-5-(4-
Intermediate 34
1 H NMR (300 MHz,
hexylphenyl)pyridin-2-
CDCl 3 ) δ 7.51 (d, J = 7.91 Hz,
yl]methanol
1H), 7.21-7.27 (m,
4H), 7.09 (d, J = 7.91 Hz,
1H), 6.16 (d, J = 2.64 Hz,
2H), 4.78 (s, 2H), 3.74 (br.
s, 1H), 2.68 (t, J = 7.62 Hz,
2H), 1.62-1.72 (m,
2H), 1.27-1.39 (m, 6H),
0.90 (t, J = 6.45 Hz, 3H)
57
[5-(4-hexyl-3-propylphenyl)-6-
Intermediate 35
1 H NMR (600 MHz,
(2-thienyl)pyridin-2-
CDCl 3 ) δ 7.60 (d, J = 7.92 Hz,
yl]methanol
1H), 7.24-7.29 (m,
1H), 7.20 (d, J = 7.63 Hz,
1H), 7.14 (d, J = 7.92 Hz,
1H), 7.04-7.10 (m, 2H),
6.82 (dd, J = 3.82, 4.99 Hz,
1H), 6.77 (d, J = 3.23 Hz,
1H), 4.82 (s, 2H),
3.41 (d, J = 6.46 Hz, 1H),
2.67 (dd, J = 7.90 Hz, 2H),
2.59 (dd, J = 7.34, 7.92 Hz,
2H), 1.53-1.65 (m, 4H),
1.33-1.44 (m, 4H),
0.90-0.95 (m, 6H)
58
{5-[4-(3-
Intermediate 36
1 H NMR (300 MHz,
phenylpropyl)phenyl]-6-(2-
CDCl 3 ) δ 7.54 (d, J = 7.91 Hz,
thienyl)pyridin-2-yl}methanol
1H), 7.16-7.33 (m,
11H), 7.10 (d, J = 7.91 Hz,
1H), 6.79 (t, J = 4.40 Hz,
1H), 6.62 (d, J = 3.52 Hz,
1H), 4.79 (s, 2H), 4.04 (br.
s, 1H), 2.66-2.75 (m,
4H), 1.95-2.08 (m, 2H)
59
[5-(4-hexylphenyl)-6-(1,3-
Intermediate 37
1 H NMR (600 MHz,
oxazol-4-yl)pyridin-2-
CDCl 3 ) δ 7.85 (d, J = 0.88 Hz,
yl]methanol
1H), 7.62 (dd, J = 2.93,
7.92 Hz, 1H),
7.34 (d, J = 7.92 Hz, 1H),
7.22 (s, 2H), 7.14-7.19 (m,
2H), 6.98-7.01 (m, 1H),
4.90 (s, 2H), 4.52 (br. s,
1H), 2.66 (t, J = 7.78 Hz,
2H), 1.63-1.69 (m, 2H),
1.30-1.39 (m, 6H),
0.88-0.92 (m, 3H)
60
[5-(4-hexylphenyl)-6-(1,3-
Intermediate 38
1 H NMR (300 MHz,
thiazol-2-yl)pyridin-2-
CDCl 3 ) δ 7.64-7.68 (m,
yl]methanol
2H), 7.33 (d, J = 7.91 Hz,
1H), 7.27 (dd, J = 1.90,
3.08 Hz, 1H), 7.16 (s, 4H),
4.83 (s, 2H),
2.59-2.65 (m, 2H), 1.57-1.67 (m,
2H), 1.19-1.37 (m, 6H),
0.87 (t, J = 6.45 Hz, 3H)
61
[6-(2-furyl)-5-(4-
Intermediate 39
1 H NMR (300 MHz,
hexylphenyl)pyridin-2-
CDCl 3 ) δ 7.59 (d, J = 7.91 Hz,
yl]methanol
1H), 7.38 (s, 1H),
7.16-7.26 (m, 5H), 6.30 (dd, J = 1.76,
3.22 Hz, 1H),
6.10 (d, J = 3.22 Hz, 1H),
4.85 (s, 2H), 3.86 (br. s, 1H),
2.67 (t, J = 7.62 Hz, 2H),
1.61-1.71 (m, 2H),
1.27-1.42 (m, 6H), 0.90 (t, J = 7.03 Hz,
3H)
Example 14
Intermediate 62
4-hexyl-1,1′:2′,1″-terphenyl-4′-carbaldehyde
[0236] To a vigorously stirred solution of pyridinium chlorochromate (1.29 g, 5.97 mmol) and celite (2.6 g) in dichloromethane (30 mL) was added a solution of (4-hexyl-1,1′:2′,1″-terphenyl-4′-yl)methanol (1.37 g, 3.98 mmol) in dichloromethane. After stirring at RT for 3 h, the reaction mixture was filtered through a plug of silica gel and eluted well with dichloromethane. Concentration yielded 1.21 g of the aldehyde as colorless oil.
[0237] 1 H NMR (300 MHz, CDCl 3 ) δ 10.08 (s, 1H), 7.92 (s, 1H), 7.90 (dd, J=1.80, 7.33 Hz, 1H), 7.57-7.60 (m, 1H), 7.21-7.26 (m, 3H), 7.13-7.17 (m, 2H), 7.05 (s, 4H), 2.54-2.59 (m, 2H), 1.58 (s, 2H), 1.25-1.33 (m, 6H), 0.88 (t, J=6.74 Hz, 3H).
Example 15
Intermediate 63
5-(4-hexylphenyl)-6-(3-thienyl)pyridine-2-carbaldehyde
[0238] To a solution of Intermediate 40 (70 mg, 0.2 mmol), NMO (58 mg, 0.5 mmol), and 4 Å molecular sieves (140 mg) in dichloromethane (5 mL) and acetonitrile (0.6 mL) was added tetrapropylammonium perruthenate (TPAP, 4 mg). After stirring at RT for 2 h, the reaction mixture was filtered through a short column of silica gel, eluted with ethyl acetate and concentrated under reduced pressure. Purification by MPLC (10% ethyl acetate in hexanes) gave rise to 45 mg 5-(4-hexylphenyl)-6-(3-thienyl)pyridine-2-carbaldehyde as a yellow oil.
[0239] 1 H NMR (300 MHz, CDCl 3 ) δ 10.15 (s, 1H), 7.91 (d, J=8.20 Hz, 1H), 7.80 (d, J=7.91 Hz, 1H), 7.33 (dd, J=1.17, 2.93 Hz, 1H), 7.12-7.22 (m, 6H), 2.65 (t, J=7.77 Hz, 2H), 1.59-1.69 (m, 2H), 1.25-1.41 (m, 6H), 0.90 (t, J=6.45 Hz, 3H).
[0240] Intermediates 64-84 were prepared from the corresponding starting materials, in a similar manner to the method described in Example 14 for Intermediate 62 or Example 15 for Intermediate 63. The starting materials and the results are described below in Table 6.
[0000]
TABLE 6
Intermediate
1 H NMR δ (ppm) for
number
IUPAC name
starting material
Intermediate
65
5-(4-hexylphenyl)-6-
Intermediate 44
1 H NMR (300 MHz,
phenylpyridine-2-
CDCl 3 ) δ 10.18 (d, J = 0.88 Hz,
carbaldehyde
1H), 7.98 (d, J = 8.20 Hz,
1H), 7.89 (dd, J = 0.88,
7.91 Hz, 1H),
7.40-7.43 (m, 2H),
7.25-7.31 (m, 3H), 7.10 (s, 4H),
2.59 (dd, J = 7.60 Hz, 2H),
1.55-1.65 (m, 2H),
1.25-1.34 (m, 6H), 0.88 (t, J = 6.70 Hz,
3H)
66
6-(6-hexylpyridin-2-
Intermediate 42
1 H NMR (300 MHz,
yl)biphenyl-3-
CDCl 3 ) δ 10.11 (s, 1H),
carbaldehyde
8.39 (dd, J = 0.88, 2.34 Hz,
1H), 7.93-7.97 (m,
2H), 7.59 (d, J = 8.50 Hz,
1H), 7.25-7.31 (m, 4H),
7.12-7.16 (m, 2H),
7.00 (dd, J = 0.59, 8.20 Hz,
1H), 2.76 (t, J = 8.00 Hz,
2H), 1.60-1.75 (m, 2H),
1.26-1.35 (m, 6H),
0.88 (t, J = 6.74 Hz, 3H).
67
4-(3-phenylpropyl)-
Intermediate 45
1 H NMR (300 MHz, CDCl 3 )
1,1′:2′,1″-terphenyl-4′-
δ 10.08 (s, 1H),
carbaldehyde
7.88-7.92 (m, 2H), 7.58 (d, J = 8.50 Hz,
1H),
7.13-7.30 (m, 10H), 7.05 (s, 4H),
2.61 (t, J = 7.62 Hz, 4H),
1.88-1.99 (m, 2H).
68
6-phenyl-5-[4-(3-
Intermediate 51
1 H NMR (300 MHz,
phenylpropyl)phenyl]pyridine-
CDCl 3 ) δ 10.18 (s, 1H),
2-carbaldehyde
7.97-8.00 (m, 1H),
7.89 (d, J = 7.91 Hz, 1H),
7.39-7.43 (m, 2H),
7.25-7.31 (m, 4H), 7.15-7.21 (m,
3H), 7.11 (s, 4H), 2.64 (td,
J = 2.93, 7.90 Hz, 4H),
1.90-2.00 (m, 2H)
69
5-(4-hexylphenyl)-6-(3-
Intermediate 50
1 H NMR (300 MHz,
hydroxyphenyl)pyridine-2-
CDCl 3 ) δ 10.18 (s, 1H),
carbaldehyde
7.99 (d, J = 8.20 Hz, 1H),
7.90 (d, J = 7.62 Hz, 1H),
7.01-7.13 (m, 6H),
6.82-6.85 (m, 1H), 6.76 (ddd, J = 1.20,
2.34, 8.20 Hz, 1H),
2.60 (t, J = 7.90 Hz, 2H),
1.59 (d, J = 7.33 Hz, 2H),
1.25-1.34 (m, 6H),
0.88 (t, J = 6.45 Hz, 3H)
70
5-(4-hexyl-3-
Intermediate 46
1 H NMR (300 MHz,
propylphenyl)-6-
CDCl 3 ) δ 10.18 (d, J = 0.59 Hz,
phenylpyridine-2-
2H), 7.97 (d, J = 7.91 Hz,
carbaldehyde
1H), 7.89 (d, J = 7.62 Hz,
1H),
7.39-7.43 (m, 2H), 7.25-7.30 (m,
3H), 7.07-7.11 (m, 1H),
6.99 (dd, J = 2.05, 7.91 Hz,
1H), 6.91 (d, J = 1.76 Hz,
1H), 2.58 (t, J = 7.90 Hz,
2H), 2.46 (t, J = 7.60 Hz,
2H), 1.50-1.62 (m,
2H), 1.26-1.45 (m, 8H),
0.90 (t, J = 6.70 Hz, 3H),
0.83 (t, J = 7.33 Hz, 3H)
71
6-(3-chlorophenyl)-5-(4-
Intermediate 48
1 H NMR (300 MHz,
hexyl-3-
CDCl 3 ) δ 10.16 (s, 1H),
propylphenyl)pyridine-2-
7.98 (d, J = 7.91 Hz, 1H),
carbaldehyde
7.90 (d, J = 8.21 Hz, 1H),
7.47 (t, J = 1.76 Hz, 1H),
7.24 (tt, J = 1.47, 7.60 Hz,
2H), 7.17 (d, J = 7.62 Hz,
1H), 7.11 (d, J = 7.91 Hz,
1H), 6.98 (dd, J = 1.47,
7.62 Hz, 1H), 6.91 (d, J = 1.76 Hz,
1H), 2.60 (t, J = 7.60 Hz,
2H), 2.49 (t, J = 7.33 Hz,
2H),
1.51-1.62 (m, 2H), 1.28-1.49 (m,
8H), 0.86-0.93 (m, J = 6.70,
6.70 Hz, 3H), 0.85 (t,
J = 7.30 Hz, 3H)
72
6-(3-chlorophenyl)-5-[4-(3-
Intermediate 49
1 H NMR (300 MHz,
phenylpropyl)phenyl]pyridine-
CDCl 3 ) δ 10.17 (s, 3H),
2-carbaldehyde
8.00 (d, J = 7.91 Hz, 1H),
7.90 (d, J = 7.91 Hz, 1H),
7.50 (s, 1H),
7.26-7.31 (m, 3H), 7.09-7.22 (m,
9H), 2.65 (dt, J = 6.70,
7.33 Hz, 4H), 1.96 (quin, J = 7.62 Hz,
2H)
73
4-(3,3,4,4,5,5,6,6,6-
Intermediate 43
1 H NMR (300 MHz,
nonafluorohexyl)-
CDCl 3 ) δ 10.09 (s, 1H),
1,1′:2′,1″-terphenyl-4′-
7.91-7.98 (m, 1H),
carbaldehyde
7.91 (dd, J = 1.50, 6.45 Hz,
1H), 7.57 (d, J = 8.50 Hz,
1H), 7.22-7.27 (m, 3H),
7.12-7.17 (m, 2H),
7.07-7.11 (m, 4H),
2.86-2.91 (m, 2H), 2.26-2.45 (m,
2H)
74
5-[4-(pentyloxy)phenyl]-6-
Intermediate 52
1 H NMR (300 MHz,
phenylpyridine-2-
CDCl 3 ) δ 10.17 (d, J = 0.59 Hz,
carbaldehyde
1H), 7.97 (d, J = 7.62 Hz,
1H), 7.87 (dd, J = 0.88,
7.91 Hz, 1H),
7.40-7.46 (m, 2H),
7.28-7.33 (m, 3H), 7.08-7.13 (m,
2H), 6.79-6.84 (m, 2H),
3.94 (t, J = 6.59 Hz, 2H),
1.73-1.83 (m, 2H),
1.33-1.49 (m, 4H), 0.93 (t, J = 7.30 Hz,
3H)
75
6-(3-fluorophenyl)-5-[4-
Intermediate 54
1 H NMR (300 MHz,
(pentyloxy)phenyl]pyridine-
CDCl 3 ) δ 10.17 (d, J = 0.60 Hz,
2-carbaldehyde
1H), 8.00 (d, J = 7.91 Hz,
1H), 7.90 (dd, J = 0.60,
7.90 Hz, 1H),
7.10-7.30 (m, 5H),
6.99-7.06 (m, 1H), 6.81-6.88 (m,
2H), 3.97 (t, J = 6.59 Hz,
2H), 1.81 (tdd, J = 6.74,
6.96, 7.07 Hz, 2H),
1.34-1.52 (m, 4H),
0.90-1.01 (m, 3H)
76
6-(4-fluorophenyl)-5-[4-
Intermediate 53
1 H NMR (300 MHz,
(pentyloxy)phenyl]pyridine-
CDCl 3 ) δ 10.14 (d, J = 0.59 Hz,
2-carbaldehyde
1H), 7.95 (d, J = 7.91 Hz,
1H), 7.85 (dd, J = 0.88,
7.62 Hz, 1H),
7.38-7.45 (m, 2H),
7.07-7.12 (m, 2H), 6.94-7.02 (m,
2H), 6.80-6.86 (m, 2H),
3.95 (t, J = 6.59 Hz, 2H),
1.73-1.84 (m, 2H),
1.34-1.50 (m, 4H), 0.93 (t, J = 7.00 Hz,
3H)
77
4-octyl-1,1′:2′,1″-
Intermediate 41
1 H NMR (300 MHz,
terphenyl-4′-carbaldehyde
CDCl 3 ) δ 10.08 (s, 1H),
7.91-7.93 (m, 1H),
7.90 (dd, J = 1.47, 7.03 Hz,
1H), 7.59 (d, J = 8.50 Hz,
1H), 7.22-7.26 (m, 3H),
7.13-7.17 (m, 2H),
7.05 (s, 4H), 2.53-2.59 (m,
2H), 1.55 (s, 2H),
1.24-1.32 (m, 10H), 0.88 (t, J = 6.74 Hz,
3H)
78
5-(4-hexylphenyl)-6-(2-
Intermediate 55
1 H NMR (300 MHz,
thienyl)pyridine-2-
CDCl 3 ) δ 10.10 (s, 1H),
carbaldehyde
7.80 (d, J = 7.62 Hz, 1H),
7.68 (d, J = 7.62 Hz, 1H),
7.28 (d, J = 4.98 Hz, 1H),
7.21 (s, 4H), 6.80 (t, J = 4.40 Hz,
1H), 6.68 (d, J = 3.52 Hz,
1H), 2.65 (t, J = 7.62 Hz,
2H), 1.63 (s, 2H),
1.23-1.39 (m, 6H),
0.87 (t, J = 6.30 Hz, 3H)
79
6-(5-fluoro-2-thienyl)-5-(4-
Intermediate 56
1 H NMR (600 MHz,
hexylphenyl)pyridine-2-
CDCl 3 ) δ 10.09 (d, J = 0.59 Hz,
carbaldehyde
1H), 7.81 (d, J = 7.92 Hz,
1H), 7.67 (dd, J = 0.88,
7.92 Hz, 1H),
7.24-7.29 (m, 4H), 6.26 (dd, J = 3.67,
4.26 Hz, 1H),
6.19 (dd, J = 1.91, 4.26 Hz,
1H), 2.69 (t, J = 7.34 Hz,
2H), 1.68 (quin, J = 7.56 Hz,
2H), 1.31-1.40 (m,
6H), 0.90 (t, J = 7.34 Hz,
3H)
80
5-(4-hexyl-3-
Intermediate 57
1 H NMR (300 MHz,
propylphenyl)-6-(2-
CDCl 3 ) δ 10.10 (s, 1H),
thienyl)pyridine-2-
7.81 (d, J = 7.91 Hz, 1H),
carbaldehyde
7.69 (d, J = 7.62 Hz, 1H),
7.28 (d, J = 4.98 Hz, 1H),
7.19 (d, J = 7.62 Hz, 1H),
7.04-7.09 (m, 2H),
6.80 (t, J = 4.40 Hz, 1H),
6.70 (d, J = 3.81 Hz, 1H),
2.65 (dd, J = 6.74, 7.91 Hz,
2H), 2.58 (dd, J = 7.62,
8.50 Hz, 2H), 1.57 (s, 4H),
1.24-1.44 (m, 6H),
0.84-0.95 (m, 6H)
81
5-[4-(3-
Intermediate 58
1 H NMR (600 MHz,
phenylpropyl)phenyl]-6-
CDCl 3 ) δ 10.15 (d, J = 0.59 Hz,
(2-thienyl)pyridine-2-
1H), 7.86 (d, J = 7.63 Hz,
carbaldehyde
1H), 7.73 (dd, J = 0.73,
7.78 Hz, 1H),
7.20-7.33 (m, 10H), 6.85 (dd, J = 3.81,
4.99 Hz, 1H),
6.74 (dd, J = 0.88, 3.81 Hz,
1H), 2.75 (t, J = 7.92 Hz,
2H), 2.71 (t, J = 7.63 Hz,
2H), 2.01-2.06 (m, 2H)
82
5-(4-hexylphenyl)-6-(1,3-
Intermediate 59
1 H NMR (300 MHz,
oxazol-4-yl)pyridine-2-
CDCl 3 ) δ 10.26 (s, 1H),
carbaldehyde
7.97 (d, J = 7.62 Hz, 1H),
7.90 (s, 1H), 7.81 (d, J = 7.91 Hz,
1H),
7.19-7.29 (m, 4H), 7.07 (s, 1H),
2.68 (t, J = 7.77 Hz, 2H),
1.61-1.72 (m, 2H),
1.22-1.41 (m, 6H), 0.83-0.95 (m,
3H)
83
5-(4-hexylphenyl)-6-(1,3-
Intermediate 60
1 H NMR (300 MHz,
thiazol-2-yl)pyridine-2-
CDCl 3 ) δ 10.19 (s, 1H),
carbaldehyde
7.98-8.07 (m, J = 8.50 Hz,
1H), 7.90 (d, J = 8.21 Hz,
1H), 7.75 (d, J = 2.93 Hz,
1H), 7.39 (d, J = 3.22 Hz,
1H), 7.19-7.24 (m,
4H), 2.66 (t, J = 7.62 Hz,
2H), 1.58-1.70 (m, 2H),
1.25-1.40 (m, 6H),
0.90 (t, J = 6.01 Hz, 3H)
84
6-(2-furyl)-5-(4-
Intermediate 61
1 H NMR (300 MHz,
hexylphenyl)pyridine-2-
CDCl 3 ) δ 10.20 (s, 1H),
carbaldehyde
7.89 (d, J = 7.62 Hz, 1H),
7.76 (d, J = 7.91 Hz, 1H),
7.46 (s, 1H),
7.19-7.27 (m, 4H), 6.33 (dd, J = 1.61,
3.37 Hz, 1H),
6.12 (d, J = 3.22 Hz, 1H),
2.68 (t, J = 7.62 Hz, 2H),
1.61-1.73 (m, 2H),
1.25-1.42 (m, 6H), 0.90 (t, J = 6.30 Hz,
3H)
Example 16
Compound 1
(3-{[6-(5-Hexyl-pyridin-2-yl)-biphenyl-3-ylmethyl]-amino}-propyl)-phosphonic acid
[0241] To a solution of 6-(5-hexylpyridin-2-yl)biphenyl-3-carbaldehyde (80 mg, 0.233 mmol) and (3-aminopropyl)phosphonic acid (32.4 mg) in methanol was added tetrabutylammonium hydroxide (1M in MeOH, 0.23 mL). The reaction mixture was heated to 50° C. for 30 min with stirring, then sodium cyanoborohydride (41 mg, 0.65 mmol) was added. The reaction mixture was heated to 50° C. with stirring for 3 h. After cooling to RT, the mixture was concentrated and purified by MPLC (0-100% ethyl acetate in hexanes) to give 36 mg of the desired product as a colorless solid. 1 H NMR (300 MHz, CD 3 OD) δ 8.34 (d, J=1.76 Hz, 1H), 7.58-7.63 (m, 3H), 7.41 (dd, J=2.34, 8.20 Hz, 1H), 7.20-7.25 (m, 3H), 7.11-7.16 (m, 2H), 6.91 (d, J=7.91 Hz, 1H), 4.21 (s, 2H), 3.11 (t, J=6.30 Hz, 2H), 2.61 (t, J=7.62 Hz, 2H), 1.92-2.07 (m, 2H), 1.55-1.74 (m, 4H), 1.31 (br. s., 6H), 0.86-0.92 (m, 3H).
[0242] Compounds 2-28 were prepared from the corresponding starting materials, in a similar manner to the method described in Example 16 for Compound 1. The starting materials and the results are described below in Table 7.
[0000]
TABLE 7
Comp.
starting
number
IUPAC name
material
1 H NMR δ (ppm) for Compound
2
(3-{[5-(4-Hexyl-phenyl)-6-
Intermediate
1 H NMR (300 MHz, CD 3 OD) δ 7.66 (d,
thiophen-2-yl-pyridin-2-
78
J = 7.91 Hz, 1H), 7.35-7.39 (m, 2H),
ylmethyl]-amino}-propyl)-
7.17-7.27 (m, 4H), 6.80 (t, J = 4.25 Hz,
phosphonic acid
1H), 6.68 (d, J = 3.81 Hz, 1H),
4.30 (s, 2H), 3.17-3.26 (m, 2H),
2.68 (t, J = 7.62 Hz, 2H), 1.98-2.12 (m,
2H), 1.61-1.77 (m, 4H),
1.28-1.48 (m, 6H), 0.91 (t, J = 6.74 Hz, 3H)
3
(3-{[6-(5-Fluoro-thiophen-
Intermediate
1 H NMR (300 MHz, CD 3 OD) δ 7.68 (d,
2-yl)-5-(4-hexyl-phenyl)-
79
J = 7.91 Hz, 1H), 7.41 (d, J = 7.91 Hz,
pyridin-2-ylmethyl]-
1H), 7.26-7.37 (m, 4H), 6.35 (dd, J = 3.80 Hz,
amino}-propyl)-
1H), 6.30 (dd, J = 1.76,
phosphonic acid
4.10 Hz, 1H), 4.36 (s, 2H), 3.26 (t, J = 6.15 Hz,
2H), 2.75 (t, J = 7.47 Hz, 2H),
2.03-2.18 (m, 2H), 1.66-1.82 (m,
4H), 1.37-1.53 (m, 6H), 0.96 (t, J = 6.74 Hz,
3H)
4
(3-{[5-(4-Hexyl-3-propyl-
Intermediate
1 H NMR (300 MHz, CD 3 OD) δ 7.64 (d,
phenyl)-6-thiophen-2-yl-
80
J = 7.62 Hz, 1H), 7.34-7.38 (m, 2H),
pyridin-2-ylmethyl]-
7.21 (d, J = 8.50 Hz, 1H), 7.05 (br. s.,
amino}-propyl)-
2H), 6.79 (t, J = 4.40 Hz, 1H), 6.67 (d,
phosphonic acid
J = 3.52 Hz, 1H), 4.23 (s, 2H), 3.12 (t,
J = 6.30 Hz, 2H), 2.69 (t, J = 7.77 Hz,
2H), 2.60 (t, J = 7.47 Hz, 2H),
1.95-2.09 (m, 2H), 1.52-1.75 (m, 6H),
1.30-1.48 (m, 6H), 0.93 (t, J = 7.03 Hz,
6H)
5
[3-({5-[4-(3-Phenyl-
Intermediate
1 H NMR (300 MHz, CD 3 OD) δ 7.68 (d,
propyl)-phenyl]-6-
81
J = 7.91 Hz, 1H), 7.35-7.39 (m, 2H),
thiophen-2-yl-pyridin-2-
7.15-7.30 (m, 9H), 6.81 (t, J = 4.54 Hz,
ylmethyl}-amino)-propyl]-
1H), 6.70 (d, J = 3.81 Hz, 1H),
phosphonic acid
4.29 (s, 2H), 3.19 (t, J = 6.74 Hz, 2H),
2.63-2.75 (m, 4H), 1.95-2.09 (m,
4H), 1.66-1.77 (m, 2H)
6
(3-{[5-(4-Hexyl-phenyl)-6-
Intermediate
1 H NMR (300 MHz, CD 3 OD) δ 7.74 (d,
thiophen-3-yl-pyridin-2-
63
J = 7.91 Hz, 1H), 7.42 (d, J = 8.21 Hz,
ylmethyl]-amino}-propyl)-
1H), 7.40 (d, J = 2.93 Hz, 1H),
phosphonic acid
7.11-7.23 (m, 5H), 7.05 (d, J = 4.98 Hz,
1H), 4.31 (s, 2H), 3.16 (t, J = 6.45 Hz,
2H), 2.64 (t, J = 7.62 Hz, 2H), 2.03 (dt,
J = 6.78, 16.92 Hz, 2H),
1.58-1.76 (m, 4H), 1.29-1.45 (m, 6H), 0.90 (t, J = 6.15 Hz,
3H)
7
(3-{[5-(4-Hexyl-phenyl)-6-
Intermediate
1 H NMR (600 MHz, CD 3 OD) δ 8.31 (d,
oxazol-4-yl-pyridin-2-
82
J = 0.88 Hz, 1H), 7.75 (d, J = 7.63 Hz,
ylmethyl]-amino}-propyl)-
1H), 7.49 (d, J = 7.63 Hz, 1H), 7.33 (d,
phosphonic acid
J = 8.22 Hz, 2H), 7.20 (d, J = 7.92 Hz,
2H), 6.88 (s, 1H), 4.39 (s, 2H), 3.19 (t,
J = 6.75 Hz, 2H), 2.71 (t, J = 7.63 Hz,
2H), 2.07 (ddtd, J = 6.46, 7.04, 7.63,
17.02 Hz, 2H), 1.63-1.75 (m, 4H),
1.32-1.45 (m, 6H), 0.91 (t, J = 7.04 Hz,
3H)
8
(3-{[5-(4-Hexyl-phenyl)-6-
Intermediate
1 H NMR (600 MHz, CD 3 OD) δ 7.83 (d,
thiazol-2-yl-pyridin-2-
83
J = 7.92 Hz, 1H), 7.74 (d, J = 3.23 Hz,
ylmethyl]-amino}-propyl)-
1H), 7.60 (s, 1H), 7.58 (d, J = 7.92 Hz,
phosphonic acid
1H), 7.21 (d, J = 8.22 Hz, 2H), 7.17 (d,
J = 7.92 Hz, 2H), 4.24 (s, 2H), 3.05 (t,
J = 6.60 Hz, 2H), 2.65 (dd, J = 7.60 Hz,
1H), 1.96-2.03 (m, 2H),
1.62-1.71 (m, 4H), 1.29-1.45 (m, 6H),
0.89-0.93 (m, 3H)
9
(3-{[6-Furan-2-yl-5-(4-
Intermediate
1 H NMR (300 MHz, CD 3 OD) δ 7.70 (d,
hexyl-phenyl)-pyridin-2-
84
J = 7.91 Hz, 1H), 7.45 (s, 2H), 7.24 (d,
ylmethyl]-amino}-propyl)-
J = 7.62 Hz, 2H), 7.15 (d, J = 8.20 Hz,
phosphonic acid
2H), 6.35-6.38 (m, J = 1.76 Hz, 1H),
6.26 (d, J = 2.93 Hz, 1H), 4.34 (s, 2H),
3.20 (t, J = 6.30 Hz, 2H), 2.67 (t, J = 7.62 Hz,
2H), 1.98-2.12 (m, 2H),
1.61-1.78 (m, 4H), 1.27-1.46 (m,
6H), 0.91 (t, J = 6.01 Hz, 3H)
10
(3-{[5-(4-Hexyl-phenyl)-6-
Intermediate
1 H NMR (300 MHz, CD 3 OD) δ 7.83 (d,
(3-hydroxy-phenyl)-
69
J = 7.91 Hz, 1H), 7.48 (d, J = 7.91 Hz,
pyridin-2-ylmethyl]-
1H), 7.10 (s, 4H), 7.02 (s, 1H),
amino}-propyl)-
6.98 (d, J = 7.62 Hz, 1H), 6.68 (d, J = 8.20 Hz,
phosphonic acid
2H), 4.34 (s, 2H), 3.17-3.23 (m,
2H), 2.59 (t, J = 7.62 Hz, 2H),
1.96-2.09 (m, 2H), 1.55-1.76 (m, 4H),
1.27-1.48 (m, 6H), 1.02 (t, J = 7.33 Hz,
3H)
11
(3-{[4-(3,3,4,4,5,5,6,6,6-
Intermediate
1 H NMR (300 MHz, CD 3 OD) δ
Nonafluoro-hexyl)-
73
7.52-7.58 (m, 2H), 7.45 (d, J = 7.33 Hz,
[1,1′;2′,1″]terphenyl-4′-
1H), 7.05-7.22 (m, 9H), 4.18 (s, 2H),
ylmethyl]-amino}-propyl)-
3.12 (t, J = 6.15 Hz, 2H),
phosphonic acid
2.84-2.91 (m, 2H), 2.33-2.52 (m, 2H),
1.92-2.07 (m, 2H), 1.61-1.74 (m, 2H)
12
(3-{[4-(3-Phenyl-propyl)-
Intermediate
1 H NMR (300 MHz, CD 3 OD) δ 7.56 (d,
[1,1′;2′,1″]terphenyl-4′-
67
J = 1.76 Hz, 1H), 7.53 (s, 1H), 7.45 (d,
ylmethyl]-amino}-propyl)-
J = 7.33 Hz, 1H), 7.10-7.27 (m, 10H),
phosphonic acid
6.97-7.04 (m, 4H), 4.18 (s, 2H),
3.12 (t, J = 6.30 Hz, 2H), 2.57 (t, J = 7.62 Hz,
4H), 1.82-2.07 (m, 4H),
1.61-1.75 (m, 2H)
13
[3-({6-(3-Chloro-phenyl)-
Intermediate
1 H NMR (300 MHz, CD 3 OD) δ 7.86 (d,
5-[4-(3-phenyl-propyl)-
72
J = 7.91 Hz, 1H), 7.54 (d, J = 7.91 Hz,
phenyl]-pyridin-2-
1H), 7.38-7.40 (m, 1H),
ylmethyl}-amino)-propyl]-
7.07-7.30 (m, 12H), 4.24 (s, 2H), 3.06 (t, J = 6.45 Hz,
phosphonic acid
2H), 2.62 (dt, J = 7.66, 9.89 Hz,
4H), 1.94 (d, J = 7.33 Hz, 4H),
1.60-1.73 (m, 2H)
14
[3-({6-Phenyl-5-[4-(3-
Intermediate
1 H NMR (300 MHz, CD 3 OD) δ 7.84 (d,
phenyl-propyl)-phenyl]-
68
J = 7.91 Hz, 1H), 7.52 (d, J = 7.91 Hz,
pyridin-2-ylmethyl}-
1H), 7.34-7.39 (m, 2H),
amino)-propyl]-
7.20-7.27 (m, 5H), 7.05-7.16 (m, 7H), 4.34 (s,
phosphonic acid
2H), 3.17 (t, J = 6.74 Hz, 2H),
2.56-2.64 (m, 4H), 1.85-2.10 (m, 4H),
1.62-1.75 (m, 2H)
15
(3-{[6-(3-Chloro-phenyl)-
Intermediate
1 H NMR (300 MHz CD 3 OD) δ 7.87 (d,
5-(4-hexyl-3-propyl-
71
J = 7.91 Hz, 1H), 7.54 (d, J = 7.91 Hz,
phenyl)-pyridin-2-
1H), 7.35-7.37 (m, 1H), 7.30 (tt, J = 1.87,
ylmethyl]-amino}-propyl)-
6.63 Hz, 1H), 7.19-7.26 (m,
phosphonic acid
2H), 7.12 (d, J = 7.91 Hz, 1H),
6.99 (dd, J = 1.90, 7.76 Hz, 1H), 6.86 (d, J = 2.05 Hz,
1H), 4.35 (s, 2H), 3.18 (t, J = 7.60 Hz,
2H), 2.61 (t, J = 8.20 Hz,
2H), 2.49 (t, J = 7.90 Hz, 2H),
1.95-2.09 (m, 2H), 1.62-1.75 (m, 4H),
1.50-1.61 (m, 2H), 1.29-1.48 (m, 6H),
0.90 (t, J = 6.40 Hz, 3H), 0.84 (t, J = 7.30 Hz,
3H)
16
(3-{[5-(4-Hexyl-3-propyl-
Intermediate
1 H NMR (300 MHz, CD 3 OD) δ 7.86 (d,
phenyl)-6-phenyl-pyridin-
70
J = 7.91 Hz, 1H), 7.50 (d, J = 7.91 Hz,
2-ylmethyl]-amino}-
1H), 7.35-7.39 (m, 2H),
propyl)-phosphonic acid
7.22-7.27 (m, 3H), 7.09 (d, J = 7.91 Hz, 1H),
6.99 (dd, J = 1.80, 7.91 Hz, 1H),
6.85 (d, J = 1.76 Hz, 1H), 4.35 (s, 2H),
3.19 (t, J = 5.86 Hz, 3H), 2.59 (t, J = 8.20 Hz,
2H), 2.45 (t, J = 8.20 Hz, 2H),
1.95-2.09 (m, 2H), 1.48-1.75 (m,
6H), 1.30-1.46 (m, 6H), 0.91 (t, J = 6.15 Hz,
3H), 0.81 (t, J = 7.33 Hz, 3H)
17
(3-{[6-(3-Fluoro-phenyl)-
Intermediate
1 H NMR (300 MHz, CD 3 OD) δ 7.84 (d,
5-(4-pentyloxy-phenyl)-
75
J = 7.91 Hz, 1H), 7.52 (d, J = 7.91 Hz,
pyridin-2-ylmethyl]-
1H), 7.06-7.28 (m, 5H),
amino}-propyl)-
6.97-7.04 (m, 1H), 6.85 (d, J = 8.79 Hz, 2H),
phosphonic acid
4.29 (s, 2H), 3.96 (t, J = 6.45 Hz, 2H),
3.12 (t, J = 6.45 Hz, 2H),
1.92-2.08 (m, 2H), 1.60-1.82 (m, 4H),
1.35-1.49 (m, 4H), 0.94 (t, J = 7.03 Hz, 3H)
18
(3-{[6-(4-Fluoro-phenyl)-
Intermediate
1 H NMR (300 MHz, CD 3 OD) δ 7.82 (d,
5-(4-pentyloxy-phenyl)-
76
J = 7.91 Hz, 1H), 7.49 (d, J = 7.91 Hz,
pyridin-2-ylmethyl]-
1H), 7.38-7.45 (m, 2H),
amino}-propyl)-
6.95-7.10 (m, 4H), 6.84 (d, J = 8.79 Hz, 2H),
phosphonic acid
4.29 (s, 2H), 3.95 (t, J = 6.45 Hz, 2H),
3.13 (t, J = 6.45 Hz, 2H),
1.93-2.08 (m, 2H), 1.60-1.81 (m, 4H),
1.33-1.51 (m, 4H), 0.94 (t, J = 7.00 Hz, 3H)
19
(3-{[5-(4-Pentyloxy-
Intermediate
1 H NMR (300 MHz, CD 3 OD) δ 7.83 (d,
phenyl)-6-phenyl-pyridin-
74
J = 7.91 Hz, 1H), 7.50 (d, J = 7.91 Hz,
2-ylmethyl]-amino}-
1H), 7.36-7.40 (m, 2H),
propyl)-phosphonic acid
7.23-7.28 (m, 3H), 7.03-7.08 (m, 2H),
6.78-6.83 (m, 2H), 4.33 (s, 2H), 3.93 (t, J = 6.45 Hz,
2H), 3.17 (t, J = 6.59 Hz,
2H), 1.94-2.09 (m, 2H),
1.61-1.80 (m, 4H), 1.33-1.50 (m, 4H), 0.94 (t, J = 7.00 Hz,
3H)
20
(3-{[6-(6-Octyl-pyridin-3-
Intermediate
1 H NMR (300 MHz, CD 3 OD) δ
yl)-biphenyl-3-ylmethyl]-
66
8.10 (dd, J = 0.59, 2.34 Hz, 1H), 7.63 (dd, J = 2.05,
amino}-propyl)-
7.91 Hz, 1H), 7.59 (d, J = 1.47 Hz,
phosphonic acid
1H), 7.50 (dd, J = 2.05, 8.20 Hz,
2H), 7.12-7.27 (m, 6H), 4.19 (s, 2H),
3.10 (t, J = 6.15 Hz, 2H), 2.72 (t, J = 7.90 Hz,
2H), 1.93-2.08 (m, 2H),
1.61-1.74 (m, 4H), 1.30 (s, 6H),
0.89 (t, J = 6.54 Hz, 3H)
21
{3-[(4-Octyl-
Intermediate
1 H NMR (300 MHz, CD 3 OD) δ 7.53 (s,
[1,1′;2′,1″]terphenyl-4′-
77
2H), 7.41-7.47 (m, 1H),
ylmethyl)-amino]-propyl}-
7.10-7.20 (m, 5H), 6.95-7.05 (m, 4H), 4.16 (d, J = 9.38 Hz,
phosphonic acid
2H), 3.04-3.14 (m, 2H),
2.54 (t, J = 7.33 Hz, 2H),
1.93-2.05 (m, 2H), 1.53-1.74 (m, 4H),
1.26-1.48 (m, 6H), 0.89 (t, J = 7.00 Hz, 3H)
22
(3-{[6-(6-Octyl-pyridin-3-
1 H NMR (300 MHz, CD 3 OD) δ 8.09 (d,
yl)-biphenyl-3-ylmethyl]-
J = 1.76 Hz, 1H), 7.59-7.65 (m, 2H),
amino}-propyl)-
7.47-7.52 (m, 2H), 7.11-7.26 (m,
phosphonic acid
6H), 4.20 (s, 2H), 3.12 (t, J = 6.01 Hz,
2H), 2.72 (t, J = 7.62 Hz, 2H),
1.93-2.11 (m, 2H), 1.60-1.76 (m, 4H),
1.29 (d, J = 3.22 Hz, 10H), 0.89 (t, J = 6.74 Hz,
3H)
23
Phosphoric acid mono-
Intermediate
1 H NMR (300 MHz, CD 3 OD) δ
{2-[(4-hexyl-
62
7.56 (dd, J = 2.05, 7.91 Hz, 1H), 7.52 (s,
[1,1′;2′,1″]terphenyl-4′-
1H), 7.42 (d, J = 7.62 Hz, 1H),
ylmethyl)-amino]-ethyl}ester
7.10-7.20 (m, 5H), 6.95-7.02 (m, 4H),
4.21 (s, 2H), 4.07-4.14 (m, 2H),
3.16-3.19 (m, 2H), 2.54 (t, J = 7.60 Hz, 2H),
1.51-1.71 (m, 2H), 1.26-1.33 (m,
6H), 0.89 (t, J = 6.74 Hz, 3H)
25
[1-(4-Hexyl-
Intermediate
1 H NMR (300 MHz, CD 3 OD) δ
[1,1′;2′,1″]terphenyl-4′-
62
7.35-7.44 (m, 3H), 7.10-7.19 (m, 5H),
ylmethyl)-pyrrolidin-3-yl]-
7.00 (s, 4H), 3.79-3.91 (m, 2H),
phosphonic acid
3.14-3.23 (m, 1H), 2.97-3.04 (m, 1H),
2.61-2.78 (m, 2H), 2.55 (t, J = 7.62 Hz,
2H), 2.30-2.44 (m, 1H),
2.06-2.19 (m, 2H), 1.52-1.61 (m, 2H), 1.30 (s,
6H), 0.89 (t, J = 6.45 Hz, 3H)
26
[1-(4-Hexyl-
Intermediate
1 H NMR (300 MHz, CD 3 OD) δ
[1,1′;2′,1″]terphenyl-4′-
62
7.40-7.49 (m, 3H), 7.16-7.21 (m, 3H),
ylmethyl)-pyrrolidin-3-yl]-
7.10-7.14 (m, 2H), 7.00 (s, 4H), 4.09 (s,
phosphonic acid
2H), 3.92 (quin, J = 7.00 Hz, 2H),
monoethyl ester
3.35 (s, 1H), 3.14-3.23 (m, 1H),
2.90-3.02 (m, 2H), 2.39-2.58 (m, 3H),
2.10-2.23 (m, 2H), 1.52-1.61 (m, 2H),
1.27-1.34 (m, 6H), 1.23 (t, J = 7.03 Hz,
3H), 0.88 (t, J = 7.00 Hz, 3H)
27
(3-{[5-(4-Hexyl-phenyl)-6-
Intermediate
1 H NMR (300 MHz, CD 3 OD) δ 7.85 (d,
phenyl-pyridin-2-
65
J = 7.91 Hz, 1H), 7.51 (d, J = 7.91 Hz,
ylmethyl]-amino}-propyl)-
1H), 7.35-7.38 (m, 2H),
phosphonic acid
7.19-7.27 (m, 3H), 7.04-7.11 (m, 4H), 4.32 (s,
2H), 3.15 (t, J = 6.59 Hz, 2H), 2.59 (t,
J = 7.62 Hz, 2H), 1.94-2.09 (m, 2H),
1.54-1.75 (m, 4H), 1.27-1.48 (m,
6H), 0.89 (t, J = 6.45 Hz, 3H)
28
(3-{[(4-hexyl-1,1′:2′,1″-
Intermediate
1 H NMR (300 MHz, CD 3 OD) δ
terphenyl-4′-
62
7.47-7.70 (m, 2H), 7.42 (d, J = 7.92 Hz,
yl)methyl]amino}propyl)phosphonic
1H), 7.05-7.28 (m, 5H),
acid
6.88-7.05 (m, 4H), 4.17 (s, 2H), 3.11 (t, J = 6.45 Hz,
2H), 2.53 (t, J = 7.62 Hz, 2H),
1.86-2.10 (m, 2H), 1.46-1.79 (m,
4H), 1.16-1.41 (m, 6H),
0.70-0.95 (m, 3H).
Example 16
Biological Data
[0243] Novel compounds were synthesized and tested for S1P1 activity using the GTP γ 35 S binding assay. These compounds may be assessed for their ability to activate or block activation of the human S1P1 receptor in cells stably expressing the S1P1 receptor. GTP γ 35 S binding was measured in the medium containing (mM) HEPES 25, pH 7.4, MgCl 2 10, NaCl 100, dithitothreitol 0.5, digitonin 0.003%, 0.2 nM GTP γ 35 S, and 5 μg membrane protein in a volume of 150 μl. Test compounds were included in the concentration range from 0.08 to 5,000 nM unless indicated otherwise. Membranes were incubated with 100 μM 5′-adenylylimmidodiphosphate for 30 min, and subsequently with 10 μM GDP for 10 min on ice. Drug solutions and membrane were mixed, and then reactions were initiated by adding GTP γ 35 S and continued for 30 min at 25° C. Reaction mixtures were filtered over Whatman GF/B filters under vacuum, and washed three times with 3 mL of ice-cold buffer (HEPES 25, pH7.4, MgCl 2 10 and NaCl 100). Filters were dried and mixed with scintillant, and counted for 35 S activity using a β-counter. Agonist-induced GTP γ 35 S binding was obtained by subtracting that in the absence of agonist. Binding data were analyzed using a non-linear regression method. In case of antagonist assay, the reaction mixture contained 10 nM S1P in the presence of test antagonist at concentrations ranging from 0.08 to 5000 nM.
[0244] Table 8 shows activity potency: S1P1 receptor from GTP γ 35 S: nM, (EC 50 ), and stimulation (%).
[0245] Activity potency: S1P1 receptor from GTP γ 35 S: nM, (EC 50 )
[0000]
TABLE 8
%
STIMU-
LATION
Compound
GTPγ 35 S
@ 5 μM
IUPAC name
EC50 (nM)
(%)
(3-{[6-(5-Hexyl-pyridin-2-yl)-biphenyl-3-
316.74
79.40
ylmethyl]-amino}-propyl)-phosphonic acid
(3-{[6-(6-Hexyl-pyridin-3-yl)-biphenyl-3-
833.01
94.70
ylmethyl]-amino}-propyl)-phosphonic acid
(3-{[5-(4-Hexyl-phenyl)-6-phenyl-pyridin-2-
252.03
112.30
ylmethyl]-amino}-propyl)-phosphonic acid
(3-{[6-(6-Octyl-pyridin-3-yl)-biphenyl-3-
771.47
89.70
ylmethyl]-amino}-propyl)-phosphonic acid
(3-{[5-(4-Pentyloxy-phenyl)-6-phenyl-
357.84
95.50
pyridin-2-ylmethyl]-amino}-propyl)-
phosphonic acid
(3-{[6-(4-Fluoro-phenyl)-5-(4-pentyloxy-
472.12
104.20
phenyl)-pyridin-2-ylmethyl]-amino}-propyl)-
phosphonic acid
(3-{[6-(3-Fluoro-phenyl)-5-(4-pentyloxy-
2200.43
83.90
phenyl)-pyridin-2-ylmethyl]-amino}-propyl)-
phosphonic acid
(3-{[4-(3-Phenyl-propyl)-
625.06
64.00
[1,1′;2′,1″]terphenyl-4′-ylmethyl]-amino}-
propyl)-phosphonic acid
(3-{[4-(3,3,4,4,5,5,6,6,6-Nonafluoro-hexyl)-
416.06
71.80
[1,1′;2′,1″]terphenyl-4′-ylmethyl]-amino}-
propyl)-phosphonic acid
(3-{[5-(4-Hexyl-3-propyl-phenyl)-6-phenyl-
29.59
73.10
pyridin-2-ylmethyl]-amino}-propyl)-
phosphonic acid
[3-({6-Phenyl-5-[4-(3-phenyl-propyl)-
93.84
86.60
phenyl]-pyridin-2-ylmethyl}-amino)-propyl]-
phosphonic acid
[3-({6-(3-Chloro-phenyl)-5-[4-(3-phenyl-
2427.07
64.00
propyl)-phenyl]-pyridin-2-ylmethyl}-amino)-
propyl]-phosphonic acid
(3-{[5-(4-Hexyl-phenyl)-6-thiophen-2-yl-
5.26
68.10
pyridin-2-ylmethyl]-amino}-propyl)-
phosphonic acid
(3-{[5-(4-Hexyl-phenyl)-6-thiophen-3-yl-
9.19
76.90
pyridin-2-ylmethyl]-amino}-propyl)-
phosphonic acid
(3-{[6-Furan-2-yl-5-(4-hexyl-phenyl)-pyridin-
0.44
88.60
2-ylmethyl]-amino}-propyl)-phosphonic acid
(3-{[5-(4-Hexyl-phenyl)-6-oxazol-4-yl-
0.87
86.10
pyridin-2-ylmethyl]-amino}-propyl)-
phosphonic acid
(3-{[5-(4-Hexyl-phenyl)-6-thiazol-2-yl-
6.52
89.30
pyridin-2-ylmethyl]-amino}-propyl)-
phosphonic acid
[3-({5-[4-(3-Phenyl-propyl)-phenyl]-6-
2.36
91.10
thiophen-2-yl-pyridin-2-ylmethyl}-amino)-
propyl]-phosphonic acid
(3-{[5-(4-Hexyl-3-propyl-phenyl)-6-thiophen-
7.72
79.10
2-yl-pyridin-2-ylmethyl]-amino}-propyl)-
phosphonic acid
(3-{[6-(5-Fluoro-thiophen-2-yl)-5-(4-hexyl-
25.05
110.70
phenyl)-pyridin-2-ylmethyl]-amino}-propyl)-
phosphonic acid
|
Novel aromatic compounds which are useful as sphingosine-1-phosphate modulators and useful for treating a wide variety of disorders associated with modulation of sphingosine-1-phosphate receptors.
| 2
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates to an apparatus for receiving and passing through laundry.
2. Description of the Related
In laundries, clean laundry such as sheets is fed to an apparatus which automatically mangles the laundry. This apparatus for feeding and laying down washed sheets is known from Dutch patent specification no. 167.743 in the name of applicant. Therein, the operator has to put two corners of the sheet between two clamps by hand.
A drawback to this apparatus is that, after the first corner has been inserted, the entire longest edge of the piece of laundry has to be searched or guided to find the second corner, in order to put it in the second clamp. This is very time-consuming.
It is an object of the present invention to obviate this drawback.
SUMMARY OF THE INVENTION
For this purpose the apparatus according to the invention was developed, which apparatus achieves this object with the measure, that the apparatus comprises intake means that require only one corner of a piece of laundry to be fed by hand, and conveyor means to convey a side edge from the corner of the piece of laundry in a stretched condition.
Because only one corner of the piece of laundry need now be fed, after which the conveying means convey a side edge from the corner of the piece of laundry, a considerable shortening of the cycle time for feeding is obtained.
The intake means preferably comprise orientating means and control means which steer a side from the corner of the piece of laundry along a substantially straight line. Hereby, the clamps can easily be placed further on, for instance by feeding the side to a clamp placing mechanism.
According to an embodiment of the apparatus, the apparatus comprises a frame, belt conveyor means and a drive mechanism for the belt conveyor means, and the orienting means comprise steering rollers and members to bring the steering rollers into contact with the piece of laundry, the steering rollers being actuated by the control means, to pass the piece of laundry through in such a way, that the side of the piece of laundry runs along a substantially straight line after a front edge area of the piece of laundry has been fed into the apparatus.
According to a further embodiment the belt conveyor means comprise front belt conveyor means and rear belt conveyor means, the belt conveyor means being arranged to clamp the piece of laundry, the rear belt conveyor means protruding forwards from below the front belt conveyor means, the rear belt conveyor means comprising a rear endless conveyor belt, wherein engagement means for the piece of laundry are placed at the forwardly protruding portion of the rear belt conveyor means, said engagement means preferably comprising at least one pressure roller, resting on the rear conveyor belt, to press a front edge area, preferably a front edge area spaced from the vertex of the corner, and following areas of the piece of laundry onto the forwardly protruding portion of the rear conveyor belt.
According to yet a further embodiment the intake means comprise a loading table having placed therein a right-hand rear steering roller and left-hand rear steering roller, a right-hand front steering roller and a left-hand front steering roller, the right-hand and the left-hand steering rollers being positioned opposite each other in pairs and the front steering rollers being suspended and liftable independently from the rear steering rollers, and each pair of steering rollers defining an equal but opposite angle with regard to the perpendicular on the longitudinal direction of the belt conveyor means, and wherein the control means comprise an edge photocell and command means for the steering rollers.
It is remarked that it is known in itself to guide long strips, such as paper strips, by means of pairs of steering rollers. In that case, however, a pair of rollers is positioned on each edge of the strip, the rollers, each on one side, having a bearing in a support block. As a consequence thereof, the strip cannot run between the rollers on both sides of both pairs of rollers.
In a more detailed embodiment, the edge photocell is arranged adjacent to the rollers in the loading table, where the side of the piece of laundry will run, in front of the protruding portion of the rear belt conveyor means and the edge photocell actuates the command means to cause a pair of rollers to cover the edge photocell again with the edge of the piece of laundry if the edge photocell is not covered and to cause the other pair of rollers not to cover the edge photocell again with the edge of the laundry if the edge photocell is covered.
According to a further embodiment the command means comprise a left-hand electromagnet with compression spring for the left-hand pair of steering rollers and a right-hand electromagnet with compression spring for the right-hand pair of steering rollers and pressure means for the front steering rollers, the edge photocell alternately opening the right-hand pair of steering rollers and the left-hand pair of steering rollers during reception of the piece of laundry, by means of the respective electromagnets. The electromagnets with compression spring are preferably arranged onto the rear steering rollers.
According to a preferred embodiment at least one activating photocell, and preferably two activating photocells spaced sideways from one another, is/are placed in the loading table to start the belt conveyor means when the activating photocell is covered if the edge photocell is also covered. As a consequence hereof, the apparatus will start automatically.
The activating photocell preferably actuates the pressure means to lift the front steering rollers when the activating photocell is no longer covered by the piece of laundry. As a consequence hereof, the intake means are immediately capable of receiving a new piece of laundry.
According to a preferred embodiment the opposite angles of the respective pairs of steering rollers with regard to the perpendicular on the longitudinal direction of the belt conveyor means are between 0° and 45°, preferably 25°.
The intake means steer the side of the piece of laundry in an advantageous manner after the at least one activating photocell has been covered for a certain, pre-settable time. Hereby, the first corner of the piece of laundry can be securely held.
According to a further embodiment, a forwardly protruding curved guide rod is placed near the lower edge of the loading table for smoothing the creases present in the piece of laundry, which guide rod protrudes sidewards from the rear conveyor belt on the side opposite the side, where the side edge of the piece of laundry will run. During conveyance, the piece of laundry will slide over this guide rod before it reaches the loading table, as a consequence of which any creases that may be present are smoothed from the piece of laundry.
According to a preferred embodiment there are placed, preferably below the loading table, spaced from the piece of laundry's edge which is to be conveyed, discontinuously operating supporting means for supporting the freely depending portion of the piece of laundry, if the piece of laundry is wider than the belt conveyor means. These supporting means assist the freely depending portion of the piece of laundry, which is hanging down next to the fed corner of the piece of laundry, during the upward conveyance, in that they discontinuously assist the freely depending portion of the piece of laundry in moving upwards.
Moreover, the supporting means spread the piece of laundry sidewards in an advantageous manner whereby the piece of laundry, which could have the tendency to shift as a consequence of the weight of the freely depending portion, is once more spread.
According to a preferred embodiment the supporting means comprise a supporting member with one or more spread cams, which move upwards at an oblique angle during operation of the supporting means, whereby the spread cams move the piece of laundry upwards as well as spread it.
An advantageous embodiment is obtained when the supporting member is a rotatable cam table of which the corners form the spread cams, the cam table preferably being essentially triangular, and wherein the cam table, seen in a plane parallel to the front belt conveyor means, is preferably upwardly inclined under an angle of 15° with regard to the horizontal. Hereby, one corner of the cam table will each time function as spread cam and help the piece of laundry upwards and spread it, when the cam table rotates one-third of a revolution.
In order to place one or more clamps on the piece of laundry, the apparatus comprises clamp placing means. By means of these, clamps are automatically placed on the piece of laundry.
The clamp placing means comprise a clamp placing unit and clamp control means. According to an embodiment the front belt conveyor means comprise a front endless conveyor belt and a front endless insert belt, the front insert belt being placed alongside the front conveyor belt, and the rear endless belt conveyor means comprising a rear endless insert belt, placed alongside the rear conveyor belt, the insert belts being essentially brought into contact with each other in order to guide and to clamp the side of the piece of laundry, the insert belts being shorter than the conveyor belts.
According to a further embodiment the clamp placing unit is placed at the exit point of the insert belts and the clamp control means comprise a clamp photocell to spot the piece of laundry and to activate the clamp placing unit.
According to a preferred embodiment the clamp placing unit comprises a buffer rail with supplied clamps, and a pivotable arm which can fetch a clamp, while opening the clamp, and the clamp photocell acutates the pivotable arm to place the clamp onto the edge of the piece of laundry.
It is preferred that the clamp placing unit comprises a pneumatic cylinder for pivoting the pivotable arm, and comprises a pneumatic cylinder for opening and closing the clamp. Two guide plates are placed between the insert belts and the path of the clamps in an advantagous manner to guide the edge of the piede of laundry. Hereby, the edge of the piece of laundry is fed into the clamp placing unit correctly.
It is preferred that blower means are provided adjacent to the guide plates to establish an air current to keep the edge of the piece of laundry stretched.
An advantageous embodiment of the apparatus is obtained if the apparatus is arranged substantially vertically, so that the apparatus occupies little floor space.
With this apparatus it becomes possible to receive and pass through laundry, only one corner of a piece of laundry needing to be fed by hand, and a side edge from the corner of the piece of laundry being conveyed in a stretched condition by conveying means, in order to handle the piece of laundry further on.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described hereafter by means of a preferred embodiment, with reference to the accompanying drawings.
FIG. 1 presents a schematical front view of a preferred embodiment of the apparatus according to the invention.
FIG. 2 presents a side view of the apparatus according to FIG. 1.
FIG. 3 presents a schematical front view of the intake means in the apparatus according to FIG. 1, on a larger scale.
FIG. 4 presents a side view of the intake means according to FIG. 3.
FIG. 5 presents a schematical front view of the clamp placing means according to FIG. 1, on a larger scale.
FIG. 6 presents a side view of the clamp placing means according to FIG. 5.
FIG. 7 presents a cross-section of the apparatus seen in FIG. 5 along the line VII--VII on a bigger scale.
FIG. 8 presents a simplified top view of the apparatus according to FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1 and 2 show the preferred embodiment of the invention. A frame 1 stands on the ground by means of legs. A front endless conveyor belt 2 and a rear endless conveyor belt 3 run substantially vertically and are actuated by a driving mechanism, generally indicated by 4. The lower portion of the rear endless conveyor belt 3 protrudes both forwards from below the front conveyor belt 2 over a length of about 50 cm and downwards under an angle of 20° with the horizontal. An equally wide pressure roll 30 rests on this lower portion, said pressure roll 30 being hinged around axis of rotation 38 by means of arms 39. The conveyor belts are 360 mm wide and have to clamp the piece of laundry between them and pass it upwards. In order to be able to place clamps 21, the piece of laundry should substantially run along the imaginary intake line 9. For this purpose intake means are present. These intake means have been indicated in greater detail in FIGS. 3 and 4.
A loading table 19 is placed at the lower end of the rear endless conveyor belt 3. The top portion of the loading table rests under the upper surface of the forwardly protruding portion of belt 3 to support it. From the front edge of belt 3 the loading table 19 extends substantially vertically downwards. On the transition of the top and the lower portion of the loading table 19 a smooth freely rotating roller 40 has been provided, which roller protrudes somewhat from the loading table. In the lower portion of the loading table 19 a right-hand rear steering roller 11 and a left-hand rear steering roller 12 are placed, which protrude forward somewhat from the back plate. A right-hand front steering roller 13 and a left-hand front steering roller 14, respectively, are placed opposite these rollers, both rollers 13, 14 being suspended on an arm 31. The steering rollers are not parellel to the end rollers for the conveyor belts, but the right-hand pair is positioned under a downward angle of 25° towards the right and the left-hand pair is positioned under a downward angle of 25° towards the left.
A pneumatic cylinder 15 can press the front steering rollers 13, 14 against the rear steering rollers 11, 12, or lift them, by means of the arm 31, which rotates around the centre of rotation 37. This happens once with each piece of laundry. Electromagnets with compression springs 17, 18 are provided on the respective rear steering rollers 11, 12. An electromagnet with compression spring can quickly withdraw the corresponding rear steering roller over a distance of about 3 mm. In this situation, the front steering rollers are tightly secured to the arm 31.
Alternatively, the electromagnets with compression spring can be provided on the respective front steering rollers 13, 14. An electromagnet with compression spring may then quickly lift the corresponding front steering roller over a distance of about 3 mm.
The rollers are covered with a mohair covering. It has been found that a pressure force of 27.5 N provides the best results.
A curved guide rod 35 has been provided near the lower edge of the loading table 19, which guide rod protrudes in front of the loading table and protrudes sidewards where the freely depending portion of a wide piece of laundry will hang.
A triangular cam table 32 is provided below the loading table 19, of which cam table the corners form three cams 45. The cam table is placed at the side of the conveyor belts, where the freely depending portion of a wide piece of laundry will hang. The cam table is actuated intermittently by a direct-current motor 33, which actuates the cam table deceleratedly via transmission 42, pulley 43 and pulley 44. When the cam table is not in motion, the current front side of the cam table lies in the same vertical plane as does the relevant portion of guide rod 35 which is placed above the cam table. Seen from above (FIG. 8) the cam table rotates clockwise. Three holes 36 are provided in the cam table, and an inductive reader 34 has been placed under it. After the cam table has been partially rotated the motor stops as soon as a hole 36 is detected by the reader 34. Seen in a plane parallel to the front conveyor belt, cam table 32 is upwardly inclined under an angle of 15° with the horizontal (FIG. 3).
Two activating photocells B01 are provided under the pairs of rollers and an edge photocell B02 is provided in the input table 19 on the right of the pair of rollers.
In order to convey the side of the piece of laundry properly towards the clamp placing means, a front insert belt 5 and a rear insert belt 6 are provided alongside the lower portions of the conveyor belts 2, 3. These insert belts clamp the side of the piece of laundry. They can be seen most clearly in FIGS. 2 and 4. These insert belts have a width of 50 mm and are positioned immediately above the edge photocell B02. The front insert belt 5 extends equally far downwards as does the front conveyor belt 2, and the rear insert belt 6 extends equally far downwards as does the rear conveyor belt 3.
Close to the front conveyor belt and the front insert belt a security plate (not shown) is provided across the entire width of the input table, which security plate causes the belts to stop immediately upon contact.
The insert belts 5, 6 are shorter than the conveyor belts 2, 3. The clamp placing unit 10 has been placed at the position where the insert belts end. The clamp placing unit 10 is shown in more detail in FIGS. 5 and 6. The clamp placing unit comprises a pivotable arm 22, with can fetch a special clamp 21 from the buffer rail 20 and can pivot it to the position on the imaginary intake line 9. The clamps 21 are supplied along arrow D (FIG. 8). The pivotable arm 22 is operated by means of a pneumatic cylinder 28. One of two pneumatic cylinders 23 opens and closes the clamp 21 at the right moment. This moment is determined by a clamp photocell B03, which also controls the pivotable arm 22.
Two guide plates 25 are provided between the top end of the insert belts 5, 6 and the placing position of the clamps 21 to guide the edge of the piece of laundry, where an air current is blown through (arrows C in FIG. 7) by means of blow-pipes 26 to keep the edge of the piece of laundry stretched and to reduce friction. This can be seen clearly in FIG. 7.
After the clamps have been placed, they run on over the rail system 29, and they may be conveyed to different directions (arrows E, F, G in FIG. 8), according to choice.
The apparatus works in the following manner. In the starting situation the front steering rollers 13, 14 are lifted and the belts 2, 3, 5, 6 are stationary. A piece of laundry 8 is laid down with a short side leading on the upper side of the protruding portion of the rear conveyor belt 3 and rear insert belt 6, and is conveyed under pressure roller 30 in such a way, that the side of the piece of laundry is positioned more or less against the imaginary intake line 9. Because the pressure roller is as wide as the rear conveyor belt 3, the hands of an operator can get to both sides of the feed roller, and the operator can convey the piece of laundry under the pressure roller and can put the corner point of the piece of laundry on the correct spot on the rear insert belt. The central supporting arm 31 for the front steering rollers 13, 14 ensures that the latter are not in the way when feeding the piece of laundry.
The driving mechanism 4 makes the belts 2, 3, 5, 6 run with a speed of 18 meters/minute when both the edge photocell B02 and at least one activating photocell B01 are covered (the piece of laundry will then also be received and passed through if one of the activating photocells B01 is not covered by, for instance, a hole or a tear in the piece of laundry).
After the piece of laundry has been conveyed under the pressure roller over a length of about 10 cm, the intake means are actuated. The front steering rollers 13, 14 are pressed against the rear rollers 11, 12 by the pneumatic cylinder 15 (arrow A in FIG. 2 and 4). When the edge photocell B02 is now not covered, the left-hand rear steering roller 12 is withdrawn a short way by the left-hand electromagnet 17. As a consequence hereof the right-hand pair of steering rollers 11, 13 will steer the piece of laundry to the right. Consequently, the edge photocell B02 is covered. Thereby, the left-hand electromagnet 17 is deactivated, so that the left-hand rear steering roller 12 will once again clamp the piece of laundry and the right-hand rear steering roller 11 is simultaneously withdrawn a short way by the right-hand electromagnet 18. As a consequence hereof, the left-hand pair of steering rollers 12, 14 now steers the piece of laundry to the left. Consequently, the edge photocell B02 is no longer covered, whereby the left-hand rear steering roller 12 is withdrawn and the right-hand rear steering roller 11 is clamped and the cycle repeats itself.
There is therefore no optimum position for the side of the piece of laundry, but instead a zigzag frequency is obtained with an amplitude of about 5 mm. This is sufficiently exact to be able to place the clamps 21.
After about 30 cm of the piece of laundry has been received, and a front edge of the piece of laundry is positioned between the conveyor belts and between the insert belts, the drive mechanism makes the belts run at a speed of 72 meters/minute.
In actual practice, it has been found that the piece of laundry has a tendency to move to the right as a consequence of the weight of the freely depending portion (on the left in FIG. 1). For that reason the cam table 32 is placed under the guide rod 35, which smooths creases present in the piece of laundry. During the fast conveyance of the piece of laundry the cam table rotates one-third of a revolution once or several times, depending on the length of the piece of laundry. Hereby, the piece of laundry is lifted for a short period and is brushed to the left, the laundry being spread simultaneously. The one-third of a revolution is executed in aproximately 3/4 seconds and after that the cam table will remain motionless for approximately the same duration. If edge photocell B02 remains covered for too long, the cam table will immediately rotate another one-third of a revolution. When the activating photocells B02 become uncovered, the cam table is switched off (at the end of its partial rotation).
The clamp photocell B03 detects the piece of laundry and makes the rotatable arm 22 with opened clamp 21 pivot from the vertical position of rest to the horizontal placing position (arrow B in FIG. 5), as soon as the corner of the piece of laundry is in the placing position. This is done to ensure that the clamp does not hinder the corner of the piece of laundry but that it rather stretches it tight. One of the two pneumatic cylinders 23 closes the clamp and the piece of laundry moves on, the clamp being taken along over the rail system 29.
Immediately after the first clamp has been placed, the rotatable arm 22 fetches a second clamp and turns it in an open condition towards the placing position, so that the last portion of the side of the piece of laundry is pulled through the clamp, which thereby stretches the side tight. The clamp photocell B03 detects the lower edge of the piece of laundry and has the second clamp placed. If the pivotable arm with the second clamp is not yet in the placing position before the second corner of the piece of laundry is present, the belts 2, 3, 5, 6 are stopped for a short period so that a portion of the side of the piece of laundry is always pulled through the clamp.
The clamps can be placed while the piece of laundry is not in motion or while the piece of laundry is slowly being conveyed.
As soon as the activating photocell B01 is no longer covered, the pneumatic cylinders 15, 16 automatically lift the front steering rollers 13, 14. A next piece of laundry can be fed directly if belts 2, 3, 5, 6 are also stopped.
In this way a next piece of laundry may already be fed while the second clamp is yet to be placed on the preceding piece of laundry.
As a consequence hereof, a cycle time of 4.5 seconds for an average single sheet is reached, so 800 pieces/hour per operator are obtainable. By placing two of these apparatus in mirror-fashion next to each other or behind each other, one mangling machine can be provided with sufficient laundry.
With this apparatus it is possible that even laundry which is fed in a non-aligned manner will immediately be corrected, provided that the skewness is clearly less than 25°. Folded sides and twisted lower sides are automatically vibrated out of the laundry as a consequence of the zigzag frequency.
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Apparatus for receiving and passing through pieces of laundry, a piece of laundry being rectangular and comprising a leading edge, a rear edge and two lateral edges, the apparatus comprising a frame and or intake device on the frame for engaging a sole corner portion of the leading edge of the piece of laundry which is fed by hand, and a conveyor arranged downstream of the intake means for clamping and conveying the corner portion and the lateral edge portion following the corner portion in a smooth and straightened out condition, independent of the other lateral edge.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority from U.S. Provisional Application Ser. No. 60/758,686 filed Jan. 13, 2006; the disclosure of which is incorporated herein by reference.
BACKGROUND OF THE INVENTION
[0002] 1. Technical Field
[0003] The invention relates to anti-shoplifting devices, and more particularly to an anti-shoplifting device for merchandise having a substantially cylindrical surface and in particular, for bottles having a cylindrical neck. The invention provides a security device that holds an electronic article surveillance tag (EAS tag) which is concealed within a rigid housing which is secured by a ratchet strap around the neck of the bottle. The housing has opposed outer surfaces which are tapered toward one another to make it difficult to grasp the housing or otherwise force the housing to pry the device off of the bottle neck. The housing further includes an arcuate channel for receiving and guiding the strap within the housing.
[0004] 2. Background Information
[0005] Many types of theft deterrent devices have been developed for protecting various types of merchandise. Many of these devices include EAS tags which are typically hidden from the potential thief and which will sound an alarm when removed from the store. Amongst these security devices are bottle security devices which are specifically configured to connect to the neck of a bottle in a manner that is difficult to remove without breaking the neck of the bottle.
[0006] In addition, various types of security devices utilize a ratchet-type strap which is secured around an object to prevent removal of the device from an item of merchandise. Many of these devices use a flat plastic strap which is either attached to or formed as part of the latching mechanism. However, many of these types of devices do not include a lock or contain an EAS tag. One of the problems that bottle security devices seek to overcome is the removal by a thief of the security device from the neck of a bottle. Attempts at such removal may involve manual manipulation of the device, gripping of the device with pliers or other like tools, prying with a screwdriver or the like and hitting the security device on a rigid structure such as a shelf or corner of a table in order to either break the device or pry it loose from the bottle neck. Thus, there is a need in the art to produce a bottle security device having a ratchet strap which is more difficult to remove from the bottle neck without breaking the bottle.
[0007] In addition, there is a need in the art to lock the ratchet strap to a housing to which it is attached in a simple and effective manner while providing a locking mechanism which may be easily unlocked by store personnel during the purchase of the bottle and contents thereof. The present invention addresses these and other problems.
BRIEF SUMMARY OF THE INVENTION
[0008] The present invention provides a security device for attaching around a generally annular article to be protected from theft, said device comprising a rigid housing defining an interior chamber with an entry port; wherein the housing has a concave inner perimeter and an outer perimeter; a ratchet strap which is connected to and extends outwardly from the housing and has a series of one-way locking teeth formed thereon; an EAS tag disposed within the housing; a locking mechanism disposed in the interior chamber for lockably engaging one of the locking teeth when the strap is inserted through the entry port to secure the strap in a locked position in which the strap and inner perimeter of the housing define therebetween an article-receiving space adapted to receive the generally annular article; wherein the strap and inner perimeter of the housing together assume a generally circular configuration which is substantially concentric about a longitudinal axis; and wherein the housing has first and second opposed outer surfaces which taper radially outwardly and longitudinally toward one another from adjacent the inner perimeter to adjacent the outer perimeter.
[0009] The present invention further provides in combination a generally annular article and a security device attached around the article to protect the article from theft, the security device comprising a rigid housing defining an interior chamber with an entry port; a ratchet strap extending outwardly from the housing and having a series of one-way locking teeth formed thereon; an EAS tag disposed within the housing; and a locking mechanism disposed within the interior chamber for lockably engaging one of the locking teeth when the strap is inserted through the entry port to secure the strap in a locked position in which the strap forms a loop around the generally annular article; wherein a portion of the article is disposed within the loop and the article extends longitudinally in opposite directions from said portion beyond the loop; wherein the housing has first and second opposed outer surfaces which taper radially outwardly and longitudinally toward one another from adjacent the article to adjacent an outer perimeter of the housing.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0010] FIG. 1 is a top plan view of the bottle security device of the present invention in an unlocked position adjacent a neck of a bottle.
[0011] FIG. 2 is a side elevational view of the device and bottle neck shown in FIG. 1 .
[0012] FIG. 3 is a sectional view taken on line 3 - 3 of FIG. 2 showing the internal structure of the housing of the security device.
[0013] FIG. 4 is similar to FIG. 1 and shows the security device in a locked position on the bottle neck.
[0014] FIG. 5 is similar to FIG. 2 and shows the security device locked on the bottle neck.
[0015] FIG. 6 is a sectional view taken on line 6 - 6 of FIG. 5 .
[0016] FIG. 6A is an enlarged fragmentary sectional view of a portion of FIG. 6 showing the locking mechanism in greater detail.
[0017] FIG. 6B is a sectional view taken on line 6 B- 6 B of FIG. 6 .
[0018] FIG. 7 is a view similar to FIG. 5 showing a hand with fingers in contact with the anti-grasping surfaces of the housing.
[0019] FIG. 8 is similar to FIG. 7 and shows the fingers of the hand having slipped off of the anti-grasping surfaces.
[0020] Similar numbers refer to similar parts throughout the drawings.
DETAILED DESCRIPTION OF THE INVENTION
[0021] The bottle security device of the present invention is indicated generally at 10 in FIGS. 1 and 2 , in which device 10 is shown in an unlocked position adjacent a substantially cylindrical neck 12 of a bottle 14 . Neck 12 has an outer surface 13 and includes an outwardly projecting annular bead 16 .
[0022] Device 10 includes a rigid housing 18 and a ratchet strap 20 which is connected to housing 18 and extends outwardly therefrom. Each of housing 18 and 20 has inwardly projecting tabs 22 which are circumferentially spaced from one another and are configured to contact a lower surface of bead 16 of neck 12 to prevent removal of device 10 from neck 12 when device 10 is locked thereon. Strap 20 is formed of a material having a sufficient stiffness to provide a preset curvature to the strap. Strap 20 is connected to housing 18 adjacent a first end thereof and includes a plurality of one way locking teeth 24 extending along a portion 26 of strap 20 adjacent a second opposed end thereof. Locking teeth 24 extend outwardly from a substantially flat body 28 of strap 20 . A finger tab 30 also extends outwardly from body 28 to facilitate insertion of portion 26 of strap 20 into housing 18 . Portion 26 of strap 20 is in the form of an arc which lies along a substantially circular path.
[0023] Housing 18 has first and second ends 32 and 34 which are circumferentially spaced from one another by a concave inner surface or perimeter 36 of housing 18 which is in the form of an arc which lies along a substantially circular path. Housing 18 has a convex outer perimeter 38 which is generally U-shaped and extends from first end 32 to second end 34 of housing 18 . Housing 18 includes first and second opposed outer anti-grasping or deflecting surfaces 40 and 42 which taper outwardly from adjacent inner perimeter 36 toward one another to closely adjacent inner perimeter 36 . Surfaces 40 and 42 are preferably smooth and slippery to help prevent manual or other grasping thereof. For purposes of description herein, outer surface 40 may be considered an upper surface and outer surface 42 may be considered a lower surface. Upper surface 40 tapers outwardly and downwardly from adjacent inner perimeter 36 to adjacent outer perimeter 38 and lower surface 42 tapers outwardly and upwardly from adjacent inner perimeter 36 to adjacent outer perimeter 38 . Each of surfaces 40 and 42 extend circumferentially from adjacent first end 32 to adjacent second end 34 of housing 18 . Each of surfaces 40 and 42 are generally frustoconical while varying somewhat from a true frustoconical shape in light of the U-shaped outer perimeter 38 of housing 18 . Housing 18 further defines a pair of spaced key alignment indentations 44 which respectively extend inwardly from surfaces 40 and 42 . Indentations 44 are utilized to align a magnetic key such as that shown and described in co-pending patent application having Ser. No. 11/022,084, the contents of which are incorporated herein by reference. Said application also shows and describes a locking mechanism similar to that of the present invention.
[0024] With reference to FIG. 3 , housing 18 defines an interior chamber 46 which serves to house an EAS tag 48 and a locking mechanism 50 which lockably engages locking teeth 24 of strap 20 when strap 20 is in a locked position to prevent removal of strap 20 from housing 18 and to secure device 10 to bottle neck 12 . Locking mechanism 50 includes a locking pawl 52 and a spring biased actuation strip 54 which biases locking pawl 52 to a locked position shown in FIG. 3 . Locking pawl 52 is formed of a metal, is pivotally mounted within interior chamber 46 and has a bent free end 56 which lockably engages locking teeth 24 when strap 20 is in a locked position. Actuation strip 54 is formed of a spring metal and includes a spring finger 58 which is cantilevered from adjacent an outer wall 60 of housing 18 and includes a free end 62 which engages locking pawl 52 to spring bias locking pawl 52 into its locked position. Housing 18 defines an entry port 64 adjacent second end 34 thereof for receiving the free end of strap 20 . Free end 56 of locking pawl 52 extends generally away from entry port 64 and free end 62 of locking finger 58 extends generally toward entry port 64 .
[0025] Housing 18 defines an arcuate channel 66 which communicates with entry port 64 and is configured to receive portion 26 of strap 20 . Channel 66 has an arcuate path which is complimentary to the arcuate shape of portion 26 of strap 20 to facilitate the insertion and removal of portion 26 into and out of channel 66 . More particularly, channel 66 is an arc which lies along a substantially circular path. Channel 66 is bounded by an arcuate inner wall 68 of housing 18 . More particularly, inner wall 68 has a convex arcuate surface 70 which bounds channel 66 opposite of inner perimeter 36 of housing 18 . Channel 66 extends from entry port 64 to adjacent the first end of strap 20 which is disposed within interior chamber 46 adjacent first end 32 of housing 18 . Channel 66 is described in greater detail further below.
[0026] FIGS. 4-6 show device 10 in the locked position in which it is lockably secured to bottle neck 12 with tabs 34 disposed below bead 16 . In the locked position of device 10 , inner perimeter 36 is in contact with the outer surface of neck 12 , in particular in contact with bead 16 . Thus, when locked onto bottle 14 , anti-grasping surfaces 40 and 42 taper outwardly toward one another from closely adjacent neck 12 , thus providing a minimal amount of surface which may be easily grasped in an attempt to force device 10 off of bottle neck 12 . To move from the unlocked to the locked position of device 10 , strap 20 is inserted as shown at Arrow A in FIG. 6 through entry port 64 and into arcuate channel 66 so that bent free end 56 of locking pawl 52 lockably engages one of locking teeth 24 of strap 20 . In the locked position, strap 20 cannot be removed from housing 18 without the appropriate key and device 10 is securely attached to bottle neck 12 . Should a potential thief move bottle 14 and device 10 to an unauthorized area, EAS tag 48 will cause an audible alarm to sound to warn store personnel of the potential theft.
[0027] As shown in FIGS. 4 and 5 , bottle neck 12 is substantially concentric about a longitudinal axis X which passes centrally through bottle 14 and is substantially vertical when bottle 14 is in an upright position as shown in FIG. 5 . Outer surface 13 of bottle neck 12 is substantially parallel to axis X. When device 10 is locked onto bottle neck 12 as shown in FIGS. 4 and 5 , inner wall 68 of housing 18 and strap 20 form a substantially circular configuration which is substantially concentric about axis X. Strap 20 and housing 18 are spaced radially outwardly of axis X and disposed substantially along a plane P which is perpendicular to axis X. Upper tapered surface 40 of housing 18 is angled with respect to plane P as indicate at angle Y and with respect to axis X as indicated at angle Z. Typically, lower tapered surface 42 has the same respective angles Y and Z as indicated in FIG. 5 although this may vary somewhat. The lines in FIG. 4 which are numbered as surfaces 40 and 42 represent respective linear intersections with a plane in which the axis X lies.
[0028] It is noted that the angle of surfaces 40 and 42 with respect to such a perpendicular plane as plane P may vary as one moves circumferentially along said surfaces 40 and 42 . Thus, for instance, the angle of surface 40 with respect to plane P adjacent second end 34 of housing 18 may be different than the angle represented at Y in FIG. 5 , which is along surface 40 intermediate first and second ends 32 and 34 of housing 18 . Each of surfaces 40 and 42 thus may represent a variable angle surface as one travels circumferentially around housing 18 . Having said this, angle Y and corresponding angles with respect to a plane such as plane P needs to be sufficiently large to provide the anti-grasping end and other characteristics described further below. In the exemplary embodiment, angle Y is approximately 30° and angle Z is approximately 60°. However, these angles may vary. Angle Y is typically at least 25°, more preferably at least 300 . In general, the greater that angle Y is, the more effective surfaces 40 and 42 may be in creating anti-grasping characteristics and other characteristics subsequently described herein. However, it is preferred to keep angle Y as small as possible while producing these desired characteristics in order to produce a housing 18 which has a size which is as small as possible for the purpose.
[0029] With reference to FIG. 6B , arcuate channel 66 is further detailed. Channel 66 has a T-shaped cross-sectional configuration as does strap 20 along portion 26 thereof. More particularly, a pair of opposed intermediate walls 72 and 74 are disposed within interior chamber 46 of housing 18 and are substantially parallel to inner and outer walls 68 and 60 of housing 18 . Walls 72 and 74 are spaced outwardly from inner wall 68 a distance which is slightly larger than the thickness of body 28 of strap 20 so that the inner surface of strap 20 along portion 26 thereof abuts the outer surface of inner wall 68 when in a locked position and the outer surface of portion 26 adjacent first and second opposed edges 76 and 78 thereof is respectively closely adjacent or in abutment with walls 72 and 74 . Each of walls 72 and 74 is arcuate and more particularly is an arc lying along a circular path. Walls 72 and 74 are respectively cantilevered from upper and lower tapered walls 80 and 82 of housing 18 . The free ends of walls 72 and 74 extend toward one another and define therebetween a portion of slot 66 in which locking teeth 24 are disposed when in the locked position. Bent free end 56 of locking pawl 52 extends into this portion of slot 66 in its locked position, as shown in FIG. 6A .
[0030] Arcuate channel 66 has a curvature which mates with that of portion 26 of strap 20 to facilitate easy insertion and withdrawal of strap 20 . Channel 66 also positions portion 26 of strap 20 more precisely than in known prior art devices to accurately align locking teeth 24 with bent free end 56 of locking pawl 52 . This greater precision of positioning and alignment allows strap 20 to perform more effectively than in known prior art devices while allowing for a loosening of tolerances in the manufacture of strap 20 , especially in portion 26 thereof. This reduction in tolerance requirements allows for less expensive manufacture of strap 20 in particular.
[0031] Once device 10 is locked onto bottle neck 12 as shown in FIGS. 7 and 8 , anti-grasping surfaces 40 and 42 make it more difficult to grasp housing 18 in a manner which would promote the prying or breaking of housing 18 from strap 20 in order to remove device 10 from bottle neck 12 . For instance, FIG. 7 shows a hand with a thumb and finger respectively in contact with outer surfaces 40 and 42 in an effort to grasp housing 18 to break housing 18 , strap 20 or the connection therebetween in order to remove device 10 from bottle neck 12 . However, the tapered nature of surfaces 40 and 42 tends to make the thumb and finger slide off of housing 18 as shown respectively at Arrows B and C in FIG. 8 . In the known prior art devices which utilize a ratchet strap and housing, the housing typically provides an upper and/or lower surface which is substantially perpendicular to axis X, thus providing surfaces which are easily grasped manually and which are easily impacted by forces substantially parallel to axis X, as indicated at Arrows D and E in FIG. 8 , which have been found to sometimes defeat such typical prior art devices. By contrast, tapered surfaces 40 and 42 of housing 18 tend to deflect such forces and reduce their effectiveness in compromising the integrity of device 10 so that device 10 remains secured to bottle neck 12 . Thus, when a potential thief moves bottle 14 in a direction indicated at Arrow E in order to impact surface 40 on a structure such as a shelf, table or the like to create a force represented by Arrow D on surface 40 , the tapered nature of surface 40 deflects the impact and thus reduces the amount of force applied in the direction of Arrow D by changing the force vector to angle inwardly towards bottle neck 12 as represented generally at Arrow F. Similarly, a force applied to surface 42 as indicated along a force vector indicated at Arrow E will similarly be deflected to a force vector indicated at Arrow G. In short, housing 18 of device 10 is configured to make it more difficult to break device 10 off of bottle neck 12 without breaking bottle neck 12 .
[0032] In the foregoing description, certain terms have been used for brevity, clearness, and understanding. No unnecessary limitations are to be implied therefrom beyond the requirement of the prior art because such terms are used for descriptive purposes and are intended to be broadly construed.
[0033] Moreover, the description and illustration of the invention is an example and the invention is not limited to the exact details shown or described.
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A bottle security device includes a housing with an electronic surveillance article tag therein and a ratchet strap which extends from the housing and loops around the bottle neck to secure the device thereto. The strap has one-way locking teeth which are lockably engaged by a locking mechanism in the housing when the strap is inserted therein to secure the strap in a locked position. The housing has first and second opposed outer surfaces which taper radially outwardly and toward one another in a manner which makes the housing difficult to grasp manually or otherwise, thus helping prevent the breakage and removal of the device from the bottle. The tapered outer surfaces also serve to deflect impact forces to the housing to help prevent unauthorized removal of the device. An arcuate channel of the housing receives and aligns the strap for improved locking capability.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 61/747,415 entitled “Optical Bench Apparatus and Method” filed Dec. 31, 2012 which is hereby incorporated herein by reference in its entirety.
BACKGROUND OF THE INVENTION
[0002] This invention relates generally to optical power monitoring. In particular, the invention relates specifically to an optical bench apparatus having integrated monitor photodetectors and a method for monitoring optical power using the optical bench apparatus for optical power monitoring in optical modules. Monitoring the level of optical power emitted by transmitters may be a highly desirable feature in many optical modules, especially optical transceivers. Monitoring the optical power may allow the bias and/or modulation currents to be optimized to achieve the desired operating characteristics of both the transmitter itself, as well as the entire optical link. Such optimization of the bias and/or modulation currents may allow operating characteristics to be adjusted for temperature variations and/or degradation due to aging, optical alignment and/or other environmental factors. Monitoring the transmitted power and/or received power in an optical link may enable health monitoring and/or functions to be implemented in the transceiver. Further, monitoring the transmitted power and/or received power in an optical link may also enable built-in test functions to be implemented in the transceiver.
[0003] Optical power monitoring of transmitters has been implemented by various methods. One such method of optical power monitoring may create a back-reflection in the optical package and utilize this back-reflection to monitor the optical power. For example, U.S. Pat. No. 5,757,836 discloses TO-can-based transmitter optical subassemblies (TOSAs) that may implement such a method of optical power monitoring. A cap on the TO-can may provide a small back-reflection that may then be detected by a monitor photodetector placed either next to the transmitting devices and/or underneath the transmitting devices such that the cap of the TO-can may extend laterally beyond the extent of the transmitter die. The TO-can-based method has been acceptably implemented but may be best-suited to modules with a small number of transmitters. Further, the method may not scale well to parallel modules with a small form factor.
[0004] Another method and/or approach to optical power monitoring may utilize back-side emission of a transmitting device. Although such a method may be possible with a Vertical-Cavity Surface-Emitting Laser (VCSEL), implementation with an in-plane laser in which emission from the back facet may be exploited to monitor the power emission from the laser may be more feasible and/or effective. An example of this method and/or approach may be implemented with a 622 Mb/s Logic Interface DFB Laser Transmitter manufactured by Hewlett Packard. The technical specifications and other information for such a device may be found on the Internet in http://www.datasheetcatalog.org/datasheet/hp/XMT5170B-622-AP.pdf. This method and/or approach to optical power monitoring may be implemented in many different ways. For example, such a method of optical power monitoring may be monolithically integrated and/or heterogeneously integrated. A fundamental approach in such methods and/or approaches may use a transmission out of the back facet. The power of the back facet transmission may be a known ratio of the power out of the front facet. The front facet power may be used for the transmitter in the optical module, while the back facet power may be absorbed by a monitor photodetector to provide the power monitoring.
[0005] Various substrates have also been utilized as optical benches for integrating transmitters and/or photodetectors. Some of these optical benches have included backside microlenses formed by a variety of techniques. For example, such microlenses are disclosed in “Parallel Free-Space Optical Interconnects Based on Arrays of Vertical-Cavity Lasers and Detectors with Monolithic Microlenses,” Eva M. Strzelecka, et al., volume 37, issue 14, pp. 2811-2821, 1998.
SUMMARY OF THE INVENTION
[0006] In an embodiment of the present invention, an optical bench apparatus is provided. The optical bench apparatus may have a transparent substrate with electrical interconnect lines and/or pads for attaching transmitters and/or receivers by flip-chip bonding. Monitor photodetectors may be aligned to these bonding sites. The monitor photodetectors may be designed to absorb a small fraction of the transmitted and/or received light and convert that fraction of light into a monitor photocurrent for optimizing bias and/or modulation currents to achieve desired operating characteristics of the transmitter and/or an optical link. Such optimization of the bias and/or modulation currents may allow operating characteristics to be adjusted for temperature variations and/or degradation due to aging, optical alignment and/or other environmental factors. Monitoring the transmitted power and/or received power in an optical link may enable health monitoring and/or functions to be implemented in the transceiver. Further, monitoring the transmitted power and/or received power in an optical link may also enable built-in test functions to be implemented in the transceiver.
[0007] In another embodiment, a populated optical bench with back-side microlenses for either focusing and/or collimating output/input optical beams is provided. The optical bench apparatus may have a transparent substrate with electrical interconnect lines and/or pads for attaching transmitters and/or receivers by flip-chip bonding. Monitor photodetectors may be aligned to these bonding sites. The monitor photodetectors may be designed to absorb a small fraction of the transmitted and/or received light and convert that fraction of light into a monitor photocurrent for optimizing bias and/or modulation currents to achieve desired operating characteristics of the transmitter and/or an optical link. Such optimization of the bias and/or modulation currents may allow operating characteristics to be adjusted for temperature variations and/or degradation due to aging, optical alignment and/or other environmental factors. Monitoring the transmitted power and/or received power in an optical link may enable health monitoring and/or functions to be implemented in the transceiver. Further, monitoring the transmitted power and/or received power in an optical link may also enable built-in test functions to be implemented in the transceiver.
[0008] To this end, an optical bench apparatus is provided. The optical bench apparatus may have a substrate with a first side and a second side. The second side may be located opposite the first side. An optical power monitor photodetector may be integrated on the first side of the substrate. A light transmitter may have an optical output, and first electrical interconnect lines located on the substrate may permit integrating the light transmitter on the substrate. Second electrical interconnect lines located on the substrate may be connected to the optical power monitor photodetector. The light transmitter may be arranged relative to the optical power monitor photodetector such that the optical output of the light transmitter impinges on the optical power monitor photodetector. The substrate may be transparent to the optical output of the light transmitter.
[0009] In an embodiment, the light transmitter may be a light emitting diode (LED), a vertical-cavity surface-emitting laser (VCSEL), a Fabry-Perot laser having an angled mirror for vertical emission, a distributed feedback (DFB) laser having an angled mirror for vertical emission or a DFB laser having a diffraction grating for vertical emission.
[0010] In an embodiment, the light transmitter may be integrated by flip-chip bonding.
[0011] In an embodiment, the light transmitter may be integrated by die placement.
[0012] In an embodiment, the light transmitter may be aligned to allow substantial overlap of the optical output emitted power with the optical power monitor photodetector.
[0013] In an embodiment, the substrate may be transparent to the light emitted by the light transmitter.
[0014] In an embodiment, the substrate may have one or more lenses formed on the side opposite the light transmitter.
[0015] In an embodiment, the lenses may be refractive lenses or diffractive lenses.
[0016] In an embodiment, the lenses may collimate the output from the light transmitter.
[0017] In an embodiment, the lenses may focus the output from the light transmitter.
[0018] In an embodiment, the lenses may steer the output from the light transmitter.
[0019] In an embodiment, the substrate may have one or more surfaces anti-reflection coated.
[0020] In an embodiment, the electrical interconnect lines may be impedance matched.
[0021] In an embodiment, the light transmitter may emit light through the optical power monitor photodetector.
[0022] In an embodiment, the optical power monitor photodetector may absorb part of the power emitted by the light transmitter and part of the power may be emitted by the light transmitter may be transmitted through the substrate.
[0023] In an embodiment, the optical power monitor photodetector may absorb a portion of the power emitted by the light transmitter.
[0024] In an embodiment, the light transmitter may emit light vertically in a first direction away from the substrate and in a second direction into the substrate.
[0025] In an embodiment, the light transmitter may emit a first portion of the optical output power away from the substrate and may emit a second portion of the power into the substrate wherein the first portion may be greater than the second portion.
[0026] In an embodiment, the monitor photodetector may absorb a portion of the light emitted into the substrate.
[0027] In an embodiment, the substrate may be a semiconductor, Gallium Arsenide (GaAs), semi-insulating Gallium Arsenide (GaAs), Aluminum Gallium Arsenide (AlGaAs), Indium Phosphide (InP), silicon, an insulator, sapphire or quartz glass.
[0028] In an embodiment, the monitor photodetector may be epitaxially grown.
[0029] In an embodiment, the monitor photodetector may be a single crystal semiconductor.
[0030] In an embodiment, the monitor photodetector may be a p-i-n photodetector.
[0031] In an embodiment, the monitor photodetector may have one or more quantum wells as the absorbing region.
[0032] In an embodiment, the monitor photodetector may have one or more absorbing layers of quantum dots.
[0033] In an embodiment, the monitor photodetector may be a metal-semiconductor-metal (MSM) photodetector.
[0034] In an embodiment, the monitor photodetector may have an absorbing region of Indium Gallium Arsenide (InGaAs).
[0035] In an embodiment, the monitor photodetector may be deposited by chemical vapor deposition.
[0036] In an embodiment, the monitor photodetector may be a single crystal, polycrystalline, or amorphous material.
[0037] In an embodiment, the monitor photodetector may be silicon, germanium, or Indium Gallium Arsenide (InGaAs).
[0038] In an embodiment, one or more transmitters may be replaced by one or more receiver photo detectors.
[0039] In another embodiment of the invention an optical bench apparatus is provided. The optical bench apparatus may have a substrate having a first side and a second side. The second side may be located opposite the first side. An optical input may be incident on the second side of the substrate. An optical power monitor photodetector may be integrated on the first side of the substrate. The optical bench apparatus may have a photodetector. First electrical interconnect lines may be located on the substrate. The first electrical interconnect lines may permit integrating the photodetector on the substrate. Second electrical interconnect lines located on the substrate may be connected to the optical power monitor photodetector. The photodetector may be aligned with the optical power monitor photodetector such that a portion of the optical input to the photodetector passes through the optical power monitor photodetector. The substrate may be transparent to the optical input.
[0040] In an embodiment, the photodetector may be a p-i-n photodetector.
[0041] In an embodiment, the photodetector may be a resonant cavity photodetector, an avalanche photodetector or a MSM photodetector.
[0042] In an embodiment, the photodetector is integrated by flip-chip bonding.
[0043] In an embodiment, the photodetector may be integrated by die placement.
[0044] In an embodiment, the photodetector may be aligned to allow substantial overlap of the received optical power with the optical power monitor photodetector.
[0045] In an embodiment, the substrate may be transparent to the light received by the photodetector.
[0046] In an embodiment, the substrate may have one or more lenses and/or microlenses formed on a back side of the substrate opposite a front side of the substrate having the photodetector.
[0047] In an embodiment, the back side microlenses may be aligned to front side devices to form optical beams.
[0048] In an embodiment, the microlenses may be refractive and/or diffractive.
[0049] In an embodiment, the microlenses may focus and/or collimate the output beams of the transmitters to simplify coupling of the light into optical fibers and/or other optical components.
[0050] In an embodiment, the microlenses may focus the incoming beam onto the receiver.
[0051] In an embodiment, the microlenses may be designed to collimate the input to the photodetector.
[0052] In an embodiment, the microlenses may be designed to focus the input to the photodetector.
[0053] In an embodiment, the microlenses may be designed to steer the input to the photodetector.
[0054] In an embodiment, the electrical interconnect lines may be impedance matched.
[0055] In an embodiment, the photodetector may receive light through the optical power monitor photodetector.
[0056] In an embodiment, the optical power monitor photodetector may absorb part of the incoming power for the photodetector and part of the power for the photodetector may be received through the substrate.
[0057] In an embodiment, the optical power monitor photodetector may absorb a portion of the power for the photodetector.
[0058] In a further embodiment, a method of monitoring optical power is provided. The method may have the steps of providing an optical bench apparatus having a substrate with electrical interconnect lines; integrating an optical power monitor photodetector with the substrate wherein the electrical interconnect lines connect the optical power monitor photodetector; integrating a light transmitter with the substrate wherein the electrical interconnect lines connect the light transmitter and further wherein the light transmitter has an optical output; and aligning the optical output of the light transmitter relative to the optical power monitor photodetector such that the optical output of the light transmitter impinges on the optical power monitor photodetector.
[0059] In an embodiment, the method may have the step of optimizing bias and/or modulation currents to achieve desired operating characteristics of the transmitter.
[0060] In an embodiment, the method may have the step of optimizing bias and/or modulation currents to achieve desired operating characteristics of an optical link.
[0061] In an embodiment, the method may have the step of adjusting operating characteristics of the transmitter for temperature variations by optimizing bias and/or modulation currents.
[0062] In an embodiment, the method may have the step of adjusting operating characteristics of the transmitter for degradation by optimizing bias and/or modulation currents.
[0063] In an embodiment, the method may have the step of implementing health monitoring in a transceiver by monitoring the transmitted power and/or received power in an optical link.
[0064] In an embodiment, the method may have the step of implementing built-in test functions in a transceiver by monitoring the transmitted power and/or received power in an optical link.
[0065] In yet another embodiment, a method of monitoring optical power is provided. The method may have the step of providing an optical bench apparatus having a substrate and an integrated optical power monitor photodetector. The method may have the step of providing electrical interconnect lines on the substrate. The method also may have the steps of integrating a photodetector with the electrical interconnect lines to the optical bench apparatus and connecting the monitor photodetectors with the electrical interconnect lines to the optical bench apparatus. The method may have the step of aligning the input of the photodetector such that the input of the photodetector overlaps with the monitor photodetector.
[0066] An advantage of the invention may be to provide an optical bench apparatus in which a smaller, faster photodetector may be used.
[0067] Another advantage of the invention may be to provide an optical bench apparatus to improve alignment tolerances.
[0068] A further advantage of the invention may be to provide an optical bench apparatus having one or more lenses formed on the side opposite the light transmitter. The lenses may be refractive and/or diffractive. The lenses collimate the output from the light transmitter, focus the output from the light transmitter and/or steer the output from the light transmitter.
[0069] Another advantage of the invention may be to provide a method of monitoring optical power having the step of optimizing bias and/or modulation currents to achieve desired operating characteristics of the transmitter and/or an optical link.
[0070] Yet another advantage of the invention may be to provide a method having the step of adjusting operating characteristics of the transmitter for temperature variations and/or degradation by optimizing bias and/or modulation currents.
[0071] Still another advantage of the invention may be to provide a method having the step of implementing health monitoring and/or built-in test functions in a transceiver by monitoring the transmitted power and/or received power in an optical link.
BRIEF DESCRIPTION OF THE DRAWINGS
[0072] FIG. 1 is a schematic diagram of an embodiment of an optical bench having a transparent substrate with electrical interconnect lines and/or flip-chip bonding bumps aligned to monitor photodetectors.
[0073] FIG. 2 is a schematic diagram of an embodiment of an optical bench with monitor photodetectors.
[0074] FIG. 3 is a schematic diagram of an embodiment of a populated optical bench with back-side microlenses for focusing and/or collimating output/input optical beams.
DETAILED DESCRIPTION OF THE INVENTION
[0075] In an embodiment of the invention, an optical bench apparatus may have a transparent substrate with electrical interconnect lines and/or pads for attaching transmitters and/or receivers by flip-chip bonding. Aligned to these bonding sites may be monitor photodetectors that may be designed to absorb a small fraction of the transmitted and/or received light and convert it into a monitor photocurrent for optimizing bias and/or modulation currents to achieve desired operating characteristics of the transmitter and/or an optical link.
[0076] Referring now to the Figures where like numerals indicate like elements, a schematic diagram of an embodiment of the optical bench apparatus is shown in FIG. 1 . In particular, FIG. 1 schematically illustrates an optical bench apparatus 10 having a transparent substrate with electrical interconnect lines 20 for monitor photodetectors and/or bonding sites 30 for attaching transmitters (see FIGS. 2 and 3 ) and/or receivers (see FIGS. 2 and 3 ) by flip-chip bonding, for example. In an embodiment, the bonding sites 30 may be bonding bumps and/or pads. Monitor photodetectors 40 may be aligned to the bonding sites 30 .
[0077] The monitor photodetectors 40 may be designed to absorb a small fraction of the transmitted light and/or the received light. Further, the monitor photodetectors 40 may be designed to convert the fraction of the light into a monitor photocurrent. The monitor photocurrent may be utilized for optimizing bias and/or modulation currents to achieve desired operating characteristics of the transmitter and/or an optical link. Such optimization of the bias and/or modulation currents may allow operating characteristics to be adjusted for temperature variations and/or degradation due to aging, optical alignment and/or other environmental factors. Monitoring the transmitted power and/or received power in an optical link may enable health monitoring and/or functions to be implemented in the transceiver. Further, monitoring the transmitted power and/or received power in an optical link may also enable built-in test functions to be implemented in the transceiver.
[0078] Further, the optical bench apparatus 10 may have the substrate 100 with the monitor photodetectors 40 on the front side. The monitor photodetectors 40 may be aligned with the flip-chip bonding bumps 30 such that the light emission of the transmitters, the VCSELs 50 and/or the Light Emitting Diodes (LEDs) 60 , after flip-chip bonding, may be aligned with the monitor photodetectors 40 . Thus, the light emission of the transmitters may pass through the monitor photodetectors 40 with a portion of the transmitted light absorbed by the monitor photodetectors 40 . The monitor photodetectors 40 may have a thin absorption region, preferably quantum wells, such that the percentage of light absorbed may be relatively small, providing sufficient photocurrent to monitor the transmitted power, but small enough to have a minimal effect of the transmitted power.
[0079] As shown in FIGS. 2 and 3 , the transmitters may be VCSELs 50 and/or LEDs 60 and/or other suitable light transmission devices. For example, the transmitters may also be a Fabry-Perot laser having an angled mirror for vertical emission, a distributed feedback (DFB) laser having an angled mirror for vertical emission or a distributed feedback (DFB) laser having a diffraction grating for vertical emission. One having ordinary skill in the art may recognize that other types of light transmitters may be suitable for the present invention. Thus, this disclosure is not limited to a particular light transmitter and all suitable light transmitters are considered to be within the scope of this disclosure.
[0080] The receivers may be a variety of different types of photodetectors 70 , for example, p-i-n photodetectors, single and/or multiple quantum well photodetectors, resonant cavity photodetectors, MSM photodetectors, avalanche photodetectors, phototransistors and/or photoconductors. The monitor photodetectors 40 may be single and/or multiple quantum well photodetectors, quantum dot photodetectors, and/or p-i-n photodetectors. The monitor photodetectors 40 and/or the photodetectors 70 may have absorbing regions consisting of a variety of materials including single crystal, polycrystalline, and/or amorphous semiconductors. The monitor photodetectors 40 may be biased or unbiased. One having ordinary skill in the art may recognize that other types of photodetectors may be suitable for the present invention. Thus, this disclosure is not limited to a particular photodetector and all suitable photodetectors are considered to be within the scope of this disclosure.
[0081] The transmitters, such as the VCSEL 50 , and/or the receivers, such as the photodetector 70 , for example a p-i-n photodetector, may be flip-chip bonded in any combination and/or number with the monitor photodetectors 40 included on at least one site, but not necessarily all of the sites. The light transmitters may also be integrated by die placement. Further, the optical power monitor photodetector 40 may be epitaxially grown or may be deposited by chemical vapor deposition.
[0082] FIG. 2 is a schematic of another embodiment of an optical bench populated with the VCSEL 50 and/or the photodetector 70 . In particular, FIG. 2 illustrates the optical bench 10 . Each bond site 30 may be populated with the VCSEL 50 and/or the LED 60 fabricated on a substrate 65 for the transmitter and/or the photodetector 70 fabricated on a substrate 75 for the receiver. As shown in FIG. 2 , an outgoing optical beam, optical output 80 and/or an incoming optical beam, optical input 90 , may pass through the respective monitor photodetector 40 and/or a substrate 100 . The monitor photodetector 40 may absorb a small fraction of the transmitted optical power and may convert the small fraction of light into a monitor photocurrent. In an embodiment, the substrate 100 may be transparent. Further, the substrate 100 may have a surface having an anti-reflection coating (not shown).
[0083] FIG. 3 is a schematic of another embodiment of the optical bench 10 populated with the VCSEL 50 and/or the LED 60 and/or the photodetector 70 . Each bond site 30 may be populated with the VCSEL 50 and/or the LED 60 for the transmitter and/or the photodetector 70 for the receiver. In the embodiment illustrated in FIG. 3 , the optical bench 10 may also have microlenses 110 located on the substrate 100 . As shown, the microlenses 110 may be arranged on a back side of the substrate 100 opposite to a front side of the substrate 100 having the monitor photodetectors 40 . The microlenses 110 may also be aligned to front side devices such as, for example, optical fibers and/or other optical components (not shown) to form optical beams. For example, the microlenses 110 may form the optical beams of the optical output 80 and/or the optical beams of the optical input 90 . The microlenses 110 may be either refractive and/or diffractive. For the transmitters, such as the VCSELs 50 and/or the LEDs 60 , the microlenses 110 may focus and/or collimate the outgoing beam of the output beam 80 to simplify coupling of the light into optical fibers and/or other optical components (not shown). For the receivers, such as the photodetector 70 , the microlenses 110 may focus the incoming beam of the optical input 90 onto the receiver 70 . In an embodiment of the invention, the use of the microlenses 110 may enable a smaller and/or faster photodetector 70 to be used. Also, the use of the microlenses 110 in this manner may improve the alignment tolerances of the optical bench apparatus 10 .
[0084] The optical bench apparatus 10 may be utilized to implement a method of monitoring optical power in an optical link. For example, the method may have the step of providing an optical bench apparatus 10 having the substrate 100 with the electrical interconnect lines 20 . The method may have the step of integrating the optical power monitor photodetector 40 with the substrate 100 . The electrical interconnect lines 20 may connect the optical power monitor photodetector 40 . The method may also have the step of integrating the light transmitter, for example, the VCSEL 50 and/or the LED 60 with the substrate 100 . The electrical interconnect lines 20 may connect the light transmitter. The light transmitter may have the optical output 80 . Finally, the method may have the step of aligning the optical output 80 of the light transmitter relative to the optical power monitor photodetector 40 such that the optical output 80 of the light transmitter impinges on the optical power monitor photodetector 40 .
[0085] The method may have additional steps to monitor optical power in an optical link. For example, the method may have the step of optimizing bias and modulation currents to achieve desired operating characteristics of the light transmitter. Further, the method may have the step of optimizing bias and modulation currents to achieve desired operating characteristics of the optical link. Also, the method may have the step of adjusting operating characteristics of the light transmitter for temperature variations by optimizing bias and/or modulation currents. Moreover, the method may have the step of adjusting operating characteristics of the transmitter for degradation by optimizing bias or modulation currents. In addition, the method may have the step of implementing health monitoring in a transceiver by monitoring transmitted power or received power in the optical link. Finally, the method may have the step of implementing built-in test functions in a transceiver by monitoring transmitted power or received power in the optical link.
[0086] In summary, the monitor photocurrent may be utilized for optimizing bias and/or modulation currents to achieve desired operating characteristics of the transmitter and/or an optical link. Such optimization of the bias and/or modulation currents may allow operating characteristics to be adjusted for temperature variations and/or degradation due to aging, optical alignment and/or other environmental factors. Monitoring the transmitted power and/or received power in an optical link may enable health monitoring and/or functions to be implemented in the transceiver. Further, monitoring the transmitted power and/or received power in an optical link may also enable built-in test functions to be implemented in the transceiver.
[0087] It should be understood that various changes and/or modifications to the presently preferred embodiments described herein will be apparent to those having ordinary skill in the art. Such changes and/or modifications may be made without departing from the spirit and/or scope of the present invention and without diminishing its attendant advantages. It is, therefore, intended that such changes and/or modifications be covered by the appended claims.
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Optical bench structure provides a platform for integrating optical transmitters, particularly Vertical-Cavity Surface-Emitting Lasers (VCSELs), with monitor photodetectors. A substrate with photodetectors on the front side is aligned with flip-chip bonding bumps so the emission of the transmitters is aligned with the monitor photodetectors and passes through the monitor photodetectors with a portion of the transmitted light absorbed by the monitor photodetectors. The photodetectors have a thin absorption region so the percentage of light absorbed may be relatively small, providing sufficient photocurrent to monitor the transmitted power having a minimal effect on the transmitted power. Microlenses are integrated on the backside of the substrate focus, steer and/or collimate the emitted optical beams from the transmitters. The structure enables photodetectors to be integrated on the optical bench allowing the received optical power to be monitored. The receiver photodetectors are integrated on the optical bench alone and/or in combination with the transmitters.
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FIELD OF THE INVENTION
A craft implement and more particularly a device having a handle and a needle where the needle is adjustable in length with respect to the handle.
BACKGROUND OF THE INVENTION
There are many art or craft implements employing needles for such purposes as embroidering and making hooked rugs, among others, which may require a loop of yarn or other material on one side of a fabric backing, for example. Such tools typically have a needle with an eye closely adjacent the pointed end. Such instruments normally having a handle which is comfortable for the user's hand have been made in different lengths but each needle and handle combination has typically had a fixed length relationship.
It has been found to be desirable to have such an implement with a needle having an adjustable length with respect to the handle for different length of loops or for other purposes. Examples of such a device are shown in U.S. Pat. Nos. 4,306,510 and 4,479,445. These devices have different structures but both of them have the purpose of providing an adjustable length needle in a craft implement. The first patent has a plastic handle with a cylindrical axial opening adapted to receive a unitary needle element having a threaded end and a pointed end. A threaded nut rotatable with respect to the handle is employed to adjust the length of the needle so that it projects outwardly from the handle by differing amounts. A pin and slot arrangement prevent rotation of the needle in the handle. U.S. Pat. No. 4,479,445 also provides a plastic handle with a needle element comprising a unitary needle and holder which are rotatably secured within the handle. This device rotates the entire needle element within the handle for accomplishing longitudinal adjustments. A projection inside the handle slidingly engages the threads on the holder to cause the relative longitudinal motion. This second patent is particularly adapted to incorporate a cannulation needle used in hypodermic syringes and is a simple adapter for use of such readily available needles.
A disadvantage of some of the prior art devices is that the needle and the adjusting threads are formed on a unitary member. Thus if the needle is changed, the threaded portion must also be changed. Alternatively the whole unit is disposable. Additionally, some of the prior art devices do not have means for retracting the needle point fully within the handle, thereby creating a safety hazard. Furthermore, U.S. Pat. No. 4,306,510 requires an additional element attached to the needle and an open slot in the handle portion to prevent rotation. This requires additional elements and the possibility of fouling the upper portion of the needle and the threads because they are exposed to the external environment and accompanying contamination through the slot in the side of the handle.
SUMMARY OF THE INVENTION
This invention relates generally to an adjustable thread carrying craft implement and more particularly to a craft handle having a needle mounted therein which may project from one end of the handle to readily adjustable lengths and may be fully retracted within the handle for safety purposes.
The housing which comprises the handle has one end with a small opening through which the needle projects and a cylindrical barrel in which a threaded cylindrical sleeve resides. The sleeve is adapted to firmly but removably retain a conventional combination needle and mounting element. The sleeve has external threads which engage the internal threads of a nut which is rotatably mounted in the housing. A projection and groove arrangement or mating flat surfaces on the threaded sleeve and the interior surface of the housing provide alternative means to prevent relative rotation of the sleeve in the housing.
As an alternative embodiment, the needle may be removably mounted directly to a modified threaded sleeve element instead of being mounted to a mounting element which combination is then mounted to the threaded sleeve. Both the needle and mounting element assembly and the removable needle are readily available from conventional sources and are adapted to be employed in the implement of the invention.
BRIEF DESCRIPTION OF THE DRAWING
The objects, advantages and features of this invention will be more readily perceived from the following detailed description, when read in conjunction with the accompanying drawing, in which:
FIG. 1 is a perspective view of the thread carrying needle assembly of the invention;
FIG. 2 is a side, partially cut away sectional view of the invention of FIG. 1;
FIG. 3 is an end view from the rear end of the assembly of FIG. 2;
FIG. 4 is a sectional view taken along cutting plane 4--4 of FIG. 3;
FIG. 5 is a reduced scale sectional view of the threaded sleeve mounted within the housing showing the tapered ribs somewhat exaggerated;
FIG. 6 is a right end view of the sleeve of FIG. 5;
FIG. 7 is an exploded side view of the invention;
FIG. 8 is an enlarged sectional view of the threaded nut and sleeve arrangement of the invention; and
FIG. 9 is a side sectional view of an alternative embodiment of the threaded sleeve and needle.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
With reference now to the drawing, and more particularly to FIGS. 1-4 thereof, needle assembly 11 is comprised of housing 12 having forward or needle end 13 and opposite rear end 14. Enlarged raceway 15 is provided at the rear end of housing 12 and is comprised of semicircular rims 18 and 19 and bridging elements 20. Needle 16 is shown projecting a short distance outwardly from needle end 13 of the housing. The needle is formed with eye 17 in the point, adapted to receive thread therethrough, after passing through the axis of the hollow needle. Threaded sleeve 21 is shown projecting rearwardly from housing 12. On a flat longitudinal surface 22 are shown indicia 23 indicating a relative distance of needle projection outwardly from the housing. Threaded nut 24 is shown with a grooved external surface 25. The nut may well have a knurled or other roughened surface to facilitate rotation thereof. Flat side 26 of housing 12 is provided for lettering or other appropriate indicia and for purposes of orientation by means of the user when the implement is grasped. Additionally, that portion of housing 12 which includes flat external surface 26 also includes flat internal surface 27, the purpose of which will be explained below.
Referring now to FIG. 5, threaded sleeve 21 is shown with internal axial opening 31 adapted to receive a needle and mounting element assembly. Stop members 32 are provided adjacent end 33 of the threaded sleeve against which the end of the needle element is positively retained. Flat side 34 (FIG. 6) is adapted to mate with flat surface 27 on the inside of housing 12 to prevent rotation of the threaded sleeve and needle element within the housing.
The threaded nut arrangement is shown in greater detail in FIG. 8. Nut 24 is shown with internal threads 36 mating with external threads 37 on threaded sleeve 21. The nut rotates freely in raceway 15 and one portion of the grooved surface 25 is accessible through opening 41 in the raceway (FIGS. 1 and 3). There may be a similar opening in the raceway on the opposite side thereof, at least that portion between bridging elements 20 and rims 18 and 19. Nut 24 is provided with reduced diameter annular shoulder 38 which projects rearwardly through the center opening 39 of rim 19. This shoulder helps stabilize the nut in the raceway and ensures that it is captured therein when it is snapped in from side opening 41. When the sleeve is inserted into hollow generally cylindrical axial opening 42 in housing 12, threads 36 and 37 are mutually engaged and the sleeve is advanced toward the needle end of the housing by rotation of nut 24. The length of needle 16 projecting forwardly from housing 12 can easily be adjusted with one hand, where the user's thumb rotates nut 24, while the hand holds the housing.
From FIG. 7, the elements of the device and their relationships can more easily be seen. Nut 24 is shown in cross section below raceway 15 and housing 12. Threaded sleeve 21 is shown at the far left of FIG. 7. In the center portion of the figure is needle assembly 45 comprised of needle 16 and mounting element or handle 46. This needle assembly is a readily available component which may be found in a craft store. Knurled surface 47 is provided and needle assembly 45 is usable as is if desired for other purposes. Sleeve 21 is formed with a hollow cylindrical center portion adapted to receive handle 46 of the needle element. Ribs 48 inside sleeve 21 are formed with a slight taper closing toward stop members 32 to provide a pressure or slip fit with respect to handle 46. Interior shoulders 51 on enlarged ribs 32 as shown in FIG. 5 provide a positive seat for end 52 of needle assembly mounting element 46.
When sleeve 21 and needle assembly 45 are engaged, the combination of them is inserted through the threaded opening of nut 24 into housing 12 with flat side 34 on the sleeve aligned with interior flat surface 27 in housing 12. To ensure initial alignment of the sleeve as it enters the housing, tabs 58 and 59 extend chordally toward each other from the open side of rim 19. The inner sides of these tabs form an extension of flat surface 27 and the outer sides are preferably an extension of external flat surface 26. Thus before the threads of the nut and sleeve engage, the sleeve is properly aligned with flat surface 27. When the threads at end 53 of sleeve 21 engage the threads at end 54 of nut 24, the needle assembly is fully within housing 12 and no portion of the point of the needle projects outwardly therefrom through forward hole 55. As nut 24 is rotated in the proper direction, the that after a longitudinal movement of a portion of the length of sleeve 21,-needle 16 begins to project outwardly through opening 55 in needle end 13 of housing 12. Because the point of needle 16 may be slightly misaligned with opening 55 as the needle moves forward, centering ribs 60 and 61 are formed on the inside of housing 12 starting slightly rearwardly from opening 55 and extending for a portion of the distance toward the rear end of the housing. The forward portion of mounting element 46 rides up on ramps 62 of the centering ribs to positively center needle 16 in opening 55. When the desired position is attained so that the indicia shown in FIGS. 1 and 7 on sleeve 21 are in the desired position, rotation of nut 24 is stopped and the needle is then used for the craft purpose a intended.
An alternative embodiment for the needle and sleeve assembly is shown in FIG. 9. The main portion 63 of sleeve 64 is formed with smaller forward cylindrical portion 65 and needle fairing 66. Portion 63 is formed with threads 67 functioning identically with threaded sleeve 21. Fairing 66 is adapted to receive needle 68 (without handle 46) which needle is also readily available. The needle is then anchored in a conventional manner on fairing 66 and the unitary element is inserted into housing 12 and moved by means of nut 24 as previously discussed. Needle 68 has penetrating end 69 and standard Luer lock end 70, adapted to positively engage fairing 66.
It is contemplated that the housing, nut and sleeve elements of this invention will be made from a relatively rigid plastic material which is easily formed as desired. The elements could be made from any suitable material, so plastic is not a limitation. The needle is of course made of an appropriate material such as stainless steel. Handle member 46 is made of aluminum or a plastic or other suitable material.
In view of the above description, it is likely that modifications and improvements will occur to those skilled in the art which are within the scope of the appended claims.
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A thread carrying needle assembly usable for a variety of craft purposes, the needle assembly having means to adjust the length of the exposed pointed end of the needle. A safety feature is that the needle may be fully retracted within the housing. The needle assembly is adapted to function with a conventional needle element which is easily replaceable.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention generally relates to watercraft and, more particularly, to an air intake system associated with an engine cover of jet-powered watercraft.
[0003] 2. Background Art
[0004] Personal watercraft are common place in the nautical industry. The personal watercraft consists of a versatile jet-powered nautical vehicle for one or more rider, that is used for touring and as a nautical sport. In the latter use, where stand-up type personal watercraft are often used, the personal watercraft is configured to be nimbler.
[0005] The personal watercraft is relatively small when compared to jet-powered watercraft, but nonetheless have similar components, such as the engine and propulsion system, the steering system, etc . . . Therefore, the use of the cavity defined between the deck and the hull must be optimized in order to have sufficient space for all the necessary equipment for the operation of the personal watercraft.
[0006] Air intake systems of personal watercraft take up a good portion of the space. As the personal watercraft is adapted for various maneuvers in the water, the air intake systems must be configured so as to prevent water infiltration in the engine. Therefore, the air intake systems of personal watercraft have an air inlet, conduits that communicate the air inlet to the engine compartment, with the conduits being in chicane configurations to prevent water from reaching the engine.
[0007] It would be desirable to provide air intake systems that use reduced volume within the cavity of the watercraft, while maintaining suitable chicane configurations to substantially prevent water from passing therethrough to reach the engine.
SUMMARY OF INVENTION
[0008] It is therefore an aim of the present invention to provide an engine cover having an air intake system.
[0009] It is a further aim of the present invention that the engine cover is readily assembled to form the air intake system.
[0010] Therefore, in accordance with the present invention, there is provided a watercraft comprising: a hull; a deck supported by the hull, so as to define a cavity therebetween, the deck having an opening to access an engine compartment in the cavity; an engine in the engine compartment; and an engine cover being displaceable between an opened position, remote from the opening in the deck to allow access to the engine, and a closed position, closing the opening, the engine cover having a first surface exposed when the engine cover is in the closed position, a second surface unexposed when the engine cover is in the closed position, a thickness dimension between the first surface and the second surface, an air conduit in the thickness dimension, the air conduit having an inlet end in the first surface and an outlet end in the second surface, the outlet end being in fluid communication with the engine compartment.
[0011] Further in accordance with the present invention, there is provided an engine cover for a watercraft, comprising: a first surface; a second surface adapted to be resting on a deck of the watercraft such that the engine cover is supported by the deck of the watercraft to cover an engine access opening; a thickness dimension between the first surface and the second surface; an air conduit in the thickness dimension, the air conduit having an inlet end in the first surface and an outlet end in the second surface, the outlet end being adapted to be in fluid communication with an an engine compartment of the watercraft.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] Having thus generally described the nature of the invention, reference will now be made to the accompanying drawings, showing by way of illustration a preferred embodiment thereof and in which:
[0013] FIG. 1 is a port side elevation view of a personal watercraft having an engine cover in accordance with the present invention;
[0014] FIG. 2 is an exploded view of the engine cover with respect to a deck of the personal watercraft, taken from a port side and bow standpoint;
[0015] FIG. 3 is an exploded view of the engine cover of the present invention, taken from a starboard side standpoint;
[0016] FIG. 4 is a perspective view of the engine cover, with an outer skin in an exploded view with respect to a core and an inner skin, from a port side standpoint;
[0017] FIG. 5 is a perspective view of the engine cover of FIG. 4 , taken from a starboard side standpoint; and
[0018] FIG. 6 is an elevation view of the engine cover of FIG. 4 , taken from a bow standpoint.
[0019] An annex of figures is provided following FIGS. 1 to 6 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0020] Referring to the drawings and, more particularly to FIG. 1 , a personal watercraft is generally shown at 10 (hereinafter PWC 10 ). The PWC 10 is configured to allow stand-up type riding, but may also be a straddle-type personal watercraft. The PWC 10 has a bow B, a stern S, a port side P and a starboard side D. The PWC 10 has two main parts, namely a hull 12 and a deck 14 . The hull 12 buoyantly supports the personal watercraft 10 in a body of water. The hull 12 and the deck 14 are sealed together at bond line 16 . The space between the hull 12 and the deck 14 forms a cavity that accommodates an engine 18 , as well as other components such as, non exhaustively, a gas tank, an electrical system (battery, electronic control unit, drive shaft, etc.), which form, together with the engine 18 , the propulsion system of the PWC 10 .
[0021] The PWC 10 has a steering system that has an exposed portion 19 connected to the deck 14 at the bow B. The steering system is provided for the steering of the PWC 10 . An engine cover 20 is generally positioned above the engine 18 , and is openable so as to provide access to the engine 18 . For instance, a foremost edge of the engine cover 20 may be hinged to the deck 14 , for opening the engine cover 20 .
[0022] The engine cover 20 defines an air intake system in accordance with the present invention. More specifically, the engine cover 20 has air inlets and conduits in a chicane configuration to connect the air inlets to the engine 18 compartment. Accordingly, beyond the air conduits of the engine cover 20 , air conduits can go relatively directly to the engine 18 , i.e., without further chicanes.
[0023] Referring concurrently to FIGS. 2 and 3 , the engine cover 20 has an outer skin 30 , a core 40 and an inner skin 50 . For reference purposes, a central longitudinal axis of the PWC 10 will be illustrated at X in the Figs. The central longitudinal axis X separates the PWC 10 in the port side P and the starboard side D.
[0024] The outer skin 30 is the exposed portion of the engine cover 20 when the engine cover 20 is in a closed position onto the deck 14 of the PWC 10 . As will be detailed hereinafter, the outer skin 30 has air inlets, and outlet gutters, such that air reaching the air inlets may be directed out of the engine cover 30 .
[0025] The core 40 is sandwiched between the outer skin 30 and the inner skin 50 . As will detailed hereinafter, the core 40 defines the chicane configuration conduits with inner surfaces of the outer skin 30 and the inner skin 50 .
[0026] The inner skin 50 supports the outer skin 30 and the core 40 . As will be detailed hereinafter, the inner skin 50 ensures the water tightness between the engine cover 20 and the deck 14 . The inner skin 50 is interconnected to the outer skin 30 , and ensures the fluid communication between the engine cover 20 and the air hoses of the engine 18 .
[heading-0027] Air Inlets
[0028] Referring to FIG. 4 , the core 40 is shown positioned onto the inner skin 50 . Reference letters B and S are shown to illustrate how the engine cover 20 is positioned on the PWC. A port inlet 60 P is defined between an underside of the core 40 and an upper side of the inner skin 50 . The port inlet 60 P remains exposed when the outer skin 30 is mounted onto the core 40 /inner skin 50 combination. The port inlet 60 P communicates with an inlet cylindrical passage 62 P of a chicane conduit extending from the underside of the core 40 to an upperside thereof. The inlet cylindrical passage 62 P emerges into a chicane conduit channel 64 P, which will be described in further detail hereinafter.
[0029] To increase the air intake through the engine cover 20 , a similar inlet configuration is provided on the starboard side D of the engine cover 20 . More specifically, referring to FIG. 5 , the engine cover 20 has a starboard inlet 60 D defined between the underside of the core 40 and the upper side of the inner skin 50 . The port inlet 60 D remains exposed when the outer skin 30 is mounted onto the core 40 /inner skin 50 combination. The starboard inlet 60 D communicates with an inlet cylindrical passage 62 D extending from the underside of the core 40 to an upperside thereof. The inlet cylindrical passage 62 D emerges into a chicane conduit channel 64 D, which will be described in further detail hereinafter. Advantageously, the chicane conduit channels 64 D and 64 P are above the inlets 60 D and 60 P, thereby providing an obstacle against water reaching the chicane conduit channels 64 D and 64 P.
[heading-0030] Outlet Gutters
[0031] Referring concurrently to FIGS. 4 and 5 , outlet gutters 66 D and 66 P are positioned forward of the air inlets 60 D and 60 P, respectively. The outlet gutters 66 D and 66 P are respectively defined by cutouts 68 D and 68 P ( FIG. 6 ) in the core 40 , and by inner surfaces of the outer skin 30 and the inner skin 50 .
[0032] The outlet gutters 66 D and 66 P are in fluid communication with the inlets 60 D and 60 P, respectively, but are slightly below the latters, such that water entering in the inlets 60 D and/or 60 P will flow toward the respective outlet gutters 66 D and/or 66 P. As seen in FIG. 6 , plenums 68 D and 68 P ensure the fluid communication between the inlets 60 D and 60 P, respectively, and the gutter portions 66 D and 66 P. The plenums 68 D and 68 P are defined by channels formed in the core 40 and an inner surface of the inner skin 50 .
[0033] When the outer skin 30 is mounted onto the inner skin 50 , there is a gap between the periphery of the outer skin 30 and the periphery of the outlet gutters 66 D and 66 P, such that water in the outlet gutters 66 D and 66 P will be drained out of the engine cover 20 upon reaching the outlet gutters 66 D and 66 P.
[heading-0034] Chicane Conduits
[0035] Referring to FIG. 4 , the chicane conduit channel 64 P is in fluid communication with the inlet cylindrical passage 62 P. The chicane conduit channel 64 P is formed into the core 40 . When the outer skin 30 is laid onto the core 40 (as in FIG. 1 ), an inner surface of the outer skin 30 contacts the core 40 at the periphery of the chicane conduit channel 64 P, such that a chicane conduit is defined therebetween. Small ribs extending from the channel contour nay be added to ensure better sealing between the channel and the outer skin 30 .
[0036] The chicane conduit channel 64 P has a transverse portion 70 P, and a longitudinal portion 72 P. The transverse portion 70 P is transversely positioned with respect to the central longitudinal axis X of the PWC 10 , so as to overlap same. The transverse portion 70 P is connected at an inlet end to the inlet cylindrical passage 62 P, and at a free end to the longitudinal portion 72 P.
[0037] The longitudinal portion 72 P is generally parallel to the central longitudinal axis X of the PWC 10 . A free end of the longitudinal portion 72 P is connected to an outlet cylindrical passage 74 P of the chicane conduit, formed concurrently by the core 40 and the inner skin 50 . The outlet cylindrical passage 74 P is in fluid communication with an air intake (not shown) of the engine 18 ( FIG. 1 ), such that air can be supplied to the engine 18 .
[0038] Referring to FIG. 4 , a groove 76 P is defined in the longitudinal portion 72 P. The groove 76 P is optionally provided to increase a cross-section of the chicane conduit. Minimal intake cross-sections are regulated, and the groove 76 P represents a simple way to increase the intake cross-section of the chicane conduit of the engine cover 20 .
[0039] Similarly to the chicane conduit channel 64 P, the chicane conduit channel 64 D forms a chicane conduit when the outer skin 30 or the rib (not shown) is laid onto the core 40 . The inner surface of the outer skin 30 contacts the core 40 at the periphery of the chicane conduit channel 64 P, thereby together forming the chicane conduit channel.
[0040] The chicane conduit channel 64 D has a transverse portion 70 D, overlapping the central longitudinal axis X of the PWC 10 , and a longitudinal portion 70 P. The transverse portion 70 D is connected at an inlet end to the inlet cylindrical passage 62 D, and at a free end to the longitudinal portion 72 D.
[0041] The longitudinal portion 72 D is generally parallel to the central longitudinal axis X of the PWC 10 . A free end of the longitudinal portion 72 D is connected to an outlet cylindrical passage 74 D of the chicane conduit, formed concurrently by the core 40 and the inner skin 50 . The outlet cylindrical passage 74 D is in fluid communication with another air intake (not shown) of the engine 18 ( FIG. 1 ), such that air can be supplied to the engine 18 . A groove 76 D is provided to increase a cross-section of the chicane conduit.
[0042] As mentioned above, the chicane conduit channels 64 D and 64 P have the transverse portions 70 D and 70 P that overlap the central longitudinal axis X. In the event that the PWC 10 has tilted on the side and thus has one of its sides (starboard D or port P) submerged, water entering the chicane conduit will not reach the longitudinal portions 72 D or 72 P, because of the transverse portions 70 D and 70 P.
[0043] Moreover, the transverse portions 70 D and 70 P are slanted toward the respective inlets 60 D and 60 P with respect to a horizon of the PWC 10 in a normal floating position of the PWC 10 (i.e., with the deck 14 being generally horizontal). Accordingly, once the PWC 10 is returned to its normal floating position after being laterally submerged, water drains out of the chicane conduit through the inlets 60 D and 60 P, because of the slant in the transverse portions 70 D and 70 P, and the fact that the inlets 60 D and 60 P are positioned below the transverse portions 70 D and 70 P. Also, the transverse portions 70 D and 70 P are positioned forward of the inlets 60 D and 60 P, respectively, thereby forming another obstacle against water penetration in the chicane conduits.
[0044] Alternatively, the chicane conduit, including the inlet cylindrical passages 62 D and 62 P and the outlet cylindrical passages 74 D and 74 P, may be provided with check valve mechanisms to prevent water from reaching the air intakes of the engine 18 ( FIG. 1 ).
[0045] The outlet cylindrical passages 74 D and 74 P will be connected to the air intakes of the engine 18 ( FIG. 1 ). As the engine cover 20 is typically openable to reach the engine 18 , it is preferred to provide mating configurations between the outlet cylindrical passages 74 D and 74 P, and respective ones of the air intakes to the engine compartment, such that the outlet cylindrical passages 74 D and 74 P will sealingly connect with the air intakes when the engine cover 20 goes from an opened position to the closed position.
[0046] Construction
[0047] It is contemplated to provide an engine cover, in accordance with the present invention, composed of conduits in a hollow shell. For instance, the outer skin 30 could be used with various conduits on an inner surface thereof, rather than with the core 40 and the inner skin 50 . These various conduits would be connected to the air intakes of the engine 18 ( FIG. 1 ), and would be positioned in suitable chicane configuration to prevent water from reaching the air intakes.
[0048] The three-layer configuration shown in FIGS. 2 to 6 is relatively simple to assemble. As the various conduits are preformed in the outer skin 30 , the core 40 and the inner skin 50 , the interconnection of the outer skin 30 and the inner skin 50 , with the core 40 therebetween, is the only step required to form a chicane configuration for the engine cover 20 .
[0049] The core 40 preferably consists of a foamy plastic, such as an expandable plastic. For instance, EPP (expandable polypropylene) or EPE (expandable polyethylene) are resilient, and are thus advantageously used in the engine cover 20 of the present invention. More precisely, the resilience of these materials can be used to isolate the various components of the engine cover 20 formed by the interconnection between the three layers. For example, the core 40 can be molded so as to be of slightly greater surface than the inner surface of the outer skin 30 that will be laid thereupon. Accordingly, when the outer skin 30 is installed onto core 40 , the latter is slightly squeezed by its exceeding surface with respect to the inner surface of the outer skin 30 . This squeeze will serve as a seal between the chicane conduits defined by the connection of the core 40 to the outer skin 30 . Also, expandable polymers increase the buoyancy of the PWC 10 , especially in the event that the PWC 10 is flipped sideways.
[0050] On the other hand, the outer skin 30 and the inner skin 50 consist of a more rigid material (e.g., fiberglass, higher density plastics). In addition to cooperating with the resilient core 40 in sealingly separating the conduits (as described above), the outer skin 30 and the inner skin 50 have structural functions. The outer skin 30 is the portion of the engine cover 20 that is exposed, and acts as a shell. The inner skin 50 bears the weight of the engine cover 20 when the latter is in its closed position on the deck 14 .
[0051] The outer skin 30 and the inner skin 50 are preferably molded. Complementary connectors are provided in the outer skin 30 and the inner skin 50 for the interconnection therebetween. For instance, referring to FIGS. 2 to 5 , connector supports 80 protrude upwardly from the inner skin 50 . The connector supports 80 each enclose a tapped tube, such that threaded fasteners can be used to releasably fix the outer skin 30 to the inner skin 50 .
[0052] It is pointed out that, although the above described embodiment has two separate conduits, more conduits may be provided for supplying the necessary air to the engine 18 .
[0053] Although the engine cover 20 has been described for use with a personal watercraft such as PWC 10 , it is contemplated to use an engine cover in accordance with the present invention on a jet-powered watercraft of greater size. Cavity space optimization is not as important a design factor for such watercraft. However, the engine cover 20 of the present invention is also convenient for such watercraft.
[0054] It is within the ambit of the present invention to cover any obvious modifications of the embodiments described herein, provided such modifications fall within the scope of the appended claims.
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A watercraft comprising a hull and a deck supported by the hull, so as to define a cavity therebetween. The deck has an opening to access an engine compartment in the cavity. An engine is provided in the engine compartment. An engine cover is displaceable between an opened position, remote from the opening in the deck to allow access to the engine, and a closed position, closing the opening. The engine cover has a first surface exposed when the engine cover is in the closed position, a second surface unexposed when the engine cover is in the closed position, a thickness dimension between the first surface and the second surface, an air conduit in the thickness dimension. The air conduit has an inlet end in the first surface and an outlet end in the second surface. The outlet end is in fluid communication with an air intake of the engine.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to liquid crystal displays. More particularly it relates to active matrix liquid crystal displays (AMLCD) having well-aligned pixel electodes, and to a method of fabricating such active matrix liquid crystal displays.
[0003] 2. Discussion of the Related Art
[0004] An active matrix liquid crystal display is typically fabricated by joining an upper plate to a lower plate, and then injecting a liquid crystal material between the plates. A lower plate usually includes a plurality of pixel cells that are formed from switching devices (usually thin film transistors) and pixel electrodes. Such lower plates further include a plurality of drive lines that connect drive signals to the pixel cells. An upper plate usually includes a plurality of color filters and a common electrode. To complete an active matrix liquid crystal display, polarizing plates are attached to the upper and lower pirates.
[0005] [0005]FIG. 1 schematically illustrates a typical prior art active matrix liquid crystal display. As illustrated, data lines, including a data line 15 L, cross a plurality of gate lines, including gate lines 11 L and 10 L. The areas between the data lines and the gate lines define pixel cell regions. A thin film transistor (hereinafter abbreviated TFT) that acts as a switching device is formed at intersections between the data lines and the gate lines.
[0006] A TFT includes a gate electrode 11 G, which is a protrusion from the gate line 11 L, a source electrode 15 S, which is a protrusion from the data line 15 L, a drain electrode 15 D, and an active layer 13 . The active layer is overlapped by the electrodes. As shown, a pixel electrode 17 connects to the drain electrode 15 D.
[0007] Prior art active matrix liquid crystal displays are usually fabricated using photolithograpy. For example, to form the data line 15 L and source electrode 15 S, the gate line 11 L and gate electrode 11 G, and the drain electrode 15 D a metallic layer is deposited on a prepared substrate. The deposited metallic layer is then coated with a photoresist layer. The deposited metallic layer is then patterned by selectivly exposing the photoresist layer through a prepared mask using a light source that is above the metallic layer. The exposed photoresist layer is then etched to leave metallic conductors for the lines and electrodes. Pixel electrodes are then formed in the same manner. However, pixel electrodes are typically fabricated after the lines and electrodes. Significantly, the pixel electrodes are fabricated from a transparent material.
[0008] While the photolithographic process described above has proven useful, it has problems. One particular problem when fabricating prior art active matrix liquid crystal displays is the likelyhood of misalignment of the pixel electrodes relative to other features. Such misalignment may be caused by misalignment of exposure masks or of the exposure apparatus, or by an etch deviation due to etch conditions.
[0009] [0009]FIG. 2 assists the understanding of pixel electrode misalignment by showing a cross-sectional view taken along the line I-I′ of FIG. 1. Initially, a gate insulating layer 12 is formed on a substrate 100 . The data line 15 L is then photolithographically formed on the gate insulating layer 12 . A protection layer 16 is then formed over the structure. Pixel electrodes 17 are then photolithographically formed on the protection layer 16 . Ideally, the data line 15 L is centered between the pixel electrodes such that the intervals L and R are the same. Unfortunately, the locations of the pixel electrodes can deviate from their intended locations. Such deviations can be caused divisional exposure.
[0010] With divisional exposure, each exposure step requires new exposure equipment, such as a photomask, to be set-up. Thus, it is very difficult to control the intervals L and R such that they are even. As a result, image defects referred to as image stains are created. Furthermore, cross-talk between the pixel electrodes and the data lines becomes more severe due to deviations of parasitic capacitances.
[0011] Therefore, an improved active matrix liquid crystal display, and a new method of fabricating such an active matrix liquid crystal display, having accurately positioned pixel electrodes would be beneficial.
SUMMARY OF THE INVENTION
[0012] Accordingly, the principles of the present invention are directed to a liquid crystal display and to a fabricating method thereof that substantially obviate one or more of the problems due to limitations and disadvantages of the related art.
[0013] An object of the present invention is to provide a liquid crystal display, and a fabricating method thereof, which has accurately positioned pixel electrodes. Uniform intervals between pixel electrodes and data lines are created by patterning the pixel electrodes using a self-alignment technique by exposing the pixel electrodes through a substrate.
[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 other advantages of the invention will be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.
[0015] To achieve these and other advantages and in accordance with the purpose of the present invention, as embodied and broadly described, the present invention includes a liquid crystal display, wherein a plurality of gate lines cross a plurality of data lines to define locations of a plurality of pixel cells. Switching devices are formed at intersections of gate lines and data lines. Pixel electrodes are formed at the pixel cells, and each pixel electrode connects to a switching device. The pixel electrodes are beneficially formed such that the distance between each side of a pixel electrode and a side of a data line adjacent to the pixel electrode is accurately controlled, preferrably less than or equal to 1 μm.
[0016] In another aspect, the present invention includes the steps of providing a substrate, fabricating a plurality of gate lines and a plurality of crossing data lines that define a plurality of pixel cells, and forming switching devices at intersections of the gate lines and the data lines. The present invention further includes the steps of depositing a protection layer over the switching devices, gate lines, data lines, and substrate, forming contact holes through the protection layer to expose electrodes of the switching devices, and forming a transparent conductive layer over the exposed surface of the substrate, including the exposed electrodes. Additional steps include forming a negative type photoresist layer on the transparent conductive layer, selectively exposing the negative type photoresist layer through the substrate such that the data lines act as masks, forming a photoresist pattern by developing the selectively-exposed photoresist layer, and etching the transparent conductive layer. Beneficially, before developing the negative type photoresist layer an exposing source and a mask that are above the photoresist layer can also be used to expose the transparent conductive layer.
[0017] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed.
BRIEF DESCRIPTION OF THE DRAWING
[0018] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the principles of the invention.
[0019] In the drawings:
[0020] [0020]FIG. 1 is shows a simplified schematic view of a prior art LCD;
[0021] [0021]FIG. 2 is a cross-sectional view along the line I-I′ in FIG. 1;
[0022] [0022]FIG. 3 shows a simplified schematic view of an LCD according to an embodiment of the present invention;
[0023] [0023]FIG. 4 is a cross-sectional view along the line II-II′ in FIG. 3;
[0024] [0024]FIGS. 5A to 5 G show cross-sectional views of the LCD shown in FIG. 3 during its fabrication;
[0025] [0025]FIGS. 6A and 6B are cross-sectional views showing how an interval between a pixel electrode and a data line can be controlled by using the direction of an exposing light; and
[0026] [0026]FIG. 7 is a cross-sectional view of an LCD that presents the interval range between a pixel electrode and a data line according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0027] Reference will now be made in detail to the preferred embodiment of the present invention, example of which is illustrated in the accompanying drawings.
[0028] [0028]FIG. 3 shows a simplified schematic view of an LCD according to an embodiment of the present invention, while FIG. 4 shows a cross-sectional view of that embodiment taken along the line II-II′ of FIG. 3. The illustrated embodiment has a structure in which a plurality of gate lines cross with a plurality of data lines so as to define locations for a plurality of pixel cells. FIG. 3 shows a data line 35 L crossing a gate line 31 L and a TFT switching device formed at the intersection. The TFT is constructed such that it overlaps with the gate line 31 L, the data line 35 L, and with a drain electrode. 35 D. The TFT includes an active layer 33 that is overlapped with the gate line 31 L. This reduces leakage current due to exposure by back lighting. A pixel electrode 37 is then photolithographically formed in the pixel area between gate lines and data lines. The pixel electrode electrically connects to the drain electrode 35 D. Furthermore, the pixel electrode overlaps an adjacent gate line 30 L, producing a storage capacitor.
[0029] According to the principles of the present invention the pixel electrode 37 is formed using self-alignment by exposing a transparent conductor layer that was deposited on the LCD structure by passing light through the LCD structure such that the data line, an auxiliary electrode, or the gate line acts as a mask. By using the data lines and/or the gate lines as masking lines the intervals between the resulting pixel electrodes and the masking lines becomes uniform.
[0030] [0030]FIG. 4 illustrates the intervals. As shown, an interval designated “L” on the left of a data line 35 L is equal to an interval “R” on the right. Therefore, the image stain defect that arises from uneven intervals between pixel electrodes and data lines is prevented.
[0031] Still referring to FIG. 4, auxiliary electrodes 35 C comprised of the same substance as the data lines are included in the LCD. Each auxiliary electrode, which electrically contacts a pixel electrode, increases the capacitance between a gate line 31 L and he contacted pixel electrode 37 . This increase in capacitance is partially a result of a reduction in the thickness of a dielectric layer between the gate line 31 L and the pixel electrode 37 .
[0032] [0032]FIG. 5A to FIG. 5G show cross-sectional views of the LCD illustrated in FIGS. 3 and 4 during its fabrication. The cross-sectional views are taken along the II-II′ in FIG. 3.
[0033] Referring to FIG. 5A, a first conductive layer is deposited on a transparent substrate 300 . The first conductive layer is photolithographically patterned to form the gate line 31 L. A transparent gate insulating layer 32 is then deposited on the gate line 31 L and the substrate 300 . An active layer, which is not shown in FIGS. 5A through 5G, is then formed at a predetermined location on the gate insulating layer 32 .
[0034] Referring now to FIG. 5B, a second conductive layer is then deposited over the gate insulating layer 32 . An auxiliary electrode 35 C and a data line 35 L are then formed using photolithography. Additionally, a drain electrode that is not shown in the drawing is also formed on the gate insulating layer 32 at this time.
[0035] Referring now to FIG. 5C, a protection layer 36 is then applied to the exposed substrate. A contact hole that exposes a portion of the auxiliary electrode 35 C is then photolithography formed through the protection layer. While not shown in the figures another contact hole that exposes a portion of the drain electrode is also formed. A transparent conductive layer 37 l is then deposited over the exposed surface or the substrate. Then, the transparent conductive layer 37 l is coated with a negative type photoresist layer PR.
[0036] Referring to FIG. 5D, exposure of the negative type photoresist layer PR is performed to define photoresist patterns for the pixel electrodes. As shown in FIG. 5D, the photoresist layer PR is exposured from both sides. This is performed by passing light through the transparent substrate, where the opaque data line 35 L and the opaque gate line 31 L act as masks, and from above, where a mask M is used. However, if the pixel electrodes are not being used to form storage capacitors with the gates, the front side exposure can be skipped. The mask M block light everywhere but near the gate layer 31 L/auxiliary electrode 35 C. As shown in FIG. 5D, a small area of the negative type photoresist layer PR is blocked both by the mask M and by the auxiliary electrode 35 C.
[0037] By exposing the negative type photoresist layer PR through the substrate (referred to as back side exposure) the exposing light exposes the negative type photoresist layer PR everywhere except where the gate line 31 L, the data line 35 L, and the auxilary electrode 35 C (if used) mask the photoresist layer PR. Furthermore, it should be understood that the exposure steps need not be performed simultaneously. For example, exposure can be carried out by first exposing from the front side and then from the back, or vice versa.
[0038] Referring now to FIG. 5E, the exposed photoresist layer PR is then developed to form a photoresist pattern PR. Referring now to FIG. 5F, pixel electrodes 37 are then formed by etching the transparent conductive layer while using the photoresist pattern PR as a mask. As shown, each pixel electrode 37 is aligned with a data line 35 L since that data line acted as a mask during exposure of the negative type photoresist layer PR. Thus, a uniform interval between the pixel electrode 37 and the data line 35 L is provided and image stains defects are prevented.
[0039] The principles of the present invention address the problem of irregular intervals between data lines and pixel electrodes that result from misalignment of exposure equipment. This is achieved by using the data lines, gate lines, or auxilary lines as a mask by exposing a photoresist through the substrate, back side exposure.
[0040] However, the principles of the present invention accomplish even more. For example, they enable the control of the intervals between pixel electrodes and data lines, gate lines, or auxilary lines. Such control is explained with the assistance of FIGS. 6A and 6B. For the convenience those figures use the same nomenclature as FIGS. 5A through 5B. Referring now to FIG. 6A, back side exposure of the negative type photoresist pattern PR is carried out through the substrate 300 and through the transparent conductive layer 37 l . However, during back-side exposure the angle of irradiation through the substrate is controlled such that the location of the resulting pixel electrode relative to the data line 35 L is controlled. FIG. 6B shows the end result of irradiating the data line 35 L with light as shown in FIG. 6A. The pixel electrode on the left side of the data line 35 L overlapps with that data line, while the pixel electrode on its right side is separated from the data line 35 L by an interval “R”. One benefit of the structure that results from FIG. 6B is that light leakage from the left of the data lines is prevented. Of course, light leakage from the right of the data lines can be prevented by changing the angle of the exposing light. Therefore, the intervals between pixel electrodes 37 and data lines 35 L can be controlled by controlling the direction and angle of light irradiation through the substrate.
[0041] The principles of the present invention can accomplish even more. In high quality LCD it is very important to control critical dimensions, such as the intervals between pixel electrodes 37 and data lines 35 L, by changing the irradiation angle. For example, the FIG. 7 illustrates a desirable result of controlling the interval 39 within ±1 μm from the pixel electrode 37 , using an edge of the data line 35 L as a reference. The critical dimension is thereby controlled by photolithography.
[0042] Accordingly, the principles of the present invention enables a reduce in the image stain defect by patterning pixel electrodes such that the pixel electrodes self-align with another element by back-side exposing a photosensitive layer through a substrate. If a data line is the element that is used to self-align the pixel electrodes, a uniform interval between the pixel electrodes and the data lines can result. Moreover, the principles of the present invention enables control of an interval between pixel electrodes and data lines by changing the irradiating angle through the substrate.
[0043] It will be apparent to those skilled in the art that various modifications and variation can be made in the present invention without departing from the spirit or scope of the invention. Thus, it is intended that the present invention covers the modifications and variations of this invention provided they come within the scope of the appended claims and their equivalents.
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A liquid crystal display, and a fabricating method thereof, wherein pixel electrodes are highly accurately located relative to opaque elements, such as gate lines, data lines, or auxilarly lines, beneficially by using opaque elements as masking elements when exposing a photosensitive layer through a substrate. The angle of the irradiating light through the substrate can be changed to achieve a desired relative location. A pixel electrode can be located within 1 μm of a data line. Image stain defects can be reduced.
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CROSS-REFERENCE
This application is divisional application of Ser. No. 11/926,608, filed Oct. 29, 2007 now U.S. Pat. No. 8,118,771 which is a continuation application of Ser. No. 10/496,357, filed Jun. 4, 2007, which application claims the benefit of priority to International Application Serial No. PCT/GB02/05220 filed Nov. 21, 2002 (now publication No. WO 03/045479) which application claims the benefit of priority to GB 0127942.1 filed Nov. 21, 2001, all of which are incorporated herein by reference in their entirety noting that the current application controls to the extent there is any contradiction with any earlier applications and to which applications we claim priority under 35 USC §120.
BACKGROUND OF THE INVENTION
Needleless injectors are used as an alternative to needle-type hypodermic injectors for delivering liquid drugs and other substances through the skin and into the underlying tissues. The drug is dispensed from a drug capsule having a piston which is driven with sufficient force that the drug is expelled at sufficiently high pressure to pierce the skin. Typically, the drug capsule will comprise a hollow cylindrical chamber with a discharge orifice at one end, and a piston slidingly and sealingly located at the other. The piston is caused to move towards the orifice to dispense the drug by a ram, powered by a variety of means such as a spring, pressurised gas or pyrotechnic charge. The orifice diameter can vary from about 0.08 mm to about 0.7 mm, according to the application.
The more successful and controllable injectors employ a two-phase injection pressure profile; the first is a short but very high pressure pulse to puncture the skin and the second is at a lower pressure to dispense the drug through the hole thus formed. Typically, the first pressure pulse will be of around 100 microsecond duration, and have a peak pressure of 300-500 bar, and the second will last for around 200 milliseconds with a pressure of around 100 bar. The duration of the second phase will vary according to the volume to be delivered.
It is highly preferred that the drug capsule is transparent, so that the contents may be checked for accuracy and contamination. This requirement has placed a severe limitation on the types of materials that may be used, because the transparent material must be strong enough to withstand the extremely high pressures, and must not adversely affect the drug. As a consequence, virtually all of the needleless injectors proposed use a plastic drug capsule, typically made from polycarbonate. However, such materials are generally unsuitable for storing the drug, because they absorb water from the drug, or are permeable to oxygen, or react in some way with the drug. Therefore, drug capsules made from plastics are required to be filled immediately before use, a rather inconvenient procedure, with risk of inaccurate filling and contamination, and requiring training of the operators.
The only material with a long history of satisfactory drug storage is borosilicate glass, but this is very brittle and hence there have been few injectors with glass capsules. The obvious problem with glass capsules is that particles of glass are ejected if they burst. The underlying causes of the weakness of glass capsules are tiny flaws which occur during manufacture, such as scratches, and cracks through incorrect control of temperatures.
The “Intraject” manufactured by Weston Medical Limited is a pre-filled single-use disposable needleless injector, having one of the very few glass capsules suitable for long term drug storage. This is a borosilicate drug capsule of up to 1 ml capacity, made to exceedingly close manufacturing specifications, and further improved by ion exchange strengthening. The breakage rate for these capsules is exceptionally low, but it is desirable to reduce this still further.
Several attempts have been made to reduce the breakage rate for these capsules. For example, further layers of material have been added to the capsule to provide increased physical strength (see international patent publication WO96/15821 in the name of Weston Medical Limited). However, this approach increases significantly the manufacturing costs of the capsule. An alternative approach has been to reduce the number of flaws in the material of the drug capsule, particularly around the discharge orifice. One method of doing this has been to manufacture the capsule without an orifice and then use a laser to drill precisely the orifice (see international patent publication WO01/58638 in the name of Weston Medical Limited). Despite these advances, there is still a requirement for further reducing the incidence of breakages.
SUMMARY OF THE INVENTION
Accordingly, the present invention provides a needleless injector drug capsule containing a liquid drug wherein the liquid drug has been purged by an inert gas having a low solubility in the liquid drug.
Surprisingly, it has been found that the presence of small bubbles of gas previously in solution encourage breakages in the drug capsule and that removal or reduction of these solute gases by purging with a gas having a low solubility reduces the incidence of breakages.
The capsule is preferably made from borosilicate glass, and which may have undergone ion exchange strengthening.
Preferably the inert gas has a solubility of 0.5 to 25 cm 3 in 100 cm 3 of the liquid drug.
Preferably the inert gas is one or more of helium, argon, neon, krypton, xenon, nitrogen, one or more chlorofluorocarbons and/or one or more hydrofluorocarbons and particularly preferably helium.
In another embodiment of the invention, a needleless injector drug capsule is provided containing a liquid drug wherein the liquid drug has been purged by a gas having a substantially constant solubility in the liquid drug over a range of temperatures corresponding to the storage temperatures for the liquid drug. This range of temperatures may be 0° C. to 30° C.
In another embodiment the present invention provides a method for filling a needleless injector drug capsule with a liquid drug, the method comprising purging the liquid drug with an inert gas having a low solubility in the liquid drug, and filling the capsule.
Preferably the purging process is carried out at a temperature corresponding to the lowest solubility of the inert gas in the liquid drug.
Preferably the inert gas is helium and the purging process is then carried out at 25° C. to 35° C.
Preferably, prior to contact with the liquid drug, the inert gas is forced through a filter having apertures of not more than 0.2 μm.
The liquid drug is preferably stirred during purging.
In another embodiment, the invention provides a method for filling a needleless injector drug capsule with a liquid drug comprising purging the liquid drug with a gas having a substantially constant solubility in the liquid drug over a range of temperatures corresponding to the storage temperatures for the liquid drug.
BRIEF DESCRIPTION OF THE DRAWINGS
Example of the invention, will now be described in detail with reference to the accompanying drawings, in which:
FIG. 1 shows the variation of the solubility of a number of gases in water with temperature;
FIG. 2 shows in greater detail the variation of the solubility of helium in water with temperature;
FIG. 3 shows the rate of increase of helium under five different conditions for a sparging method of the invention using helium;
FIG. 4 shows the rate at which nitrogen and oxygen are displaced by helium for the five different conditions of FIG. 4 ; and
FIG. 5 compares the rate of increase of helium with the rate of decrease of nitrogen and oxygen.
DETAILED DESCRIPTION
Careful investigation of the causes of breakage of the drug capsule has revealed that, in addition to manufacturing flaws in the glass, bubbles of gas (normally air) entrained in the drug may result in the fracture of the capsule. The high initial pressure in the injection cycle causes bubble collapse resulting in localised high stress in the region of the discharge orifice of the capsule (where the bubbles tend to collect). Filling under vacuum will practically eliminate the bubbles of air present in the liquid drug at the time of filling, but dissolved gas tends to come out of solution during storage. Bubbles of up to 2 μl volume do not appear to cause breakage, but above this, the incidence of breakage rises with increasing bubble size.
The present invention seeks to reduce the evolution of gas bubbles from the drug by replacing the dissolved gas by a gas of low solubility in the liquid drug. Interestingly, the applicant has found that alternative methods of removing dissolved gas, e.g. by applying a vacuum to the liquid or sonication of the liquid do not work for certain drug types. Applying a vacuum, for example, has the drawback of removing volatile components which may be part of the drug, and water, in addition to the dissolved gas: This can result in an unacceptable change in the drug formulation. Sonication results in “hot-spots” in the liquid which can them 1 ally degrade the drug.
The applicant has found that purging a liquid drug with an inert gas, such as helium (He), effectively displaces dissolved gases, particularly oxygen and nitrogen, and that the drug may then be stored within a drug capsule without the risk of gas bubbles appealing during storage at normal temperatures.
Pre-treatment of the drug product by sparging with low solubility gas species minimises the total mass of dissolved gas. By selecting a sparging gas with a low variation in solubility of the gas in the drug as a function of temperature, the propensity for those gases to come out of solution during temperature cycling is also minimised. Helium is one gas satisfying this condition.
Other gases may be used according to the application such as neon, argon, krypton or xenon. Other inert gases of low solubility may also be used, including nitrogen as well as chlorofluorocarbons and hydrofluorocarbons.
FIG. 1 shows the solubility of various gases in water over temperature. A flat solubility curve over a range of temperatures corresponding to the temperature range expected during storage will prevent gas coming out of solution during storage.
Plots are shown in FIG. 1 for Hydrogen, Helium, Nitrogen, Oxygen, Neon, Argon, Krypton and Xenon. The storage temperature range may typically be 280° K to 310° K, and a flat solubility curve over this range of temperatures is desired, in addition to low solubility and an “inert” property of the gas. As shown, hydrogen, helium, neon and nitrogen best satisfy the solubility requirements.
The term “inert” used herein denotes a gas which will not react with the liquid drug at normal temperatures and pressures. The term “low solubility” denotes a solubility of the inert gas in the liquid drug which reduces the incidence of bubbles in the liquid drug. Preferably the solubility is from 0.5 to 25 cm 3 in 100 cm 3 of the liquid drug, preferably 0.9 to 5.0 cm 3 in 100 cm 3 of the liquid drug and particularly preferably from 0.9 to 1.5 cm 3 in 100 cm 3 of the liquid drug. Solubility is measured at 25° C. The term “liquid drug” denotes a drug which is liquid at room temperature and pressure, or a drug dissolved or suspended in a solvent, such as water.
A preferred embodiment of the invention is to “sparge” the liquid drug with tiny bubbles of a sparging gas.
Taking helium as one specific example, FIG. 2 shows that the solubility of helium is at its lowest at approximately 30° C., and wherever the drug is stable at such temperature, it is particularly preferred to conduct the sparging process at this temperature, with a tolerance of about +/−5° C. Preferably, the bubbles may be generated by forcing pressurised helium through a sterile 0.2 micron filter placed in the bottom of a vessel. This produces a very large number of very small bubbles, and after treating, say, 2 litres of an aqueous drug for 15 minutes, the sparging device is removed, and the vessel sealed in a helium (or other gas used for sparging) atmosphere, with minimal over-pressure, until required for the filling of injector capsules.
Obviously, the duration of the treatment will vary according to the volume of liquid, the gas pressure, volume flow rate, and the size and number of the bubbles generated by the sparging device. The gas pressure and volume flow rate are of course linked. Preferably, capsule filling is carried out by first evacuating the capsule to about 0.5 mbar before admitting the drug into the capsule; a full description of a suitable process is disclosed in International patent publication WO02/060516-“Method for filling needleless injection capsules” in the name of Weston Medical Limited.
It has also been found that stirring of the liquid during sparging reduces the required sparging time. In particular, it has been found that key input parameters for the control of the sparging process are stirring speed (for example using a magnetic mixer) and the gas flow rate. Increasing the gas flow rate reduces the time required, but there is a maximum practical gas flow rate above which foaming of the drug being sparged is too great. The additional step of stirring reduces further the time required by increasing the time taken for the sparging gas to travel through the liquid, for the same gas flow rate.
In order to monitor the rate at which gas is displaced by the sparging gas, an oxygen probe is used. The air being removed from the drug by sparging is of course almost entirely nitrogen and oxygen, and it has been found that the concentration of dissolved nitrogen and .oxygen can be deduced from a measurement of the dissolved oxygen concentration alone.
In order to analyse the effects of the stirring rate and the gas flow rate, a number of experiments were carried out. The table below show the experimental conditions for 5 tests, in which helium was used as the sparging gas. All conditions were equal other than the stiffing speed and flow rate. The experiments involved the sparging of 3 litres of solution in a 5 litre Schott glass bottle, with an oxygen probe used to measure (and deduce) the dissolved gas concentrations. In these experiments, the solution contained 0.1% polysorbate 80.
Experiment number
1
2
3
4
5
6
7
Magnetic mixer speed
150
150
150
250
350
250
250
(rpm)
Fine flow meter
80
150
190
145
145
150
150
(ml min −1 )
FIG. 3 shows the evolution over time of the helium concentration in the drug. Using best fit techniques, the curves can be. characterised as exponential graphs, each having a characteristic time constant, β.
As there are two sets of three experiments where either the stirrer speed or the flow rate is held constant, it is possible to explore the variation of β as a function of each variable. In both cases, a proportional relationship is found. This suggests that the variables are independent and proportional. From this, it is found that β varies twice as much with stiffing speed as with the gas flow rate, so that the stirrer speed is approximately twice as important as the gas flow rate.
FIG. 4 shows the concentration of oxygen and nitrogen over time for the five experimental conditions. The decay curves also follow the exponential model and agree with the graphs of FIG. 3 .
It is then possible to compare the time constants for the exponential increase in helium concentration and for the exponential decrease in combined nitrogen and oxygen concentration. FIG. 5 shows this comparison, with the five plotted point representing the five experiments. There is clearly a proportional relationship between the two tin1e constants for different sparging conditions. The constant of proportionality is given as 0.575.
The principal conclusion is that the helium concentration varies at approximately 1.75 times the speed of the combined nitrogen and oxygen concentration. The helium mass transfer process is quicker than the nitrogen and oxygen processes. Selecting the optimum sparging conditions results in operation at the high gas transfer rate portion of the line in FIG. 5 .
The sparging operation effectively displaces the dissolved gases in the drug. By selecting the sparging gas to have a flat solubility curve over temperature, the possibility of gas coming out of solution during storage is minimised. As a result, the capsule can be formed from a material which is impermeable to the sparging gas, as there is no need to discharge the sparging gas. For example, a borosilicate glass capsule is selected partly for its impermeability to oxygen, which prevents deterioration of the stored drug. Such a capsule is also impermeable to nitrogen. However, nitrogen can still be used as a sparging gas, particularly if the sparging conditions are selected to correspond to the minimum solubility of nitrogen.
Thus, although examples are given for sparging conditions with helium, the invention is not restricted to helium, and other gases suitable for sparging have been identified.
As can be seen from the experiments above, a preferred stiffing speed is in the range 100 rpm to 300 rpm, preferably 200 rpm to 300 rpm.
Other modifications will be apparent to those skilled in the art.
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A method for tilling needleless injector capsules with liquid drug, whereby dissolved gas within the drug is replaced by a less soluble gas in order to reduce the inclusion of gas bubbles, or to prevent the growth of bubbles during storage and thereby prevent breakage of the capsules.
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BACKGROUND OF THE INVENTION
The present invention relates to an apparatus and a method for cleaning a pipe or a pipe system and a method for cleaning and verifying the cleanliness of the pipe or pipe system after completed cleaning.
Today, large transportable flush units are often used for cleaning pipes and pipe systems when there is no permanently installed equipment for pigging the pipe or pipe system. Such known flush units are large and cannot be handled without using cranes or the like because they require a high oil pressure and a substantial flow of liquid. This makes the work more complicated; it takes more time and requires more resources. Moreover, the known systems do not give satisfactory results when a high degree of cleanliness in the pipes is required, especially, for example, in the areas right against the pipe wall and at pipe joints.
Another problem with known systems is verification of cleanliness after the cleaning of the pipe or pipe system has been completed, when a certain standard of cleanliness is required. In many cases it is in fact a requirement that a satisfactory degree of cleanliness can be proven. This is, inter alia, the case in the petroleum industry. Eighty percent of all faults in hydraulic systems can be related to the particle cleanliness of the hydraulic oil. The formula for load-life calculations for ball and roller bearings is, inter alia, calculated based on particle concentration and water content of the oil. This is the basis for lifetime and reliability calculations for critical machine installations.
Systems for cleaning a pipe are already known from U.S. Pat. No. 5,444,886. This document teaches a system with a combined unit for launching and receiving a pig at each end of the pipe to be cleaned. The pig is driven through the pipe by a pressurised gas.
U.S. Pat. No. 6,391,121 B1 teaches a permanently installed system for cleaning the tubing of a heater where a combined launching and receiving unit is provided on either side of the heater. In addition, a parallel connection of the pipe and a pump is provided so that the pigs can be run back through the parallel connection.
It is therefore an object to provide a cleaning system that is substantially smaller and lighter than known systems and which therefore can be transported and handled with relative ease.
It is a further object of the invention to provide a cleaning system and a method for cleaning pipes and pipe systems which increase the degree of cleanliness after cleaning compared with existing systems, especially in problem areas of the pipes such as pipe joints and close to the surface of the pipes where turbulent flow is necessary to remove particles that are found on the interior walls of the pipe.
It is also an object to provide a cleaning system that is capable of verifying the internal cleanliness of the pipes after the cleaning operation.
SUMMARY OF THE INVENTION
An apparatus is described for use in the internal cleaning of pipes and pipe systems. The apparatus is arranged so as to be capable of being connected to a first pipe end of the pipe or pipe system and to a second pipe end of the pipe or pipe system that is to be cleaned. The apparatus will in general comprise at least a coupling device which is designed for connection to a reservoir of a pressurised gas, a pressure chamber in which the cleaning pigs are placed and which acts as a launching unit for the cleaning pigs. If the pressurised gas is provided through a pipe or a hose, the coupling device may, for example, be a standard quick release coupling designed to be used for such a purpose. If the pressurised gas is provided in another manner, an adapted coupling device will then have to be used. The apparatus further comprises a pig receiver for receiving cleaning pigs that are sent through the pipe or pipe system and a pressure booster for pressurising a liquid fluid. This liquid fluid is preferably a hydraulic oil, but other types of liquid fluids can also be used if appropriate. The apparatus also comprises at least one valve means so that a cleaning pig can be driven through the at least one pipe with the aid of the pressurised gas or the pressurised liquid fluid. It is also conceivable that two valves can be used, each valve in that case admitting and shutting off the supply of the pressurised gas or the liquid fluid, respectively. Other solutions may be chosen if desired, provided the apparatus allows cleaning pigs to be driven through the at least one pipe to be cleaned either by using pressurised gas or a pressurised liquid fluid and that it is possible to alternate between the use of a pressurised gas and a pressurised liquid fluid.
If necessary, the apparatus can also be provided with a sampler for sampling the liquid fluid after it has flowed through the pipe or pipe system. Such a sampler may be as described in the Applicant's own Norwegian Patent NO 171430, or another type of sampler that is capable of taking a representative sample of the oil or of counting particles in the oil so that the degree of cleanliness of the pipe or pipe system can be determined accurately.
The sampler may also be provided with means for adding an antimicrobial agent, as for example, Biocid, to reduce microbial growth on the pipe surface.
In a preferred embodiment, the apparatus is connected to the first pipe end and the second pipe end of the at least one pipe in such manner that the apparatus and the at least one pipe to be cleaned form a fluid flow circuit.
To carry out the cleaning process in which cleaning pigs are driven through the pipe or pipe system with the aid of a pressurised gas or a liquid fluid, the pig receiver is provided with an interchangeable pig basket for receiving cleaning pigs. When the cleaning pig is driven through the pipe with the aid of the pressurised gas, the pig receiver pig basket is configured with through apertures to allow the pressurised gas to be released.
Correspondingly, the pig receiver's pig basket for use when the cleaning pig is driven through the pipe with the aid of the pressurised liquid fluid is fluid-tight.
The liquid fluid will preferably be circulated in the fluid flow circuit when the apparatus is configured so as to form such a circuit together with the pipe or pipe system.
The pressure booster preferably comprises a container for storing the liquid fluid.
Furthermore, a method is provided for cleaning pipes and pipe systems wherein an apparatus is used that is connected to a pipe or a pipe system to be cleaned at a first pipe end and a second pipe end of the pipe or pipe system. The apparatus comprises at least a coupling means for connection to a reservoir of a pressurised gas, a pressure chamber for introduction of cleaning pigs, a pig receiver for receiving cleaning pigs that are sent through the at least one pipe, and a pressure booster for pressurising a liquid fluid. During the cleaning of the at least one pipe, the following steps are carried out:
at least one solid cleaning pig is sent through the at least one pipe, driven by the pressurised gas; at least one solid cleaning pig is sent through the at least one pipe, driven by the pressurised liquid fluid; at least one adjustable cleaning pig is sent through the at least one pipe, driven by the pressurised liquid fluid for verification.
In each of the above steps, just one pig may be launched, or if required, two or more pigs can be launched in one or more or all of the steps. It is in the last step, where an adjustable pig is sent through the pipe, that the desired cleaning effect right against the pipe wall and in pipe joints is achieved. Such cleaning pigs, with an adjustable diameter, are generally known and are therefore not discussed further here.
In a preferred embodiment, the apparatus and the pipe or pipe system to be cleaned are joined in such manner that together they form a fluid flow circuit so that a fluid can circulate in the fluid flow circuit.
In a preferred embodiment an antimicrobial agent, as for example Biocid, is added to the liquid fluid before it flows through the pipe or pipe system.
When a pig that is driven by the pressurised gas is sent through the pipe or pipe system, the pig receiver is used with a pig basket configured with through apertures to allow the pressurised gas to be released.
When the pig is driven by the pressurised liquid fluid through the pipe or pipe system, the pig receiver is used with a pig basket that is fluid-tight.
A method is also provided for cleaning and verifying the cleanliness of a pipe or pipe system wherein an apparatus is used that is connected to a pipe or pipe system to be cleaned at a first and a second end of the pipe or pipe system. The apparatus comprises at least a coupling device designed for connection to a reservoir of pressurised gas, a pressure chamber for introduction of cleaning pigs, a pig receiver for receiving cleaning pigs that are sent through the at least one pipe, a pressure booster for pressurising a liquid fluid, and a sampler capable of taking samples of the liquid fluid after it has flowed though the at least one pipe. During the cleaning of the pipe or pipe system and verification of the cleanliness of the pipe or pipe system, the following steps are carried out:
at least one solid cleaning pig is sent through the at least one pipe, driven by the pressurised gas; at least one solid cleaning pig is sent through the at least one pipe, driven by the pressurised liquid fluid; at least one adjustable cleaning pig is sent through the at least one pipe, driven by the pressurised liquid fluid; and using the sampler, at least one sample is taken of the pressurised liquid fluid that has flowed through the at least one pipe.
The sampler takes at least one sample of the pressurised, liquid fluid after the last cleaning pig has been sent through the at least one pipe, but more samples may of course be taken, both during the cleaning process and when the, initially, last cleaning pig has been sent through the pipe or pipe system.
If desirable, an antimicrobial agent, as for example Biocid, can be added to the pressurised liquid fluid before it flows through the at least one pipe. This may, for example, be done in the sampler. A sampler that is provided with means for adding such an antimicrobial agent is described in the Applicant's Norwegian Patent NO 171430.
In a preferred embodiment, the apparatus and the pipe or pipe system are joined in such manner that together they form a fluid flow circuit so that a liquid fluid can circulate in the fluid flow circuit.
When a pig is driven through the pipe or pipe system by the pressurised gas, it is preferable to use the pig receiver with a pig basket configured with through apertures for release of the pressurised gas.
When a pig is driven through the pipe or pipe system by the pressurised liquid fluid it is preferable to use the pig receiver with a pig basket that is fluid-tight.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 shows an apparatus for the cleaning of a pipe according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
An embodiment of the invention will be described in detail below with reference to the attached FIGURE which shows how a system for cleaning a pipe or pipe system according to the invention can be set up.
FIG. 1 shows an apparatus 40 for cleaning a pipe 10 or a pipe system consisting of several pipes, such as the pipes 10 , 11 illustrated here. The pipes 10 , 11 in the pipe system are joined by a T-shaped pipe fitting 32 , where the pipe 10 is connected to a first branch 33 of the T-shaped pipe fitting 32 and the pipe 11 is connected to a second branch 34 via a valve 12 that can close the pipe 11 when the pipe 10 is to be cleaned. A pressure chamber 20 is connected via a valve 13 at a first pipe end 14 of the pipe 10 . The pressure chamber 20 acts as a launching unit for cleaning pigs 21 .
At the other end, the pressure chamber 20 is connected to a first branch 38 of a T-shaped pipe fitting 19 . A source of pressurised gas, as for instance air, may be connected to the second branch 39 of the T-shaped pipe fitting 19 by means of a suitable coupling device (not shown). A supply of the pressurised gas to the pressure chamber 20 may be admitted and shut off by means of a valve 16 .
A pressure booster 29 comprising a pump 30 that pumps a liquid fluid is connected to a third branch 40 of the T-shaped pipe fitting 19 . The pressure booster 29 also comprises a tank 31 for storing the liquid fluid. A supply of the liquid fluid to the pressure chamber 20 can be admitted and shut off by means of a valve 17 . The liquid fluid is preferably a hydraulic oil, but if appropriate, other types of liquid fluids may also be used. A filter 22 through which the liquid fluid passes may advantageously be disposed between the pressure booster 29 and the T-shaped pipe fitting 19 .
The FIGURE shows an embodiment of the invention that employs two valves 16 , 17 for admitting and shutting off the supply of respectively pressurised gas and a liquid fluid. An alternative embodiment will employ a single valve instead of the T-shaped pipe fitting 19 , which valve has three positions, a first position in which it admits supply of pressurised gas and shuts off supply of liquid fluid, a second position in which it admits supply of liquid fluid and shuts off supply of pressurised gas, and a third position in which it shuts off supply of both pressurised gas and liquid fluid.
A pig receiver 23 comprising a pig basket 24 , 25 for catching cleaning pigs 21 that are sent through the pipe 10 is connected to the third branch 34 of the T-shaped pipe fitting 32 . In the FIGURE only one cleaning pig 21 is shown in a merely schematic form. During the cleaning process of the pipe 10 , several different types of cleaning pigs will be launched, so that even though the FIGURE only shows one cleaning pig it must be understood that in reality this schematically drawn pig represents several different types of cleaning pigs.
In the FIGURE, a pig basket 24 , for use when the cleaning pig 21 is driven through the pipe 10 with the aid of pressurised gas, is mounted on the pig receiver 23 . This pig basket 24 is provided with a suitable number of apertures 36 for release of the pressurised gas. The other pig basket 25 is fluid-tight and therefore has no holes or through apertures and is mounted on the pig receiver 23 before cleaning pigs 21 are driven through the pipe 10 with the aid of a liquid fluid.
The embodiment of the apparatus 40 shown in the FIGURE is provided with a sampler 26 for sampling the liquid fluid that has flowed through the pipe 10 . The sample can be analysed and, on the basis of the result of the analysis, the degree of cleanliness in the pipe 10 can be verified. When a sampler 26 is provided in the apparatus 40 , it can, as shown in the FIGURE, be connected to the pig receiver 23 by a hose 37 . Furthermore, a return hose 27 is connected from the sampler to the pressure booster 29 via a valve 28 .
There may also be cases where verification of the cleanliness of the pipe or pipe system after cleaning is not required. It is then unnecessary to provide a sampler 26 in the apparatus 40 . There will thus be an embodiment where the sampler 26 and the hose 37 are not included in the apparatus 40 . In this case, the return hose 27 is connected directly to the pig receiver 23 .
In the FIGURE, the apparatus 40 and the pipe 10 form a fluid flow circuit in which the liquid fluid can circulate. This is the preferred embodiment of the invention, but it is also possible to have an embodiment where the fluid does not circulate in a fluid flow circuit. It is possible that at the point where the pipes 10 , 11 are located, there is also access to a liquid fluid under pressure which can be used to drive the cleaning pig 21 . The hose 41 can in such a case be connected to the reservoir. The return hose 27 can then empty the liquid fluid into a receptacle of a suitable kind. It is also conceivable that the pressure booster 29 is equipped with a fluid tank 31 which has the capacity to hold a sufficient amount of liquid fluid for conducting the cleaning of the pipe 10 without the liquid fluid circulating, but instead being collected in a receptacle.
When carrying out the cleaning process, a cleaning pig 21 having a solid form will, in a first step, be sent through the pipe 10 . The valve 17 for supply of the liquid fluid is kept closed during this step. The cleaning pig 21 is placed inside the pressure chamber 20 and the pressure chamber 20 is closed, and the pig basket 24 that is provided with apertures 36 is mounted on the pig receiver 23 . The valve 16 is opened to admit a supply of pressurised gas so that the cleaning pig 21 is driven through the pipe 10 and performs a rough cleaning of the pipe 10 . When the cleaning pig 21 has passed through the pipe 10 , it is caught in the pig basket 24 and the pressurised gas that drives the cleaning pig through the pipe 10 is released through the apertures 36 . If necessary, this operation can be carried out several times.
In the second step of the cleaning process, a cleaning pig 21 having a solid form will also be sent through the pipe 10 . The valve 16 for supply of the pressurised gas is kept closed during this step. The cleaning pig 21 is placed inside the pressure chamber 20 and the pressure chamber 20 is closed, and the fluid-tight pig basket 25 is mounted on the pig receiver 23 . The valve 17 is opened to admit a supply of the liquid fluid under pressure so that the cleaning pig 21 is driven through the pipe 10 and cleans the pipe 10 whilst the liquid fluid collects and removes unwanted particles. When the cleaning pig 21 has passed through the pipe 10 , it is caught in the pig basket 25 and the liquid fluid that drives the cleaning pig through the pipe 10 , flows on through the hose 37 to the sampler 26 if the apparatus 50 is provided with such a sampler 26 , or out through the return hose 27 if a sampler 26 is not provided in the apparatus 50 . If necessary, this operation can also be carried out several times.
In the third step of the cleaning process, an adjustable cleaning pig 21 is sent through the pipe 10 . This adjustable cleaning pig 21 is configured so that its diameter can be adjusted to allow the cleaning pig to be pressed against the inner wall of the pipe 10 at a desired pressure. What the desired pressure is in each case will to a great extent be an empirical matter that a person of skill in the art will be able to decide on or arrive at by trial and error. The adjustable cleaning pig creates turbulence in the liquid fluid which will contribute to a better cleaning right in against the pipe wall and in pipe joints. The valve 16 for supply of the pressurised gas is kept closed during this step. The adjustable cleaning pig 21 is placed inside the pressure chamber 20 and the pressure chamber 20 is closed. The fluid-tight pig basket 25 is kept on the pig receiver 23 . The valve 17 is opened to admit a supply of the liquid fluid under pressure so that the adjustable cleaning pig 21 is driven through the pipe 10 and cleans the pipe 10 in particular right in against the pipe wall and in pipe joints where other known cleaning systems are not effective. When the cleaning pig 21 has passed through the pipe 10 , it is caught in the pig basket 25 and the liquid fluid that drives the cleaning pig through the pipe 10 , flows on out through the hose 37 to the sampler 26 if the apparatus 50 is provided with such a sampler 26 , or out through the return hose 27 if a sampler 26 is not provided in the apparatus 50 . If necessary, this operation can also be carried out several times.
In one embodiment of the invention, it has been taken into account that it is not always enough simply to clean the pipes according to a given procedure, but that it is also necessary to be able to verify that the pipe has a desired degree of cleanliness. For such cases, the apparatus 50 will preferably be provided with a sampler 26 as described above, and in addition to the three steps for cleaning a pipe 10 , also as described above, there will be a fourth step in which a sample of the liquid fluid that has flowed through the pipe 10 is taken in the sampler 26 . This sample is analysed and if the result is satisfactory, i.e., that the number of particles per volume unit of the liquid fluid is below a certain level, it is verified that the cleaned pipe 10 has a sufficient degree of cleanliness in accordance with the standards that are set.
In the above, a sampler 26 is provided which takes a sample of the liquid fluid which is subsequently analysed. Instead of a sampler, it is conceivable that a particle counter may be used which counts the number of particles per volume unit of the liquid fluid so that it can similarly be verified that the cleaned pipe has the necessary cleanliness in relation to the standards set.
It should also be mentioned that the sampler 26 may be provided with means for adding an antimicrobial agent such as Biocid to the liquid fluid for combating microbial growth on the surface of the pipe 10 .
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An apparatus ( 50 ) is provided for use in internal cleaning of at least one pipe ( 10 ), which apparatus ( 50 ) is arranged for connection to a first pipe end ( 14 ) of the at least one pipe ( 10 ) and to a second pipe end ( 15 ) of the at least one pipe, wherein the apparatus ( 50 ) at least comprises a coupling device designed for connection to a reservoir of pressurized gas, a pressure chamber ( 20 ) for introduction of cleaning pigs ( 21 ) and a pig receiver ( 23 ) for receiving cleaning pigs ( 21 ) which have passed through the at least one pipe ( 10 ). The apparatus ( 50 ) further comprises a pressure booster ( 29 ) for pressurizing a liquid fluid and at least one valve means ( 16,17 ) so as to allow a cleaning pig ( 21 ) to be driven through the at least one pipe ( 10 ) by means of either the pressurized gas or the pressurised liquid fluid.
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FIELD OF THE INVENTION
[0001] This application provides a unique construction of Anti-ballistic Shelters for personal and group use which are both portable and fixed in location. More particularly, protective elements of the Anti-ballistic Shelters will consist of layers of flexible anti-ballistic fabric, known as soft armor, layered in at least two directions attached to Quonset hut buildings or other shelters, pipe, rods or other tubular frame structures, room dividers, panels, doors, cots, mattresses, pads, umbrellas and tents.
BACKGROUND OF THE INVENTION
[0002] This application describes new and unique methods using the latest design of anti-ballistic protection available in the construction of a wide variety of anti-ballistic shelters. Presently these materials are fabricated using not only Aramid fibers and KEVLAR® from DuPont, but also polyethylene fibers and GOLD SHIELD®, which is a KEVLAR® based material, and SPECTRA SHIELD®, which is polyethylene based material, both available commercially from Honeywell, GOLD SHIELD® and SPECTRA SHIELD® that are high strength synthetic fibers impregnated in partially cured resin for use in anti-ballistic material. Moreover, both of the Honeywell materials can be used as layered soft armor as well as in hard armor when they are autoclaved or compression molded into anti-ballistic components for construction of the Anti-ballistic Shelters, as shown and described. Other similar materials manufactured by any number of providers, of like purpose and functionality is also anticipated by this disclosure.
[0003] Bullet proofing or bullet-resistance is the process of making something capable of stopping a bullet or similar high velocity projectiles e.g. shrapnel. The term bullet resistance is often preferred because few, if any, practical materials provide complete protection against all types of bullets, or multiple hits in the same location. Bullet designs vary widely, not only according to the particular firearm used (e.g. a 9×19 mm Parabellum caliber hollowpoint handgun cartridge will have inferior penetration power compared to a 7.62×39 mm assault rifle cartridge), but also within individual cartridge designs. As a result, whilst so-called “bullet-proof” panels may successfully prevent penetration by standard 7.62×39 mm bullets containing lead cores, the same panels may easily be defeated by 7.62×39 mm armor piercing bullets containing hardened steel penetrators.
[0004] Bullet-resistant materials, also called ballistic materials or, equivalently, anti-ballistic materials, are usually rigid, but may be supple. They may be complex, such as KEVLAR®, LEXAN®, and carbon fiber composite materials, or they may be basic and simple, such as steel or titanium. Bullet resistant materials are often used in law enforcement and military applications, to protect personnel from death or serious injuries.
[0005] With the advent of new materials and the improvement of manufacturing processes, items like ballistic-proof or bullet resistant structures can become practical. It is well known that the construction of bullet-proof vests is done by applying multiple layers of fabric woven from an aramid fiber together, which is sold by Du Pont under the Trade Mark KEVLAR, and has been done for many years. It can be used in a flexible state or laminated in a more rigid configuration. The success of the product is attained by multiple layers of the semi-impregnable flexible structure. This material combines high penetration resistance with lightness and flexibility but until presently no one has endeavored to manufacture items like Anti-ballistic Shelters of this material.
[0006] There is a growing need for methods of self-protection in an increasingly wide variety of locations. In the modern world, crimes and attacks committed by persons with guns are an ever more common occurrence. In the past, police personnel and military personnel have been the primary targets of gunfire which has been directed toward them during work or duty. Because of this continual risk of harm, bullet resistant vests and shields have been developed which may be deployed or worn on the user's body as a protective component of their work attire. Such devices, when employed for protection against weapons fire have worked fairly well in preventing a high velocity bullet or shell from penetrating the wearer's body since the velocity is slowed considerably.
[0007] It has been made clearly evident by the shooting at Fort Hood that additional means of self-protection has become very necessary. The mass shooting took place on Nov. 5, 2009, at Fort Hood, the most populous U.S. military installation in the world, located just outside Killeen, Tex. In the course of the shooting, a single gunman killed 13 people and wounded 29 others. According to witnesses, Army reserve Captain John Gaffaney attempted to stop Hasan, either by charging him or throwing a chair at him, but was mortally wounded in the process. Civilian physician assistant Michael Cahill also tried to charge Hasan with a chair before being shot and killed. Army reserve Specialist Logan Burnette tried to stop Hasan by throwing a folding table at him, but he was shot in the left hip, fell down, and crawled to a nearby cubicle.
[0008] Consequently, there exist a need for a methods which will give anti-ballistic protection to a wide variety of structures. It has been found through the endeavors of the inventor and the patent search that there is no method on the market and no apparent patents reviewed that have similar characteristics to the unique method of creating Anti-ballistic Shelters.
[0009] Numerous innovations for the Anti-ballistic Shelter have been provided in the prior art that are described as follows. Even though these innovations may be suitable for the specific individual purposes to which they address, they differ from the present design as hereinafter contrasted. The following is a summary of those prior art patents most relevant to this application at hand, as well a description outlining the difference between the features of the Anti-ballistic Shelter and the prior art.
[0010] U.S. Pat. No. 5,392,686 of Wilfred A. Sankar describes a protective shield, comprising a frame. The frame having a frame top, a frame bottom, frame sides, and frame upper sides between the frame sides and frame top. The shield further having a front panel and a back panel, each made from a bullet-proof plastic fabric such as KEVLAR. The shield has a viewing window, made of a transparent bullet-proof material, such as LEXAN. A shield inner channel is mounted between the front panel and back panel. A first extension is mounted within the shield inner channel that slidably extends from the shield, bottom for use, and retracts for storage.
[0011] This patent describes a protective shield and it's construction only and does not endeavor to make any reference to using the design in the construction of a wide range of Anti-ballistic Shelters, doors, cots, pads, umbrellas and tents and does not describe the unique method of attaching the anti-ballistic materials to various pipe frame structures.
[0012] U.S. Pat. No. 4,412,495 of Wilfred A. Sanker describes a Total Body Protective device including a pair of fabric panels made of bullet-proof material, handles on an upper of the panel pieces for holding the device in front of a person, and a window through the top panel piece for observing an assailant, and means to roll up or fold the device when not in use.
[0013] This patent describes a Total Body Protective device but does not deal with sheltering devices such as Quonset buildings or huts, pipe frame structures, doors, cots, pads, umbrellas and tents.
[0014] U.S. Pat. No. 8,017,048 of James H. Carter describes an emergency shelter that includes a domed foam structure that is constructed on-site or at a remote location from foam that can be mixed on-site. The structure can be made on-site by spraying foam in a flowable state in a predetermined pattern to build up walls to form a dome. The foam can be sprayed, for example, in a substantially helical pattern from a centrally located spray nozzle that is rotated to deposit a finite-thickness increment of foam over a time period sufficient that, by the time the nozzle reaches a previously sprayed area, the foam already deposited has had time to cure.
[0015] This patent describes an emergency shelter that includes a domed foam structure but does not use the flexible anti-ballistic fabric.
[0016] U.S. Pat. No. 8,001,987 of Marty Williams describes a support system for tents and other shelters. The support system includes base support members that are in the shape of an arch. These base support members are secured in a desired configuration by an upper support member that is in the shape of a circle or other geometrical shape. A roof support may be added as well. The size and configuration of the shelter may be easily changed by adding or deleting the number of base support members.
[0017] This patent describes a support system for tents and other shelters but additionally does not use the flexible anti-ballistic fabric.
[0018] U.S. Pat. No. 7,882,849 of Matt Franta describes a flame-resistant fabric for shelters including a flame-resistant interior layer, a flame-resistant, insulating middle layer adjacent the interior layer, a flame-resistant exterior layer adjacent the insulating middle layer, and at least one threaded seam quilting the insulating middle layer between the interior layer and the exterior layer to form a flame-resistant fabric. The flame-resistant fabric is capable of being formed into a flame-resistant, insulated shelter for use in extreme weather.
[0019] This patent describes flame-resistant fabric for shelters but does address the use of flexible anti-ballistic fabric.
[0020] U.S. Pat. No. 7,856,761 of James Heselden a protective shelter that can be used to provide protection within a war zone, and which can be readily assembled in a quick, secure and reliable manner. The shelter is formed of opposite outer walls and a roof structure extending there between, wherein the roof structure comprises a plurality of tray members supported by beam supports and in which the plurality of tray members is arranged to receive earth, sand or aggregate material so as to provide a first layer of protection via the roof structure. The tray members can be supported by beams serving to define a shallow arch across the shelter such that the internal height of the shelter centrally, and away from the opposite walls, which is greater than the height of the said walls.
[0021] This patent describes a protective shelter that can be used to provide protection through the use of earth, sand and aggregate material within a war zone, but does not address the use of the flexible anti-ballistic fabric used on the Anti-ballistic Shelters disclosed within this application.
[0022] None of these previous efforts, however, provides the benefits attendant with the Anti-ballistic Shelters. The present designs achieves their intended purposes, objects and advantages over the prior art devices through a new, useful and unobvious combination of method steps and component elements, with the use of a minimum number of functioning parts, at a reasonable cost to manufacture, and by employing readily available materials.
[0023] In this respect, before explaining at least one embodiment of the methods of manufacturing Anti-ballistic Shelters in detail it is to be understood that the Anti-ballistic Shelters are not limited in its application to the details of construction and to the arrangement, of the components set forth in the following description or illustrated in the drawings. The Anti-ballistic Shelters are capable of other embodiments and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein are for the purpose of description and should not be regarded as limiting. As such, those skilled in the art will appreciate that the conception, upon which this disclosure is based, may readily be utilized as a basis for designing of other structures, methods and systems for carrying out the several purposes of the present methods of manufacturing Anti-ballistic Shelters. It is important, therefore, that the claims be regarded as including such equivalent construction insofar as they do not depart from the spirit and scope of the present application.
SUMMARY OF THE INVENTION
[0024] The principal advantage of the Anti-ballistic Shelters are to provide a full range of shelter structures capable of ballistic protection.
[0025] Another advantage of Anti-ballistic Shelters is to supply a full range of numerous shelter structures capable of ballistic protection in portable modular designs.
[0026] Another advantage of Anti-ballistic Shelters is to supply a wide range of items that can be relatively inexpensive to manufacture.
[0027] Another advantage is to supply Anti-ballistic Shelters fabricated of a variety of materials including multiple layers of soft fabric woven material from an aramid fiber which is sold by Du Pont under the registered trademark KEVLAR®, or other providers, and will resist and absorb the impact of a bullet and referred to in this application as soft armor.
[0028] Another advantage of the Anti-ballistic Shelters is that the unique mounting of the anti-ballistic material can be used on different items such as doors, room dividers, cots, umbrellas and tents.
[0029] Another advantage of the Anti-ballistic Shelters is that camouflage and water resistant materials or coatings can easily be added to the construction materials.
[0030] Another advantage of the Anti-ballistic Shelters is that they can be used in a wide range of applications from military, governmental, schools and private applications, as well as personal applications.
[0031] The foregoing has outlined some of the more pertinent advantages of the methods of manufacturing Anti-ballistic Shelters. These advantages should be construed to be merely illustrative of some of the more prominent features and applications of the intended methods of manufacturing Anti-ballistic Shelters. Many other beneficial results can be attained by applying the disclosed methods of manufacturing Anti-ballistic Shelters in a different manner or by modifying the invention within the scope of the disclosure. Accordingly, other advantages and a fuller understanding of the methods of manufacturing Anti-ballistic Shelters may be had by referring to the summary of this application and the detailed description of the embodiments in addition to the scope of the methods of manufacturing Anti-ballistic Shelters defined by the claims taken in conjunction with the accompanying drawings
[0032] The methods of manufacturing Anti-ballistic Shelters make use of materials that are fabricated using not only Aramid fibers and KEVLAR® from DuPont, but also polyethylene fibers and GOLD SHIELD®, which is a KEVLAR® based material, and SPECTRA SHIELD®, which is polyethylene based material, both available commercially from Honeywell, and other providers. GOLD SHIELD® and SPECTRA SHIELD® that are high strength synthetic fibers impregnated in partially cured resin for use in anti-ballistic material. Moreover, both of the Honeywell materials can additionally be used as layered soft armor as well as in hard armor when they are autoclaved or compression molded into anti-ballistic components for construction of the Anti-ballistic Shelters. This material combines high penetration resistance with lightness of weight.
[0033] Soft armor requires an area of flexibility or expansion to work effectively when struck by a projectile. If these materials are completely restricted their effectiveness is diminished. With the unique design of this application the soft armor can be attached to a pipe frame structure allowing the flexibility or expansion required for maximum protection. Using these methods of manufacturing a wide range of Anti-ballistic Shelters may be constructed, including but not limited to, Quonset buildings or huts, tents, pipe, rod and other tubular or other frame structures, cots, pads room dividers, doors and umbrellas.
[0034] The Anti-ballistic Shelters have many very similar applications. The Quonset Hut style of Anti-ballistic Shelter with horizontal steel pipe members and hoop style pipe supporting members is a prime example. Additional door support pipe members and the ground level pipe members will be held together by the means of Speed-Rail Fittings® made by Hollaender™ Manufacturing Inc. for aluminum fittings or Kee Klamp™ pipe fittings for steel fittings, in one possible example. The upper anti-ballistic fabric surface the front wall anti-ballistic fabric and rear wall will be covered with layers of flexible anti-ballistic fabric (soft armor) layered in two directions. Varying numbers of horizontal pipe members and hoop style pipe supporting members may vary depending upon where larger numbers are required for adequate protection from possible larger projectiles. A variety of shapes of pipe, rod, tubular and other frame structures including tents, lean-tos and canopies can be constructed in this manner and will remain within the scope of this application.
[0035] An anti-ballistic material fabric clamp has been designed having upper clamp member and lower clamp member each having a plurality of teeth on the gripping edges. A nut and bolt will secure the two halves tightly together. With the potential forces exerted on the material by a projectile the fabric clamps must be very rugged and closely spaced.
[0036] A bi-directional pipe clamp has been designed to attach the horizontal members to the curved hoop style pipe supporting members. The bi-directional pipe clamp consists of four common clamping segments with elongated holes where the two pairs of the clamping segments will interlock. Orifices will be used by the bolts and nuts to clamp the bi-directional pipe clamp to the horizontal pipe member and the hoop style pipe supporting members. The benefit in using these fittings is that they are made of steel not aluminum and much less subject to breakage under high impacts.
[0037] An additional means of attachment of the anti-ballistic fabric surface is by using a fabric inverted “T” construction method with a breakaway stitch and a holding stitch over the structural members. The inverted “T” construction method has been designed where the anti-ballistic fabric surface is loosely covering the supporting pipe members with two or more rows of stitches running the length of the section. The breakaway stitches on either side of the supporting members will absorb the initial shock and most likely break away while the holding stitch will receive less shock and will resist being completely broken away. This method may use adhesive for the same purpose or a combination of both adhesive and stitching to accomplish the desired task.
[0038] An additional use will be in a wall tents, pup tents and dome tents where the anti-ballistic fabric covering will be attached to the sides walls and the top.
[0039] Another application will use the attachment of the anti-ballistic fabric to a pipe frame door or room divider with the inverted “T” construction method or Speed-Rail Fittings® or other appropriate fittings at the corners and pipe intersections of the unit. Fabric clamps, as one possible method, are used to secure the fabric surface completely around the individual pipe segments. Additionally, a progressive expandable sleeve with breakaway stitching and progressively stronger stitching is another possible way to construct the Anti-Ballistic Shelters herein.
[0040] Still another possible application is the attachment of the anti-ballistic fabric to a pipe frame cot by using the inverted “T” construction method or fabric clamps to secure the anti-ballistic fabric surface completely around the pipe segments with Speed-Rail Fittings® at the corners and intersections. This application could be used on a conventional wood or aluminum or other material cot and still remain within the scope of this application, but it would not have the structural strength of the steel pipe frame construction.
[0041] A further application will be the attachment of the anti-ballistic fabric to the inside of an existing door. Soft armor has been placed on the outer surface of the inside of the door (this is the protected side as opposite of the outside or perpetrator side of the door) because it requires an area of flexibility or expansion to work effectively when struck by a projectile. If these materials are completely restricted their effectiveness is diminished. The anti-ballistic fabric is held in place by the means of threaded fasteners.
[0042] The anti-ballistic fabric can additionally be used as a covering for a pad, a cushion or a mattress with or without handles where it can be held up in a defensive position.
[0043] The unique use of anti-ballistic fabric is also anticipated as a covering for an umbrella with the conventional shepherds hook or other common use handle or an additional second hand support grip with or without a defensive spike on the top. The umbrella has bendable rib members in the manner of a conventional umbrella, and may have a sliding opening mechanism that is held in the open position by the means of spring loaded latching mechanism. The sliding opening mechanism will have extension arms extending out to each of the rib members supporting the umbrella in the open position. The design of the umbrella may have fewer or greater bendable rib members compared to the conventional umbrella with flexible ribs is to accommodate the heavier weight of the anti-ballistic fabric. The number of frame members or ribs used will depend upon the degree of bullet resistance required.
[0044] With respect to the above description then, it is to be realized that the optimum dimensional relationships of the methods of manufacturing Anti-ballistic Shelters, to include variations in size, materials, shape, form, function and manner of operation assembly and use, are deemed readily apparent and obvious to one skilled in the art, and all equivalent relationships to those illustrated in the drawings and described in the specification are intended to be encompassed by the present methods of manufacturing Anti-ballistic Shelters. Therefore, the foregoing is considered as illustrative only of the principles of this application. Further, since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the methods of manufacturing Anti-ballistic Shelters to the exact construction and operation shown and described, and accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of this application.
BRIEF DESCRIPTION OF THE DRAWINGS
[0045] The accompanying drawings, which are incorporated in and form a part of this specification, illustrate embodiments of the Anti-ballistic Shelters and together with the description, serve to explain the principles of this application.
[0046] FIG. 1 depicts a perspective illustration of a Quonset hut style of Anti-ballistic Shelter.
[0047] FIG. 2 depicts a perspective illustration of the attachment of the anti-ballistic fabric surface by using clamps to the supporting frame structure.
[0048] FIG. 3 depicts a perspective illustration of the method of attachment of the anti-ballistic fabric surface to the curved support structure by using clamps.
[0049] FIG. 4 depicts an exploded perspective view of the anti-ballistic fabric surface clamping means.
[0050] FIG. 5 depicts a perspective illustration of the attachment of the anti-ballistic fabric surface to the horizontal support structure and the unique bi-directional pipe clamp.
[0051] FIG. 6 depicts an exploded perspective illustration of the bi-directional pipe clamp used to attach the horizontal member to the curved support structure.
[0052] FIG. 7 depicts a perspective illustration of the attachment of the anti-ballistic fabric surface using the fabric inverted “T” construction method.
[0053] FIG. 8A depicts an end view of the cross-over of the horizontal pipe frame and the hoop style pipe member with the anti-ballistic fabric surface covering.
[0054] FIG. 5B depicts an end view of the inverted “T” construction method with a breakaway stitch and a holding stitch in the anti-ballistic fabric surface.
[0055] FIG. 9 depicts a perspective view of the cross-over of the horizontal pipe frame and the hoop style pipe member with the anti-ballistic fabric surface covering using the bi-directional pipe clamp and a soft or hard armor patch.
[0056] FIG. 10 depicts a perspective view of a conventional pup tent incorporating the anti-ballistic fabric surface.
[0057] FIG. 11 depicts a perspective view of a conventional dome tent incorporating the anti-ballistic fabric surface.
[0058] FIG. 12 depicts a perspective view of a wall tent with the door flaps closed.
[0059] FIG. 13 depicts a perspective view of a wall tent with the door flaps open.
[0060] FIG. 14 depicts a perspective illustration of the attachment of the anti-ballistic fabric surface to a pipe frame door or room divider.
[0061] FIG. 15 depicts a perspective illustration of the attachment of the anti-ballistic fabric surface to a pipe frame cot.
[0062] FIG. 16 depicts a perspective illustration of the attachment of the anti-ballistic fabric surface to the inside surface, or the protected side, of an existing door or room divider.
[0063] FIG. 17 depicts a perspective illustration of the anti-ballistic fabric surface used as a covering for a cushion, pad or mattress.
[0064] FIG. 18 depicts a perspective illustration of the anti-ballistic fabric surface used as a covering for a unique umbrella.
[0065] FIG. 19 depicts a side view of a section through the open umbrella frame illustrating the rigid or bendable rib members and the opening mechanism.
[0066] FIG. 20 depicts a side view of the closed umbrella frame illustrating the rigid or bendable rib members and the opening mechanism.
[0067] FIG. 21 depicts a perspective view of a single rib member end and the end covering cap.
[0068] FIG. 22 depicts an end view of a single rib member.
[0069] FIG. 23 depicts an end view of a single rib member when struck by a projectile.
[0070] For a fuller understanding of the nature and advantages of the Anti-ballistic Shelters, reference should be had to the following detailed description taken in conjunction with the accompanying drawings which are incorporated in and form a part of this specification, illustrate embodiments of the design and together with the description, serve to explain the principles of this application.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0071] As required, detailed embodiments of the present methods of manufacturing Anti-ballistic Shelters are disclosed herein, however, it is to be understood that the disclosed embodiments are merely exemplary of the methods of manufacturing Anti-ballistic Shelters that may be embodied in various forms. Therefore, specific functional and structural details disclosed herein are not to be interpreted as limiting, but merely as basis for the claims and as a representative basis for teaching one skilled in the art to variously employ the present design in virtually any appropriately detailed structure.
[0072] Referring now to the drawings, wherein similar parts of the methods of manufacturing Anti-ballistic Shelters 10 is depicted as a steel pipe frame Quonset Hut style of Anti-ballistic Shelter 12 with horizontal pipe (or other) members 14 and hoop style pipe supporting members 16 . Additional door support pipe members 18 and the ground level pipe members will be held together by the means of Speed-Rail Fittings® 20 made by Hollaender™ Manufacturing Inc. for aluminum fittings or Kee Klamp™ pipe fittings for steel fittings. The upper anti-ballistic fabric surface 22 , the front wall anti-ballistic fabric 24 and rear wall not shown will be covered with layers of flexible anti-ballistic fabric (soft armor) layered in two directions. Varying numbers of horizontal pipe members 14 and hoop style pipe supporting members 16 may vary depending upon where larger numbers are required for adequate protection from possible larger projectiles. A variety of shapes of pipe frame structures including tents, lean-tos and canopies can be constructed in this manner and will remain within the scope of this application.
[0073] FIG. 2 depicts a perspective illustration of the attachment of the upper anti-ballistic fabric surface 22 to the horizontal pipe members 14 and front wall anti-ballistic fabric 24 to the hoop style pipe supporting members 16 with fabric clamps 26 . Having potential forces exerted on the material by a projectile the fabric clamps must be very rugged and closely spaced.
[0074] FIG. 3 depicts a perspective illustration of the method of attachment of the anti-ballistic material to the curved support structure by rolling the material around the pipe members and using multiple fabric clamps 26 . Here again the potential forces exerted on the material by a projectile the fabric clamps must be very rugged and closely spaced.
[0075] FIG. 4 depicts an exploded perspective view of the anti-ballistic material fabric clamp 26 illustrating the upper clamp member 28 and lower clamp member 30 having a plurality of teeth 32 on the gripping edges 34 . A nut 36 and bolt 38 will secure the two halves tightly together.
[0076] FIG. 5 depicts a perspective illustration of the attachment of the anti-ballistic upper fabric surface 22 to the horizontal support structure 14 and the unique bi-directional pipe clamp 40 . The bi-directional pipe clamp 40 has been designed to raise the horizontal pipe members 14 away from the hoop style pipe supporting members 16 (as shown in FIG. 1 ) and to give enough space for the fabric clamps 26 to secure the upper anti-ballistic fabric surface 22 completely around the horizontal pipe members 14 with the added benefit of the inverted “T” construction method 21 with a breakaway stitch 23 and a holding stitch 25 .
[0077] FIG. 6 depicts an exploded perspective illustration of the bi-directional pipe clamp 40 used to attach the horizontal member 14 to the curved hoop style pipe supporting members 16 . The bi-directional pipe clamp 40 consists of four common clamping segments 42 with elongated holes 44 where the two pairs of the clamping segments 42 will interlock. Orifices 46 will be used by the bolts 48 and nuts 50 to clamp the bi-directional pipe clamp 40 to the horizontal pipe member 14 and the hoop style pipe supporting members 16 (as shown in FIG. 1 ). The benefit in using these fittings is that they are made of steel not aluminum and much less subject to breakage under high impacts.
[0078] FIG. 7 depicts a perspective illustration of the attachment of the upper anti-ballistic fabric surface 22 using the fabric inverted “T” construction method 21 with fabric stitches 23 and 25 over the horizontal pipe member 14 and the hoop style pipe supporting members 16 . The inverted “T” construction method 21 has been designed where the anti-ballistic fabric surface 22 is loosely covering the supporting pipe members 14 and 16 with two or more stitches 23 and 25 running the length of the section. This creates a progressive expandable sleeve. The stitches 23 and 25 on either side of the supporting pipe members 14 and 16 will absorb the initial shock and most likely one or more of these stitches will break away while one or more of the stitches will receive less shock and will resist being completely broken away, depending upon the direction and angle of the projectile. In this way, the layers of fabric stop a projectile from penetration, by the stitches breaking away until they hold. The number of layers and the quantity of stitches will depend upon the degree of bullet resistance required.
[0079] FIG. 8A depicts an end view of the cross-over of the horizontal pipe member 14 and the hoop style pipe supporting member 16 illustrating the gap 27 with loose upper anti-ballistic fabric surface 22 covering the horizontal pipe member 14 .
[0080] FIG. 8B depicts an end view of the inverted “T” construction method 21 with a stitches 23 and 25 shown, and the gap 27 in the loose upper anti-ballistic fabric surface 22 clearly depicted. It must be understood that the inverted “T” construction method 21 is not limited to two lines of stitches but may have two or more and still remain within the scope of this application. The number of stitches and distance apart create a progressive expandable sleeve. The number of layers and the quantity of stitches will depend upon the degree of bullet resistance required.
[0081] FIG. 9 depicts a perspective view of the cross-over of the horizontal pipe frame 14 with the hoop style pipe member 16 having the upper anti-ballistic fabric surface 22 and the bi-directional pipe clamp 40 . The space below the intersection of the horizontal pipe frame 14 with the hoop style pipe member 16 creates an opening 41 in the upper anti-ballistic fabric surface 22 that will be closed with a patch 43 made from soft armor or hard armor material.
[0082] FIG. 10 depicts a perspective view of a conventional pup tent 52 incorporating the anti-ballistic fabric surface 22 . The perimeter of the pup tent will have a plurality of tent stakes 54 and a cable 56 along the lower edge 58 .
[0083] FIG. 11 depicts a perspective view of a conventional dome tent 64 incorporating the anti-ballistic fabric surface 22 using the inverted “T” construction method 21 over the supporting flex poles 66 (not seen). A plurality of tent stakes 54 and a cable 56 along the lower edge 58 will support the lower edge. This illustration shows the basic dome tent 64 with two flex poles 66 (not seen) but it must be understood that two, four, six, eight, etc. or more of these poles may be used depending upon the size and degree of anti-ballistic protection required and will still remain within the scope of this application.
[0084] FIG. 12 depicts a perspective view of a wall tent 70 with anti-ballistic fabric surface 22 using the inverted “T” construction method 21 on all four sides and top with a steel pipe frame work 72 . The wall tent in this view has the overlapping door flaps 74 closed. It is anticipated that more sections may be added to the wall tent depending upon the need for space and they can be extended longitudinally with other frame and anti-ballistic fabric constructed sections.
[0085] FIG. 13 depicts a perspective view of a wall tent 70 with the door flaps 74 held open by tent stakes 54 . The wall tent in this view has the overlapping door flaps 74 opened. It is anticipated that more sections may be added to the wall tent depending upon the need for space and they can be extended longitudinally with other frame and anti-ballistic fabric constructed sections.
[0086] FIG. 14 depicts a perspective illustration of the attachment of the anti-ballistic fabric surface 22 to a pipe frame door or room divider 80 with Speed-Rail Fittings® 20 used at the corners and pipe intersections of the unit. Fabric clamps 26 are used to secure the anti-ballistic fabric surface 22 completely around the individual pipe segments 82 . The inverted “T” construction method 21 will work equally well in this application.
[0087] FIG. 15 depicts a perspective illustration of the attachment of the anti-ballistic fabric surface to a pipe frame cot 88 by using the fabric clamps 26 to secure the anti-ballistic fabric surface 22 completely around the pipe segments 90 with Speed-Rail Fittings® 20 at the corners and intersections. The inverted “T” construction method again will work equally well in this application. This application could be used on a conventional wood or aluminum cot and still remain within the scope of this application, but it would not have the structural strength of the steel pipe frame construction. The cot sleeping surface 68 would act as a bullet resistant or bulletproof shield, when easily and quickly picked up and held up, or transported as needed.
[0088] FIG. 16 depicts a perspective illustration of the attachment of the anti-ballistic fabric surface 22 to the inside surface (the protected side) of an existing door 78 . Soft armor has been placed on the inside protected surface of the door because it requires an area of flexibility or expansion to work effectively when struck by a projectile. If these materials are completely restricted their effectiveness is diminished. The anti-ballistic fabric surface 22 is held in place by the means of multiple threaded fasteners 98 . Other means for fastening are also anticipated, such as the use of adhesives, edge molding, or other fastening means. A bullet 100 is shown traveling towards the front outside, the perpetrator side, of the existing door indicating the maximum means of protection offered by the anti-ballistic fabric surface 22 .
[0089] FIG. 17 depicts a perspective illustration of the anti-ballistic fabric surface 22 used as a covering for a cushion or mattress 102 with handles 104 on both sides so that the cushion or mattress 102 can be held up in a defensive position if required.
[0090] FIG. 18 depicts a perspective illustration of the anti-ballistic fabric surface 22 used as a covering for a unique umbrella 108 with the conventional shepherds hook handle 110 having an additional second hand support grip 112 and a defensive spike 114 on the top. A cable 56 is attached around the perimeter of the lower edge of the umbrella 108 . Other handle arrangements are also anticipated by this invention.
[0091] FIG. 19 depicts a side view of a section through the open umbrella frame 116 illustrating the rigid or bendable rib members 118 and the sliding opening mechanism 120 that are held in the open position, by the means of spring loaded latching mechanism 122 . The anti-ballistic fabric surface 22 may in one embodiment be held in place by a large central grommet 124 at the top that will go over the defensive spike 114 and smaller grommets 126 located at the ends of the rib members 118 that are held in place by small grommet retainers 128 . The anti-ballistic fabric surface 22 will also have intermittent ties or stitching 130 to each of the rib members 118 . The sliding opening mechanism 120 will have extension arms 132 extending out to each of the rib members 118 supporting the umbrella 108 in the open position. The design of the umbrella 108 with fewer rigid rib members 118 compared to the conventional umbrella with flexible ribs is to accommodate the heavier weight of the anti-ballistic fabric surface 22 . The central shaft 134 is fully exposed displaying the sliding opening mechanism 120 with the extension arms 132 , spring loaded latching mechanism 122 , the defensive spike 114 the shepherds hook handle 110 and the additional second hand support grip 112 . It should be understood that the anti-ballistic umbrella may be constructed with any number of rib members depending upon the degree of bullet resistance desired. In this way, the umbrella may be constructed with fewer or more rigid or bendable rib members as needed.
[0092] FIG. 20 depicts a side view of a section through the closed umbrella frame illustrating the rigid or bendable rib members 118 and the sliding opening mechanism 120 in the closed position. In an alternate embodiment, the previously described progressive expandable sleeve construction may be used. This construction calls for the addition of numerous stitches, including breakaway stitches and stronger holding stitches. The number of stitches and the relative strength of each stitch will depend upon the level and degree of bullet resistance desired or required by the user.
[0093] FIG. 21 depicts a perspective view of a single rib member 118 end and the end covering cap 140 .
[0094] FIG. 22 depicts an end view of a single rib member 118 illustrating the loose fit of the progressive expandable sleeve type of attachment anti-ballistic fabric surface 22 and the gap (or sleeve) 27 created on either side of the rib member 118 . In an alternate embodiment the previously described progressive expandable sleeve construction may be used. This construction calls for the addition of numerous stitches, including breakaway stitches and stronger holding stitches. The number of stitches and the relative strength of each stitch will depend upon the level and degree of bullet resistance desired or required by the user.
[0095] FIG. 23 depicts an end view of a single rib member 118 when struck by a bullet 100 where the breakaway stitch 23 has broken away and deformed the anti-ballistic fabric surface 22 while the holding stitch 25 has resisted the forces. The bullet 100 has been shown easily penetrating the anti-ballistic fabric surface 22 top layer 142 and the rib member 118 but not being able to fully penetrate the anti-ballistic fabric surface 22 lower layers 144 due to the flexibility and breakaway stitching component of the construction.
[0096] The Anti-ballistic Shelters 10 shown in the drawings and described in detail herein disclose arrangements of elements of particular construction and configuration for illustrating preferred embodiments of structure and method of operation of the present application. It is to be understood, however, that elements of different construction and configuration and other arrangements thereof, other than those illustrated and described may be employed for providing an Anti-ballistic Shelters 10 in accordance with the spirit of this disclosure, and such changes, alternations and modifications as would occur to those skilled in the art are considered to be within the scope of this design as broadly defined in the appended claims.
[0097] Further, the purpose of the foregoing abstract is to enable the U.S. Patent and Trademark Office and the public generally, and especially the scientists, engineers and practitioners in the art who are not familiar with patent or legal terms or phraseology, to determine quickly from a cursory inspection the nature and essence of the technical disclosure of the application. The abstract is neither intended to define the invention of the application, which is measured by the claims, nor is it intended to be limiting as to the scope of the invention in any way.
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The present invention is directed to methods of manufacturing Anti-ballistic Shelters such as Quonset buildings or huts, tents, pipe, rod, tubular and other frame structures, doors, room dividers, cots, pads and umbrellas using soft armor fabric or hard armor materials. Soft armor consists of flexible high-strength layered anti-ballistic material attached to a frame and layered in at least two directions. Soft armor requires an area of flexibility or expansion to work effectively when struck by a projectile along with a very secure attachment. With the design disclosed within this application the soft armor fabric is affixed to frameworks by an inverted “T” fabric construction method or which allows the flexibility or expansion required for maximum anti-ballistic protection within the shelter.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates to a household appliance and more particularly, to a household appliance, such as a refrigerator or freezer, including glass interior walls.
[0003] 2. Related Art
[0004] In a related art household appliance, such as a refrigerator, the interior of the refrigerator is usually illuminated using a light housing or a lamp that is switched on and off on opening and closing the door of the appliance by a switch actuated by the door. The light housing or lamp is mounted on one of the inner walls of the refrigerator, usually on the ceiling area or one of the side walls. As a result of built-in components in the appliance such as base plates, pull-out drawers or door compartments and as a result of food which has been inserted, which act as light barriers, large parts of the appliance are not reached or only inadequately reached by the light emanating from the lamp. Thus, only non-uniform illumination of the interior of the appliance may be possible.
[0005] The illumination may also be affected by the material making up the inner walls of the refrigerator, such as stainless steel used in the related art. Additionally, the use of stainless steel for the inner walls naturally creates parting lines between an inner wall and adjacent light housing.
[0006] The present invention overcomes the problems associated with the related art by introducing a household appliance with one or more glass inner walls providing increased illumination of the interior of the appliance and facilitating the ability to clean the inner walls by removing the parting lines.
SUMMARY OF THE INVENTION
[0007] A first aspect of the present invention is directed to a household appliance. The household appliance may include a housing defining an interior space. The housing may include a plurality of internal walls, wherein at least one of the plurality of internal walls comprises a material including glass.
[0008] A second aspect of the present invention is directed to a housing defining an interior space under a refrigeration condition. The housing may include a plurality of internal walls, wherein at least one of the plurality of internal walls comprises a material including glass.
[0009] The illustrative aspects of the present invention are designed to solve the problems herein described and other problems not discussed.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] These and other features of this disclosure will be more readily understood from the following detailed description of the various aspects of the disclosure taken in conjunction with the accompanying drawings that depict various exemplary embodiments of the disclosure, in which:
[0011] FIG. 1 depicts a household appliance including inner walls made from a glass material according to an exemplary embodiment of the invention; and
[0012] FIG. 2 depicts an interface between a side wall of the household appliance and a light housing according to an exemplary embodiment of the invention.
[0013] The drawings are merely schematic representations, not intended to portray specific parameters of the invention. The drawings are intended to depict only typical embodiments of the invention, and therefore should not be considered as limiting the scope of the invention. In the drawings, like numbering represents like elements.
DETAILED DESCRIPTION OF THE INVENTION
[0014] FIG. 1 shows an exemplary embodiment of a household appliance, such as a refrigerator 1 . The refrigerator 1 comprises a housing 2 which is formed from a plurality of housing panels 11 . The refrigerator 1 may comprise the following inner walls: a bottom area 9 , respectively two side walls 6 , a ceiling area 10 and a rear wall 5 and a door inner wall 8 of a door 7 .
[0015] The refrigerating appliance 1 has an interior space 3 which may be fitted with base plates 13 , containers 14 in the form of pull-out drawers 14 , and door compartments 15 for placing or inserting food.
[0016] The rear wall 5 and the two side walls 6 may each include an organic light-emitting diode (OLED) 30 or any other lighting technology such as, e.g., light-emitting diodes (LED) or halogen bulbs to illuminate the interior 3 of the refrigerating appliance 1 . Of course, the OLED's, LED's, halogen bulbs, etc. may be placed in other locations we well.
[0017] The OLED's, LED's, halogen bulbs, etc. may be integrated in the corresponding inner walls 5 , 6 of the refrigerating appliance 1 in a manner such as disclosed in U.S. Pat. No. 7,588,340, incorporated herein by reference, and commonly owned by BSH Bosch and Siemens Hausgeräte GmbH.
[0018] In FIG. 1 , the inner walls may be comprised from a material including glass.
[0019] Using glass for the inner walls improves visibility within interior space 3 as opposed to related art inner walls formed from stainless steel, because glass helps distribute the lighting throughout the interior space 3 . In addition, glass is a high-value material with regards to producing a quality product as opposed to some related art stainless steel materials.
[0020] Glass is also a versatile material. For decorative or illumination purposes, the glass may be back-painted allowing for good visibility within the interior space 3 .
[0021] Further, in addition to or in place of back-painting, the glass may be a laminated glass including a sheet of a plastic material disposed between sheets of glass. The plastic material may be chosen for cosmetic purposes, for insulation, or to improve visibility within the interior space 3 based on the placement of the lighting within the interior space 3 .
[0022] For safety purposes, the glass inner walls may be formed from a tempered glass. Also, the glass may include a plurality of panes, and wherein between adjacent panes, a gas, such as air is disposed. The air trapped between the adjacent panes of glass may serve as an insulator to increasing the energy efficiency of the refrigerator 1 and help prevent the formation of frost by reducing the movement of cooler air and the subsequent accumulation of water vapor.
[0023] Of course, the invention is not limited to the aforementioned glass compositions and other glass compositions known in the related art are envisioned including annealed glass, slumped glass, casted glass, laminated glass, etc.
[0024] FIG. 2 depicts another exemplary embodiment of the invention. In FIG. 2 , rather than use OLED's, LED's, halogen bulbs, etc. to light the interior space 3 of the refrigerator 1 , an internal lighting system 50 may be disposed within the housing for illuminating at least a portion of the interior space 3 .
[0025] As shown in FIG. 2 , the interface between a side wall 6 and the light housing 50 allows for a fabrication such that no parting lines are created. This helps to improve the ability to clean the refrigerator 1 .
[0026] While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.
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A household appliance having a housing defining an interior space. In an exemplary embodiment, the housing may include a plurality of internal walls, wherein at least one of the plurality of internal walls is made of a glass material. Further, the interior space may be under a refrigeration condition.
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FIELD OF THE INVENTION
The present application is a continuation application of co-pending patent application Ser. No. 10/840,527, filed on May 5, 2004, which is a continuation of patent application Ser. No. 09/527,905 filed on Mar. 17, 2000 and issued as U.S. Pat. No. 6,748,072 on Jun. 8, 2004, which are incorporated herein in their entirety by reference.
BACKGROUND OF THE INVENTION
The field of telecommunications has grown significantly with the advent of computer-integrated-telephony (CTI) and more recently, data-network-telephony (DNT). Contributions to both of these technologies have led to the advent of multimedia communications centers capable of handling a wide variety of communication types and mediums.
A large customer-care center serves as a good example of a telecommunications center that may be dedicated to serving a very large customer base through constant communication using state-of the-art techniques aided by intelligent software applications running on processors connected to the centers telecommunication system.
A communication center of the type described in this specification typically employs a plurality of agents whom have been trained to operate communication equipment and applications for the dedicated purpose of serving customers who call into the center.
A multimedia communication center enhanced with DNT capability as known to the inventor will include, along with a connection-oriented-switched-telephony (COST) system, an Internet protocol (IP) telephony system for handling communication events sourced from a data-packet-network (DPN), which, in many cases, is the well-known Internet network. It will be appreciated by one with skill in the art that agent responsibilities in such a system are expanded over those of a traditional or conventional call-in center to include working with e-mails, video mails, IP voice calls, computer-aided chat sessions, and other computer/network aided communication mediums.
In such a multimedia center agents are typically located at workstations adapted with equipment and network connections that are suitable for communication in both a COST and DNT environment. For example, each agent station typically comprises a telephone connected to a central COST routing system and a personal computer with a video display unit (PC/VDU), which is connected to a local-area-network LAN. The LAN is further connected to an IP routing system and agents receive IP calls routed to them over the LAN to their PC/VDU's. In some cases, DNT capable telephones are also incorporated such that they may be switched from COST mode to DNT mode and back again.
In addition to enhanced equipment utilized at agent level, other equipment is provided for the purpose of automated interface with customers calling into the system at network level. Such equipment includes interactive voice response (IVR) systems, which may be adapted for both COST and DNT communication. In systems known to the inventor, intelligent routing is available at levels above the agent level (internal routing system).
CTI software known to the inventor as T-Server software is provided to run on processors implemented at switches and terminals existing in COST, and in some instances, DPN network levels for the purpose of providing intelligent routing routines to be executed at network level. These CTI processors are interconnected with a separate DPN such that routing commands may be communicated between instances of T-Servers. Moreover, additional data may be obtained about a caller at network level and passed to agent level over the separate data network, often ahead of a routed communication event.
Extending intelligent routing capability into networks allows performance of agent level routing from within a network. These routing rules are, of course, adapted to communication center capability. For example, statistical call routing, predictive call routing, skill-based routing, priority routing and other routines known to the inventor may be utilized at network level.
With all of the advanced routing and communication capabilities available in the art, communication center managers and supervisors must continually motivate agents working in the center along with managing agent function in accordance with the agent's designated duties. One of the traditional tools used for this purpose is known in the art as a communication center display board sometimes referred to as a signboard.
A communication-center display board is a computerized display system that is hung or mounted in a centrally visible location within a communication center for the purpose of providing call-load status, call event alerts, motivational messages, and any other information that managers deem pertinent to agent function and performance. A good example of a communication-center display board existing in prior art is the NetBrite™ display system provided by SYMON™.
The NetBrite™ system comprises a network-connected, full matrix, light-emitting-diode (LED) display board that may be configured for the type of data that is to be displayed to agents. The system has an internal sound card and speaker system including software for playing WAV, MIDI and other audio files as well as steaming audio. The system may be configured to a number of differing modes such as flashing data, scrolling data, page-through data, and audible alerting. Moreover, the physical display interface may be configured to display a plurality of separate addressable sections for individualizing portions of the display for an agent or group of agents.
Display systems like the one described in the example above are network-connected and receive data directly from a data server or servers providing the status and performance information for communication center activity. The system uses standard network data wiring and connection means for interface and integration to a communication center LAN system enhanced typically with transfer control protocol/Internet protocol (TCP/IP) capability.
One obvious problem associated with a display system of this type is that it is shared by many communication center agents who must devote a significant amount of attention to the system throughout their workday. Diverting attention to the common or shared system may take away from or delay other agent duties. Another drawback with a common or shared system is that the volume level must be loud enough for all agents to hear. In some cases, this fact may distract some agents engaged in audible communication with customers. Still another problem is that the display characteristic is limited to a compact set of abstractly metered data, which an agent must read to understand and act upon.
What is clearly needed is a communication center status reporting and warning system that may be distributed to and executed from individual agent stations such that an agent need not devote primary attention to a shared system. Such a system could be configured to use graphical images as well as audible conventions for data provision and would allow a system-trained agent to quickly grasp communication center status and alert states without diverting the agent from other duties.
SUMMARY OF THE INVENTION
In a preferred embodiment of the present invention, in a call center having agent stations each having a personal computer with a video display unit (PC/VDU), a system for informing agents of call center-related status is provided, comprising a server tracking call center activities and calculating status for individual call center entities, the server connected on a network in the call center; and an agent-informing application executing on individual ones of the PC/VDUs at agent stations, the PC/VDUs at the agent stations also connected on the network. The system is characterized in that the application draws on status data from the server and provides status information to an agent using an individual PC/VDU through output apparatus of the individual PC/VDU.
In some embodiments status includes status and warnings related to transaction queues to which the agent using a PC/VDU is related. The software may provide graphic displays indicating call center status information, audio renditions through a speaker associated with the PC/VDU used by the agent, or combinations thereof. Audio may be played over call conversations at a level not interrupting the conversations.
In another aspect of the invention a software application for use with a personal computer having a video display unit (PC/VDU) at an agent station in a call center is provided, comprising an access module for drawing status information from a server connected on a common network with the PC/VDU; and a rendition module for rendering the status information through output apparatus of the PC/VU for an agent using the PC/VDU.
In a preferred embodiment rendition is by graphic and text display on the video display monitor of the PC/VDU. Rendition may also be by audio rendition through a speaker associated with the PC/VDU used by the agent, and audio may be provided over telephone conversations engaged in by the agent. The status information includes status and warnings related to transaction queues to which the agent using a PC/VDU is related.
In another aspect of the invention, in a call center having agent stations each having a personal computer with a video display unit (PC/VDU), a method for informing agents of call center-related status is provided, comprising steps of (a) drawing status information by a software application executing on an individual (PC/VDU) from a server commonly connected on a communication network with the PC/VDU at the agent station; and (b) rendering the information to an agent using the PC/VDU through output apparatus of the PC/VDU.
In preferred embodiments of the method, in step (a), status includes status and warnings related to transaction queues to which the agent using a PC/VDU is related. Also in preferred call center status information may be provided to an agent by audio rendition through a speaker associated with the PC/VDU used by the agent, or by text and graphic displays, or in combination. The audio-rendered information may be rendered over telephony call audio as an agent converses with a caller, at a whisper lever.
In embodiments of the present invention, taught in enabling detail below, for the first time a system is provided for informing agents of status information in a call center, wherein information and its presentation may be tailored to individual agents, and provided in a manner to avoid disturbing other agents, or distracting the receiving agents attention from other tasks.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 is an overview of a dual-capable communication center utilizing a communication-center performance display and warning system according to an embodiment of the present invention.
FIG. 2 is a block diagram of an agent workstation adapted with the communication center performance display and warning system of FIG. 1 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
According to a preferred embodiment of the present invention, a personalized communication-center performance and warning system is provided as a distributed software application adapted to run at each agent workstation within the center.
FIG. 1 is an overview of a dually-capable communication center 25 utilizing a communication-center performance display and warning system (SW) according to an embodiment of the present invention. A communication network 9 is illustrated as a preferred network embodiment for practicing the present invention. Network 9 comprises a connection oriented switched telephony (COST) network 11 (conventional telephone network), a data packet network (DPN) 13 (such as the Internet), and communication center 25 .
COST network 11 may be any type of switched telephony network public or private in nature. In a preferred embodiment, COST 11 is a well-known public switched telephony network (PSTN). The inventor chooses the PSTN network as a preferred COST network because of its high public-access characteristic.
DPN 13 may be-any type of wide-area-network (WAN) public or private in nature, operating as a shared bandwidth, data-packet network. In a preferred embodiment, DPN 13 is the well-known Internet network and will hereinafter be referred to as Internet 13 . The inventor chooses the Internet network because of its high public-access characteristic. The invention, however, is not limited to the Internet.
Communication center 25 is a dually-capable center meaning that it is capable of handling both COST and DNT communication. Communication center 25 may be a small or large corporate center serving as a central location for customer service. In typical application, center 25 communicates with customers calling in from COST network 11 or initiating communication events from Internet 13 . It is important to note here that the method of practicing the present invention is not limited to a dually-capable center as illustrated in the example, but may be practiced in either a COST only center or a DNT only center separately.
Communication network 9 demonstrates the state of the art in network communication and communication-center service. All of the communication capability and routing functionality mentioned in the background section may be assumed to be present in this example.
COST network 11 comprises a telephony switch 15 enhanced by a CTI processor 17 running an instance of T-Server 17 . T-Server 17 is a CTI application known to the inventor that is adapted to provide intelligent control over switch 15 for such as call routing purposes. Switch 15 may be any type of telephony switch known in the art and capable of processing calls. Processor 17 is connected to switch 15 by a CTI link. Other functional equipment known in the art such as a service control point (SCP) in the network, network access points, network bridges, as well as other telephony switches may be assumed to be present within COST network 11 .
Switch 15 is connected to a telephony switch 39 within communication center 25 by a telephony trunk 23 . Switch 39 functions as a central switch adapted for routing incoming calls within communication center 25 . Switch 39 is enhanced by a processor 41 running an instance of T-Server. Processor 41 is connected to processor 17 , within network 11 , by a digital data network (DDN) 21 separate from trunk lines over which telephone calls are established. DDN 21 and connected processors 17 and 41 provide an effective means for enabling communication-center control over switch 15 in network 11 . T-Server provides intelligent routing determination for incoming calls and DDN 21 allows added data about callers to be forwarded to center 25 , often ahead of an arriving COST call.
A COST call, represented herein by a vector labeled 19 , may arrive at switch 15 from anywhere in network 11 , or from another network through a network bridge. At switch 15 , interaction may be initiated with the caller and additional data about the caller may be obtained. An ultimate agent-level destination may be determined for call 19 while it is stationed in switch 15 . It is assumed in this example, that call 19 is destined for center 25 and therefore, will be routed to switch 39 over trunk 23 . Additional data about call 19 is passed over DDN 21 . The data and call routing determination is matched such that the data and call 19 are routed to the appropriate agent within center 25 .
Center 25 has a plurality of manned agent-workstations provided therein for the purpose of enabling optimum service to customers. These are represented by workstations 59 , 61 , and 63 . It will be appreciated that there will be many more workstations provided in a very large communication center, however, the illustration of three stations in this example is deemed adequate for explanation of the present invention.
Agent station 59 comprises an agent telephone 65 and a personal computer with a video display unit (PC/VDU) 71 . Agent telephone 65 is connected to central switch 39 by COST wiring 47 . PC/VDU 71 is connected to a local area network (LAN) 51 , which is adapted, in this embodiment, for transfer control protocol/Internet protocol (TCP/IP).
Although it is not required to practice the present invention, agent workstations 61 and 63 are illustrated as having identical equipment and connections as station 59 . For example, agent telephones 67 (workstation 61 ) and 69 (workstation 63 ) are connected to switch 39 by internal wiring 47 . Agent PC/VDU's 73 (station 61 ) and 75 (station 63 ) are connected to LAN 51 . The inventor illustrates identical capabilities for simplicity in illustration only. It is not to be construed as a limitation.
Agent telephones 65 – 69 are chiefly adapted for COST communication as exemplified by COST wiring 47 , which connects them to switch 39 as previously described. However, telephones 65 – 69 may also be used as DNT-capable telephones as illustrated by data connections to respective PC/VDU's in each station 59 – 63 . In some cases, telephones 65 – 69 may be adapted for either COST only or DNT only communication.
PC/VDU's 71 – 75 are adapted for DNT communication by virtue of their connections to LAN 51 and installed IP-telephony software. Because LAN 51 is Internet enabled, agents operating PC/VDU's 71 – 75 may deal with all manner of IP communication arriving at center 25 from Internet 13 .
Internet 13 has an Internet backbone 35 illustrated therein and intended to represent the many lines, connection points, and equipment types making up the Internet network as a whole. In this example, two WEB-servers (WS) 33 and 29 are illustrated as connected to backbone 35 . WEB-servers 33 and 29 represent well-known file servers adapted to serve electronic WEB pages to those accessing the servers from remote appliances through Internet connection. Servers 33 and 29 are, in this example, hosted by the enterprise hosting communication center 25 . Servers 33 and 29 contain WEB pages that provide contact means and information to Internet visitors who desire contact with an agent working in center 25 .
Communication center 25 has an IP router 55 provided therein and adapted to receive IP calls from Internet 13 . IP calls are represented as a vector 31 entering WEB server 33 , and as a vector 27 entering WEB server 29 . Calls 31 and 27 may represent any of the DNT communication means mentioned in the background section. IP telephone calls, e-mail, video calls, represent but a few of the possibilities. IP calls 31 and 27 are initiated at servers 33 and 29 respectively by customer initiation of appropriate interactive means provided in a given WEB page accessed by the customer.
IP calls are routed over backbone 35 to a network-connection line 37 that ultimately connects to IP router 55 held within center 25 . Connection line 37 is, in this example, an Internet capable data line. IP router 55 is connected to LAN 51 . IP calls 31 and 29 are routed over LAN 51 to appropriate LAN connected terminals.
A customer information system (CIS) server 57 is provided within center 25 and is connected to LAN 51 . CIS server 57 is adapted to store and server any data about known customers that may be useful to agents communicating with them. Data held in CIS 57 may include but is not limited to customer account information, personal transaction histories, address and contact information, and so on.
Other systems adapted to aid agents in interacting with customers are also available within communication center 25 , and in some cases, within networks 11 and 13 . For example, switch 39 is illustrated as having an interactive voice response (IVR) system 44 . IVR 44 is adapted to interact with COST callers on an agent's behalf when required by enterprise rules. A queue (Q) system 43 is also available at switch 39 as is generally known in the art. Queue system 43 may be a first-in-first-out (FIFO) queue, or it may be an enhanced queue with enhancement provided by CTI processor 41 . DNT equivalents are provided at IP router 55 and represented by an IP queue 53 and an IVR system 43 . Such conventions are used to aid in handling call flow within communication center 25 . A data link 45 connecting queue 53 to processor 41 provides T-Server enhancement to queue 53 as well as IVR 43 and IP router 55 . In this way, all call events may be handled by one integrated set of communication center rules.
As described in the background section, traditional communication signboards adapted to notify agents of certain communication-center call states and other information are prone to divert agent's responsibilities from tasks at hand by virtue of their centralized location within a center. Therefore, the inventor provides a distributed software application illustrated herein as (SW) to run in the background at each agent workstation 71 , 73 , and 75 .
Distributed instances of SW are adapted to function as personalized information systems for the agents and are capable of visual as well as audible modes of information processing. Each distributed instance of information SW is configured to periodically check communication-center data sources for applicable information based on that particular station's configuration.
To further illustrate, consider an example wherein all three illustrated instances of information SW (one at each of stations 71 – 77 ) are identically configured to retrieve the same information as it becomes available from data sources. In this case, an applicable data source is, for example, processor 41 , which is adapted (among other functions) to serve T-Server data to requesting nodes. T-Server data may include communication-center call-load status, agent call performance data, percentages of required out-bound calls per agent, total number of calls in queue, average call handling time statistics, and any other applicable information that may be deemed by the enterprise hosting center 25 to be applicable for agent dissemination.
SW distributed at each of stations 71 – 75 periodically checks data. sources, such as processor 41 , over LAN 51 for the most current data available. In some cases, each distributed SW instance is time-configured to request data simultaneously such that all agents are privy to the same data at the same time. In other cases, the data is picked up at different times by different stations if required. Similarly, the distributed applications may be somewhat personalized to a particular agent's station and a current agent's duties.
If for example, an agent at station 63 is only answering DNT communication, then SW at station 75 might be configured to communicate the number of calls in queue 53 , but not the number of calls in queue 43 and so on. If the agent switches to answering only COST calls, then SW at station 75 may detect the switch and change request protocol accordingly such that now only data about COST queue 43 is available.
In most instances, much of the same data will be applicable to all active agents and may help to direct an agent's responsibilities in some respects. SW of the present invention utilizes pre-recorded WAV or other audible files for conveying informative states to agents. The system utilizes the internal PC speaker at each workstation 71 – 75 to play audible files as is illustrated by speaker icons 81 – 77 , or alternatively may utilize additional speaker or speakers installed and operable at the agent station. In this way, an agent may control the volume to a low level (or whisper) so that other individual agents are not distracted. Audible files played to agents may indicate many of the types of available data that would otherwise be displayed on a signboard perhaps in numeric format.
In addition to an ability to play audio files, SW of the present invention also enables visual display of communication-center data through the use of animated figures or graphics that flash or move across a PC monitor screen. Each different figure or icon may represent a different set of data. Moreover, SW of the present invention may also be configured to provide a standard signboard display having all of the metered data displayed thereon in numeric, text, and/or symbol form. There are many possibilities in alternative embodiments.
FIG. 2 is a block diagram of agent workstation 61 adapted with the communication center performance display and warning system of FIG. 1 . The SW of the present invention of which an instance is represented on each of stations 71 – 75 of FIG. 1 is represented in this example as elements 83 and 85 . Element 83 represents a graphics icon or animated figure moving in the display screen of PC 73 . Movement of element 83 is represented by the directional arrows showing movement from right to left in this example.
It is important to note here, that element 83 may represent any conceivable graphic illustration that may be used to equate to a “state” existing in communication center 25 . For example, a man pushing a full wheel barrel and laboring across the screen may indicate a full call-waiting queue. A superman figure with an agent's name emblazoned across his jersey may indicate the center's current top-performing agent. The possibilities are limited only by the imagination.
Element 85 represents a legible signboard that is minimized to the available task bar area of the screen. Element 85 may be maximized to occupy a full screen and may serve as a real time interface for communication center data. The data may appear in any conventional form such as text data, symbols representing data, numeric data, or a combination thereof. When the displayed board is minimized, the data that would normally be viewable may be expressed audibly with generated WAV files. For example, a WAV file may be used to express the number of calls currently waiting in queue. There could be a pre-recorded version of the file such as “the number of calls in queue for department 10 is now” and a parsing technique and synthesized voice addition could fill in the current number as indicated at the data source to complete the sentence. Call-load thresholds and other real-time data may be expressed in similar fashion.
Other data such as statistical information, averages, number of disconnects, and the like may also be expressed audibly. Speaker 79 , which in actual implementation is an internal PC speaker in this example, may be controlled in volume by the application such that audible alerts do not interfere with other audible communication engaged in by an agent. In some embodiments, all of the agent's internal speakers may be set to a specific volume decided upon by a supervisor or manager.
In still another embodiment, the “whisper capability” of the internal speaker may be extended to an agent's headset, represented herein as element number 87 , such that the agent may still hear audible system information while engaged with a customer on a telephone call.
The SW of the present invention is, in a preferred embodiment, configurable to individual agents and or groups of agents. This is preferred because of a fact that in a large communication center it is common to have separate groups of agents that are responsible for different types of communication and levels of customer service. There may be separate queues set up for these agents. Statistics regarding the performance of different groups of agents as well as call-load statistics about calls directed to the separate groups may vary widely. Therefore, individually configurable instances of SW provide a means for getting the right information to the right group of agents.
In yet other embodiments, managers and supervisors may have instances of SW on their stations that are configured to obtain certain parts of data from a number of different groups for monitoring purposes. Such an instance of SW would report, for example, the numbers of completed calls per hour from sales, finance, service, and technical support. There are many possibilities. Moreover, distributed instances of SW may be upgraded to new versions and new capabilities over the network from a remote location or by a knowledge worker within center 25 .
It will be apparent to one with skill in the art that the method and apparatus of the present invention is not limited to practice in a conventional customer care center wherein all agents are LAN-connected and operating in a centralized location. The method and apparatus of the present invention may also be practiced on a WAN wherein agents occupy stations that are remote from each other as long as there is a central data source such as a server connected to the WAN to supply the desired data to remotely distributed applications.
It will also be apparent to one with skill in the art that the software of the present invention may make full use of media capabilities and display options supported by current platforms and display systems without departing from the spirit and scope of the present invention. For example, instead of distributed applications residing at independent and fully functional workstations, the SW may be centrally executed and extended to such as “dumb” display terminals having only enough memory to support distributed display interfaces.
The method and apparatus of the present invention should be afforded the broadest scope under examination. The method and apparatus of the present invention should be limited only by the claims that follow.
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In a call center having agent stations including personal computers having video display units (PC/VDUs), connected on a LAN with a server tracking status for call center entities, a system for agent information includes a software application executing on individual PC/VDUs at agent stations. The software application draws on status information from the server and renders the information to the agent using the PC/VDU through output apparatus of the PC/VDU. Rendering may be by text, graphics, or audio, depending on such as conditions and user selection.
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BACKGROUND
[0001] 1. Field
[0002] Embodiments of the invention relate to boom assemblies. More specifically, embodiments of the invention relate to a track roller assembly for supporting a boom section and facilitating the telescoping of the boom section. In further embodiments of the invention, the boom section is formed of fiberglass.
[0003] 2. Related Art
[0004] Utility workers utilize an aerial device to reach inaccessible locations. The aerial device is usually mounted on a utility truck and generally includes a boom assembly with a utility platform connected at a boom tip. The utility platform includes a bucket, sometimes referred to as a platform, in which one or more utility workers stand. Alternatively, or in addition, the boom assembly may have a winch or other tool at the boom tip.
[0005] Electric utility workers typically use an aerial device to access overhead electric power lines and electric power components for installation, repair, or maintenance. Utility workers in these situations will often utilize an aerial device that is electrically insulated and/or electrically isolated to prevent the discharge of electricity through the utility truck, and especially through the utility worker. Many aerial devices utilize at least one boom section that is formed of fiberglass or other electrically non-conductive material. The use of such material in the boom section insulates and isolates a utility worker or other tool or implement. While fiberglass has excellent insulating properties, it is susceptible to contact stresses and abrasion. Some fiberglass boom sections therefore utilize a roller mounted within the outer boom section to minimize damage to the fiberglass boom section. However, if the roller is too hard it can cause just as much damage, and if the roller is too soft its useful life is limited.
SUMMARY
[0006] Embodiments of the invention solve the above-mentioned problems by providing a track roller assembly for supporting and facilitating the telescoping of the fiberglass boom section. The track roller assembly comprises a plurality of rollers and a continuous track disposed around the rollers. The track roller assembly is located at least partially within a hollow first boom section. The rollers are rotatably coupled to either a bracket or the interior of the first boom section. The fiberglass boom section contacts the continuous track, such that the continuous track provides a larger surface area than a single roller.
[0007] A telescoping boom assembly for an aerial device in accordance with a first embodiment comprises a first boom section, a second boom section, and a track roller assembly. The second boom section is at least partially disposed within the first boom section. The track roller assembly is coupled to an interior channel of the first boom section, such that the second boom section is in contact with the track roller assembly. The track roller assembly provides support and facilitates the telescoping of the second boom section in and out of the first boom section.
[0008] A track roller assembly in accordance with a second embodiment comprises a bracket, a plurality of rollers, and a continuous track disposed around the plurality of rollers. The bracket is deformable into a first interfacing shape and a second interfacing shape. The plurality of rollers comprises a first roller, a second roller, and at least one secondary roller. The first roller is rotatably coupled at one end of the bracket, and a second roller is rotatably coupled at a second end of the bracket. The at least one secondary roller is disposed between the first roller and the second roller and rotatably coupled to the bracket. Upon the placement of a heavy load onto the boom assembly, the bracket will deform such that the at least one secondary roller contacts the interior surface of the continuous track. This will provide additional support and further distribute the load.
[0009] This summary is provided to introduce a selection of concepts in a simplified form that are further described below in the detailed description. This summary is not intended to identify key features or essential features of the claimed subject matter, nor is it intended to be used to limit the scope of the claimed subject matter. Other aspects and advantages of the current invention will be apparent from the following detailed description of the embodiments and the accompanying drawing figures.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
[0010] Embodiments of the current invention are described in detail below with reference to the attached drawing figures, wherein:
[0011] FIG. 1 is an environmental view of a utility truck with an attached boom assembly;
[0012] FIG. 2 is a fragmentary cross-sectional view along a length of the boom assembly;
[0013] FIG. 3 is a perspective view of the boom assembly in FIG. 1 ;
[0014] FIG. 4 is a perspective view of the boom assembly as illustrated in FIG. 3 , but with an outer boom removed to more clearly show a first embodiment of a track roller assembly;
[0015] FIG. 5 is a cross-sectional view through a width of the boom assembly illustrating the position of two track roller assemblies in the boom assembly;
[0016] FIG. 6 is a perspective view of the first embodiment of the track roller assembly;
[0017] FIG. 7 is a perspective view of the first embodiment of the track roller assembly, illustrating a removed continuous track to expose the plurality of rollers;
[0018] FIG. 8 is an exploded view of the first embodiment of the track roller assembly and its component parts;
[0019] FIG. 9 is a side view of a second embodiment of the track roller assembly that comprises five rollers and illustrated in a first interfacing position; and
[0020] FIG. 10 is a side view of the second embodiment of the track roller assembly of FIG. 9 illustrated in a second interfacing position.
[0021] The drawing figures do not limit the current invention to the specific embodiments disclosed and described herein. The drawings are not necessarily to scale, emphasis instead being placed upon clearly illustrating the principles of the invention.
DETAILED DESCRIPTION
[0022] The following detailed description references the accompanying drawings that illustrate specific embodiments in which the invention can be practiced. The embodiments are intended to describe aspects of the invention in sufficient detail to enable those skilled in the art to practice the invention. Other embodiments can be utilized and changes can be made without departing from the scope of the current invention. The following detailed description is, therefore, not to be taken in a limiting sense. The scope of embodiments of the invention is defined only by the appended claims, along with the full scope of equivalents to which such claims are entitled.
[0023] In this description, references to “one embodiment,” “an embodiment,” or “embodiments” mean that the feature or features being referred to are included in at least one embodiment of the technology. Separate references to “one embodiment,” “an embodiment,” or “embodiments” in this description do not necessarily refer to the same embodiment and are also not mutually exclusive unless so stated and/or except as will be readily apparent to those skilled in the art from the description. For example, a feature, structure, act, etc. described in one embodiment may also be included in other embodiments, but is not necessarily included. Thus, the current technology can include a variety of combinations and/or integrations of the embodiments described herein.
[0024] An aerial device 10 , constructed in accordance with various embodiments of the invention, is shown in FIG. 1 . The aerial device 10 utilizes a tool 12 to perform tasks that could include, but are not limited to: raising and lowering one or more people located inside of a utility platform; lifting a pallet of wood with a crane; drilling a hole for the emplacement of a pole or post; or excavating material such as dirt or sand by way of an earth-interfacing implement (not illustrated). The aerial device 10 generally includes a telescoping boom assembly 14 mounted on a base 16 . The base 16 may be a large earth-working vehicle with wheels or tracks, a utility truck, or the like, as further discussed below. In the embodiment illustrated in FIG. 1 , the base 16 is a truck on which the aerial device 10 is mounted. In another embodiment, the tool 12 supported by the aerial device 10 comprises a video camera, a microphone, or a photography camera. In this embodiment, the aerial device 10 comprises a base 16 that is selectively movable or stationary. The boom telescopes to achieve angles for the camera or microphone that a cameraperson could not achieve individually.
[0025] The telescoping boom assembly 14 broadly comprises a first boom section 18 , a second boom section 20 , and a track roller assembly 22 . The track roller assembly 22 spreads the load placed upon the second boom section 20 across a greater surface area to prevent damage to the second boom section 20 . In embodiments of the invention, the boom assembly 14 may comprise additional equipment including any of the following: power lines for the routing of hydraulic, pneumatic, or electrical power; communication wires for user-controls located on the boom assembly 14 ; or support cables (not illustrated).
[0026] The base 16 of the aerial device 10 is a selectively stabilized platform. In embodiments of the invention, the base 16 is a utility truck, a crane, an oil rig, or other fixed structure. The base 16 provides stability and a counterweight to the load and the various boom sections. Larger loads typically require a more stable and a heavier base 16 . To achieve this stability, in embodiments of the invention, the base 16 may utilize hydraulic stabilizers, outriggers, and/or sand bags.
[0027] As used herein, the “first boom section” refers to an exterior boom section of the boom assembly 14 that has a larger diameter or vertical cross-sectional area about the width than the second boom section 20 . As used herein, the “second boom section 20 ” refers to an inner boom section that has a smaller diameter or vertical cross-sectional area about the width than the first boom section 18 . The second boom section 20 is at least partially disposed within the first boom section 18 . The second boom section 20 telescopes to extend or retract into the first boom section 18 . In embodiments of the invention, a second boom section 20 can serve as the first boom section 18 for a third boom section that is yet a further inner section that has a smaller diameter or vertical cross-sectional area about the width than the second boom section 20 . The third boom section is at least partially disposed within the second boom section 20 , which is itself at least partially disposed within the first boom section 18 . In still further embodiments, the boom assembly further comprises a fourth boom section, a fifth boom section, etc.
[0028] As shown in FIGS. 1 and 2 , in one embodiment of the invention the first boom section 18 is rectangular about its vertical cross-section, i.e., the cross-section through a width of the boom section 18 , and the second boom section 20 is round about its vertical cross-section. In other embodiments, other shapes can be used, such as ovals, squares, pentagons, hexagons, octagons, or other regular and irregular shapes. In some embodiments, the first boom section 18 and the second boom section 20 will have a substantially similar cross-sectional shape. In other embodiments, the cross-sectional shapes are different.
[0029] As shown in FIGS. 1 and 2 , the first boom section 18 comprises an elongated body that is at least partially hollow. The first boom section 18 presents a distal end 24 having a leading edge 26 , a proximal end 28 having a trailing edge 30 , a length, and an interior channel 32 extending through the hollowed body. In embodiments of the invention, the first boom section 18 is formed of fiberglass or a polymer. In other embodiments, the first boom section 18 is formed of metal. The proximal end 28 of the first boom section 18 is rotationally coupled to the base 16 . In some embodiments, the proximal end 28 of the first boom section 18 is rotationally coupled to the base 16 such that the boom assembly 14 can rotate along more than one axis. In embodiments of the invention, the first boom section 18 presents a mount for the second boom section, which is schematically illustrated in FIG. 1 . In embodiments of the invention, the first boom section 18 may further comprise a covering (not illustrated) over its trailing edge 30 . The covering may be partially open to receive any of the power lines, communication wires, or cable.
[0030] The interior channel 32 of the first boom section 18 is of a sufficient vertical cross-sectional area about the width such that the interior channel 32 may house the second boom section 20 and the track roller assembly 22 , as will be discussed below. In embodiments of the invention, the interior channel 32 may further house power cables, including hydraulic cables, communications lines, etc. In other embodiments, these cables and lines are coupled to the exterior of the first boom section 18 .
[0031] Referring to FIG. 3 , the first boom section 18 may further include any or all of the following at the distal end 24 of the section 18 : one or more exterior mounts 34 for an attached tool 12 , a support flange 36 , and a mount 38 for the track roller assembly 22 . In embodiments of the invention, the first boom section 18 has a different vertical cross-sectional size and/or shape for a portion of its length near the distal end 24 . In other embodiments, the first boom section 18 has a substantially constant vertical cross-sectional size and shape all along the length. As best shown in FIG. 3 , in embodiments of the invention, the support flange 36 may be splayed around multiple sides of the distal end 24 of the first boom section 18 . The support flange 36 provides additional bracing material around the distal end 24 . The mount 38 for the track roller assembly 22 is located in the interior channel 32 of the first boom section 18 . The mount 38 is generally flat to accept the track roller assembly 22 . In embodiments, there is a plurality of mounts 38 to accept a plurality of track roller assemblies 22 .
[0032] As shown in FIGS. 2-3 , the second boom section 20 of the boom assembly 14 comprises an elongated body. The second boom section 20 presents a distal end 40 having a leading edge 42 , a proximal end 44 having a trailing edge 46 , and a length. In embodiments the second boom section 20 is solid (i.e., the second boom section 20 is not hollow). In other embodiments, the second boom section 20 is hollow. In some embodiments, the hollow second boom section 20 is adapted to receive a third boom section (not illustrated).
[0033] The second boom section 20 may telescope into a plurality of positions with respect to the first boom section 18 , including a fully retracted position, in which the length of the body of the second boom section 20 is substantially inserted within the first boom section 18 (see, FIG. 3 ), and a fully extended position, in which only a relatively small portion of the length of the body of the second boom section 20 is inserted within the first boom section 18 . In embodiments of the invention, a plurality of intermediate positions is also possible. In embodiments of the invention, the length of the second boom section 20 is substantially the same length of the first boom section 18 . In other embodiments, the second boom section 20 may be shorter or longer than the first boom section 18 .
[0034] The second boom section 20 is formed of fiberglass, a composite, or other polymer. Fiberglass has electrically insulative properties that electrically isolate the operator or tool and prevent a discharge of electricity from the power line through the fiberglass. In still other embodiments, the second boom section 20 is formed of a polymer. In yet further embodiments, the second boom section 20 is formed of metal.
[0035] In embodiments of the invention, the distal end 40 of the second boom section 20 is coupled to the tool 12 , utility platform, or other device for performing work. As noted above, multiple types of tools 12 could be used with the boom assembly 14 . For example, the tool may be a pulley for guiding a cable and a hook, an earth-working implement, such as a digger derrick, or a platform upon which a utility worker can stand.
[0036] Referring now to FIG. 2 , in embodiments of the invention the second boom section 20 further comprises a base segment 48 coupled to the trailing edge 46 of the proximal end 44 . The base segment 48 presents a top edge 50 . When a load 52 is placed on the distal end 40 of the second boom section 20 , the downward force of the load 52 translates to an upward force on the proximal end 44 of the second boom section 20 . Therefore, at least when the load 52 is relatively heavy and placed on the distal end 40 of the second boom section 20 , the top edge 50 of the base segment 48 is in contact with the interior channel 32 of the first boom section 18 . It should be appreciated that the same would be true if the heavy load 52 was placed on a third boom section or a fourth boom section, etc., as these forces could damage the second boom section 20 .
[0037] As illustrated in FIG. 2 , the second boom section 20 further comprises a wear pad 54 . In one embodiment, the wear pad 54 is coupled to the top edge 50 of the base segment 48 . In another embodiment, the wear pad 54 is coupled to the interior channel 32 of the first boom section 18 . In still further embodiments, multiple wear pads 54 are utilized. The wear pad 54 has a relatively low coefficient of friction so as to facilitate the translation of the second boom section 20 within the first boom section 18 . In some embodiments, the wear pad 54 is removably coupled to the second boom section 20 , such that it can be easily replaced upon being damaged or worn.
[0038] The second boom section 20 telescopes to extend out of the first boom section 18 and retract into the first boom section 18 . A hydraulic cylinder (not illustrated) applies hydraulic power to the second boom section 20 . The hydraulic cylinder is coupled to the base segment 48 of the second boom section 20 and to the first boom section 18 . In one embodiment of the invention, the hydraulic cylinder acts as a double acting cylinder. In other embodiments, the boom assembly 14 acts as a single acting cylinder. In still further embodiments, the second boom section 20 telescopes via electrical power.
[0039] Turning now to FIGS. 5-8 , the track roller assembly 22 of the telescoping boom assembly 14 will be described. The track roller assembly 22 facilitates the telescoping of the second boom section 20 in and out of the first boom section 18 . The track roller assembly 22 is adapted to rotate a continuous track 56 with minimal friction. The track roller assembly 22 comprises a mounting assembly 58 , a plurality of rollers 60 , and the continuous track 56 . The mounting assembly 58 rotatably couples each of the plurality of rollers 60 to the interior channel 32 of the first boom section 18 . Each of the plurality of rollers 60 is adapted to rotate about a respective center axis. The continuous track 56 is wrapped around each of the plurality of rollers 60 , such that at least two of the plurality of rollers 60 are in contact with the continuous track 56 .
[0040] As illustrated in FIG. 5 , the telescoping boom assembly 14 comprises a plurality of track roller assemblies 22 . The track roller assembly 22 is securely coupled to the mount 38 on the first boom section 18 . In embodiments as discussed below, the track roller assembly 22 is deformable into at least a first interfacing shape, as shown in FIG. 9 , and a second interfacing shape, as shown in FIG. 10 .
[0041] The mounting assembly 58 is illustrated in FIGS. 5-8 and comprises a generally U-shaped bracket 62 , a roller housing 64 having at least one opening 65 in which the plurality of rollers 60 is attached, and securing pins 66 for securing the plurality of rollers 60 in the roller housing 64 . The mounting assembly 58 is formed of metal or other rigid structure that can withstand the weight of the first and second boom sections 18 , 20 , the load 52 , and the stresses accompanying the telescoping of the boom sections 18 , 20 .
[0042] As best illustrated in FIG. 8 , the bracket 62 includes a mounting plate 68 and opposing arms 70 extending upwardly from the mounting plate 68 , such that the mounting plate 68 and opposing arms 70 form the general U-shaped bracket 62 . The mounting plate 68 is generally flat and includes a plurality of openings 72 to receive fasteners 74 , such as screws or bolts. In embodiments of the invention, the mounting plate 68 is secured to the interior channel 32 of the first boom section 18 , as illustrated in FIGS. 3 and 5 . The mounting plate 68 is sized and shaped to fit flush against the mount 38 of the first boom section 18 . In embodiments of the invention, the plate 68 may be another shape to complement a shape of the mount 38 of the first boom section 18 . For example, if the mount 38 of the first boom section 18 is curved, the mounting plate 68 may also be curved so that substantially all of a bottom surface of the plate 68 may be in contact with the mount 38 of the first boom section 18 .
[0043] The mounting plate 68 , and thus the bracket 62 , is secured to the mount 38 of the first boom section 18 by inserting screws or fasteners 74 through the plurality of openings 72 in the mounting plate 68 and into the first boom section 18 . Other securement methods may also be employed, such as adhering the mounting plate 68 to the first boom section 18 via a high-strength adhesive, welding the mounting plate 68 to the first boom section 18 , or integrally forming the mounting plate 68 (and/or the bracket 62 ) with the first boom section 18 .
[0044] As noted above, the arms 70 extend upwardly from the plate 68 and are spaced from each other to form a receiving area 76 for the roller housing 64 . The arms 70 are integrally formed with the mounting plate 68 , such that the bracket 62 comprising the mounting plate 68 and arms 70 is a monolithic unit. Each arm 70 includes an opening 78 therethrough for receiving the securing pins 66 , as further described below.
[0045] The roller housing 64 is sized and configured to rest within the receiving area 76 formed by the mounting plate 68 and upwardly extending arms 70 . The roller housing 64 is generally H-shaped (when viewed from above) and comprises two spaced side plates 80 and a support bar 82 extending therebetween. Each side plate 80 has a generally oblong shape that allows the continuous track 56 to roll around an exterior edge of the side plate 80 during use of the track roller assembly 22 .
[0046] One advantage of the roller housing 64 is being able to quickly and easily replace the track roller assembly 22 should one or more of the rollers 60 or the track become damaged. Another advantage is the ability of the roller housing 64 to pivot about the securing pin 66 . The pivoting action allows each of the rollers 60 to stay in contact with the second boom section 20 even if the second boom section 20 is not substantially parallel to the first boom section 18 due to a heavy load 52 being placed on the second boom section 20 or the third boom section.
[0047] The roller housing 64 is pivotably coupled to the arms 70 via the securing pin 66 , such that the roller assembly 68 can be pivoted up and down in the longitudinal direction of the first boom section 18 . The securing pin 66 is emplaced through the opposing arms 70 and the support bar 82 when the roller housing 64 is in the receiving area 76 of the bracket 62 . Pivoting allows the track roller assembly 22 to accommodate the second boom section 20 based upon the extended position of the second boom section 20 relative to the first boom section 18 and the weight of the load 52 placed upon the second boom section 20 . The securing pin 66 may also utilize at least one securing washer 84 to facilitate the pivoting. The securing washer 84 facilitates the pivoting of the roller housing 64 around the securing pin 66 and prevents damage to each. The securing pin 66 and the at least one securing washer 84 are formed of a metal. In other embodiments, the securing pin 66 and the at least one securing washer 84 are formed of a hardened polymer. In another embodiment, the roller housing 64 is fixedly secured to the arms 70 . In yet another embodiment, the roller housing 64 and the arms 70 are monolithic.
[0048] The track roller assembly 22 comprises a plurality of rollers 60 , including at least a first roller 86 and a second roller 88 . Each of the plurality of rollers 60 is wheel or cylindrically shaped and presents an outer rim 90 . The outer rim 90 of the rollers 60 presents a vertical cross-sectional shape across the outer rim 90 . As shown in FIG. 8 , the cross-sectional shape can be substantially flat. In other embodiments, the cross-sectional shape may be convex, concave, arcuate, semi-circular, V-shaped, or A-shaped. The rollers 60 are adapted to freely rotate about an axis that is substantially perpendicular to the longitudinal direction of the first boom section 18 . As such, the outer rim 90 of the rollers 60 rotates in a direction substantially parallel to the longitudinal direction of the first boom section 18 . The rollers 60 are substantially rigid so as to support the load 52 of the second boom section 20 as it telescopes into the plurality of positions with respect to the first boom section 18 . Each roller 60 has a diameter such that a portion of the outer rim 90 of the roller 60 extends beyond the roller housing 64 when the roller 60 is rotatably coupled to the roller housing 64 . This allows for the free rotation of the continuous track 56 about the rollers 60 .
[0049] The arms 70 are adapted to rotatably couple the plurality of rollers 60 . In embodiments, a plurality of securing pins 66 is utilized to rotatably couple each of the plurality of rollers 60 to the arms 70 . Each of the plurality of securing pins 66 is disposed in the opening 78 in the arms 70 and through a respective opening 92 in each of the rollers 60 . The securing pin 66 is substantially cylindrical such that the roller 60 may rotate about the securing pin's 66 vertical cross-section about the width. The securing pin 66 may further comprise a head 94 . The head 94 of the securing pin 66 is adapted to secure the securing pin 66 to the roller housing 64 , the arms 70 of the bracket 62 , or the interior channel of the first boom section 18 . One roller 60 is placed into the receiving area 76 between the two arms 70 of the roller housing 64 , and one securing pin 66 passes through the opening 92 in the roller 60 and the pair of arms 70 in the roller housing 64 . In embodiments of the invention, the securing pin 66 further comprises a plurality of bearings to facilitate free rotation of the roller.
[0050] In other embodiments, the track roller assembly 22 further comprises at least one securing washer 84 , which presents an interior diameter approximately equal to, or slightly larger than, an outer diameter of the securing pin 66 . This allows the securing washer 84 to be disposed around the securing pin 66 when it is attached to the roller assembly 68 .
[0051] The continuous track 56 of the roller assembly 68 of the track roller assembly 22 is a belt presenting an interior surface 96 and an exterior surface 98 . In embodiments of the invention, the continuous track 56 is formed of one or more layers of pliable material, such as a polymer or composite. The pliable material provides linear strength and retains the shape of the continuous track 56 . The pliable material has a high compliance, which is the inverse of stiffness, such that it will easily deform under the forces. The compliance is advantageous in facilitating the rotation of the continuous track 56 and in providing greater contact surface area with the second boom section 20 . The pliable material of the continuous track 56 also has a lower elastic modulus than the second boom section 20 . The pliable material will therefore deform to a greater extent than the material of the second boom section 20 . Because the second boom section 20 rests on the exterior surface 98 of the continuous track 56 , the continuous track 56 prevents and/or reduces damage to the second boom section 20 caused by the force of the load 52 .
[0052] In other embodiments, the continuous track 56 comprises a plurality of pivotably linked segments (not illustrated). Each of the plurality of segments is rigid or semi-rigid.
[0053] The interior surface 96 of the continuous track 56 is disposed around the first roller 86 and second roller 88 . In embodiments of the invention, the interior surface 96 of the continuous track 56 is substantially smooth. In other embodiments, the interior surface 96 of the continuous track 56 further comprises a plurality of protrusions (not illustrated) that are disposed in a corresponding plurality of recesses (not illustrated) in the first roller 86 and the second roller 88 . In embodiments, the first roller 86 and the second roller 88 may have a plurality of teeth or cogs (not illustrated), so as to present a sprocket shape.
[0054] The exterior surface 98 of the continuous track 56 is substantially smooth. In other embodiments, the exterior surface 98 of the continuous track 56 further comprises a plurality of protrusions (not illustrated) or recesses (not illustrated), also called tread. The recesses and protrusions may provide advantages including facilitating the rotation of the continuous track 56 around the roller 60 ; ensuring that a rotation of the continuous track 56 corresponds to a similar rotation of the first roller 86 and the second roller 88 , so as to minimize damage to the continuous track 56 ; ensuring that the continuous track 56 rotates in a direction substantially parallel to the rotation direction of the first roller 86 and the second roller 88 , so as to minimize the likelihood that the continuous track 56 will slip or dislodge off the rollers 60 ; and providing increased frictional contact between the continuous track 56 , so as to provide a stable support for the second boom section 20 .
[0055] A track roller assembly 22 in accordance with another embodiment of the invention further comprises at least one roller 60 that is a secondary roller 100 . The at least one secondary roller 100 is rotatably coupled to the roller housing 64 between the first roller 86 and the second roller 88 . The at least one secondary roller 100 provides the advantage of distributing the weight of the second boom section 20 and the load 52 more evenly.
[0056] In embodiments, the roller housing 64 is deformable or deflectable into a first interfacing shape, as illustrated in FIG. 9 , and a second interfacing shape, as illustrated in FIG. 10 . In the first interfacing shape, only the first roller 86 and the second roller 88 are in contact with the interior surface 96 of the continuous track 56 that is adjacent to the second boom section 20 . In the second interfacing shape, the first roller 86 , second roller 88 , and each of the at least one secondary roller 100 is in contact with the interior surface 96 of the continuous track 56 that is adjacent to the second boom section 20 .
[0057] In one embodiment of the invention, the roller housing 64 is formed of a material, such as a polymer or a metal, that deforms or deflects upon the application of a heavy load 52 . In another embodiment of the invention, the roller housing 64 further comprises a compression element (not illustrated), such as a spring, which provides a force pushing the roller housing 64 into the first interfacing position. Upon the application of a heavy load 52 , the compression element compresses until the at least one secondary roller 82 interfaces with the interior surface 96 of the continuous track 56 . In one embodiment, as illustrated in FIGS. 9-10 , the roller housing 64 has a substantially V-shape when in the first interfacing position and has a substantially straight shape when in the second interfacing position. In another embodiment of the invention, the roller housing 64 has an arcuate shape in the first interfacing position and a substantially straight shape in the second interfacing position.
[0058] The installation and emplacement of the track roller assembly 22 will now be described in greater detail. The following is an exemplar of the installation and emplacement of the track roller assembly 22 . In embodiments of the invention, the roller assembly 68 is formed by the following steps: emplacing the first roller 86 into the roller housing 64 and aligning the at least one opening 65 in the roller housing 64 with the opening 92 in the first roller 86 ; emplacing the securing pin 66 through the securing washer 84 , the at least one opening 78 in the arm 70 , the opening 92 in the first roller 86 , and through another securing washer 84 ; locking the securing pin 66 to the first roller 86 to prevent its unintentional displacement; repeating steps 1-3 for the second roller 88 ; and emplacing the continuous track 56 around the first roller 86 and the second roller 88 .
[0059] The track roller assembly 22 is then formed by emplacing the roller assembly 68 into the receiving area 76 between the arms 70 of the bracket 62 and aligning the at least one opening 78 in the arm 70 with a corresponding opening 65 through the support bar 82 in the roller housing 64 ; emplacing the securing pin 66 through the securing washer 84 , the at least one opening 78 in the arm 70 of the bracket 62 , the opening 65 in the roller housing 64 , and through another securing washer 84 ; and locking the securing pin 66 to prevent its unintentional displacement. The track roller assembly 22 is then installed by emplacing the track roller assembly 22 into the first boom section 18 and aligning the plurality of openings 72 in the mounting plate 68 with a corresponding plurality of openings (not illustrated) in the mount 38 of the first boom section 18 ; securing the track roller assembly 22 to the first boom section 18 by applying the plurality of fasteners 74 to the aligned openings 72 in the mounting plate 68 and the openings in the mount 38 of the first boom section 18 ; and emplacing and telescopically securing the second boom section 20 into the first boom section 18 , such that the exterior surface 98 of the continuous track 56 is adjacent an exterior portion of the second boom section 20 .
[0060] In embodiments of the invention, multiple track roller assemblies 22 are installed into the first boom section 18 . In one embodiment, as illustrated in FIG. 5 , two track roller assemblies 22 are emplaced adjacent to each other such that they provide lateral support in addition to their longitudinal support. In this embodiment, the first boom section 18 comprises two mounts 38 that form an obtuse angle near the distal end 24 of the first boom section. This embodiment of the invention is advantageous because it provides lateral support as well as vertical support to the second boom section 20 .
[0061] In another embodiment, two adjacent track roller assemblies 22 are emplaced such that in the event of a failure of one, the other track roller assembly 22 provides the support for the second boom section 20 and the load 52 . In another embodiment of the invention, a plurality of track roller assemblies 22 is spaced along the longitudinal direction to further distribute the weight of the second boom section 20 .
[0062] Operation and use of the track roller assembly 22 will now be described in greater detail. The track roller assembly 22 is a passive element in the telescoping boom assembly 14 . The track roller assembly 22 receives no direct power input of its own. The continuous track 56 and the rollers 60 rotate as a by-product of the friction between the second boom section 20 and the exterior surface 98 of the continuous track 56 as the second boom section 20 extends and retracts relative to the first boom section 18 . In other embodiments of the invention, the track roller assembly 22 is powered, such that the rotation of the rollers 60 provides at least some of the force that extends or retracts the second boom section 20 relative to the first boom section 18 .
[0063] Although the invention has been described with reference to the embodiments illustrated in the attached drawing figures, it is noted that equivalents may be employed and substitutions made herein without departing from the scope of the invention as recited in the claims.
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A track roller assembly for supporting telescoping boom sections of aerial devices. The track roller assembly is positioned in an interior channel of a hollow first boom section. The track roller assembly supports a majority of the weight of a second boom section and facilitates the second boom section telescoping in and out of the first boom section. The track roller assembly comprises a bracket to securely couple the track roller assembly to the interior channel of the first boom section, a plurality of rollers rotatably connected to the bracket, and a continuous track engaging the plurality of rollers on an interior surface and adjacent to the second boom section on an exterior surface.
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BACKGROUND OF THE INVENTION
The invention relates to a microvalve. More particularly it relates to a microvalve which has pressurized-medium connections and a valve seat inserted between them with which a closure member is associated and is deflectable by electrical actuating means.
GB 2,155,152 A has already disclosed such a microvalve which is produced in the multilayer structure known from semiconductor technology. This micromechanical valve has essentially three layers, of which an inlet and an outlet, and also a valve seat are constructed in a silicon base layer and an intermediate layer adjoins said base layer and also an outer covering layer adjoins the latter. The layers form a space producing the pressurised-medium link between the two connections. In this microvalve, the covering layer is at the same time constructed as a membrane into which a closure member belonging to the valve seat is integrated. When this microvalve is operated, an electrostatic actuating device disposed on the membrane has to overcome not only the forces of the resilient membrane but also the fluid pressure present in the inlet since the membrane which closes the valve seat is not compensated with respect to this pressure. The result of this is that the microvalve is suitable only for relatively low pressures and consequently produces a relatively low hydraulic switching power. The dynamic behaviour of the micromechanical valve is consequently also adversely affected. The non-pressure-compensated construction of the microvalve results, in addition, in relatively large actuating forces and consequently in relatively expensive actuating devices.
Reference is furthermore made to the publications EP 0,250,948 A2 and EP 0,261,972 A2 in which the technology of producing such microvalves is described more precisely and it is explained how three-dimensional shapes can be machined in multilayer structures so that different mechanical elements are possible as a result of combining different structural details. The microvalve can consequently be constructed as a 2- or 3-way valve. The membrane can also be disposed in an intermediate layer.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to provide a microvalve which avoids the disadvantages of the prior art and is a further improvement.
In keeping with these objects and with others which will become apparent hereinafter, one feature of the present invention resides, briefly stated, in a microvalve of the above mentioned type in which a pressure-compensating area acting opposition to a pressure-loaded membrane is disposed in a spa at a closure member firmly joined to the membrane.
When the microvalve is designed in accordance with the present invention it has the advantage that it makes possible a statically pressure-compensated construction of the microvalve in a relatively simple and inexpensive way. As a result of this pressure-compensated construction, higher pressures can be controlled or lower actuating forces can be employed. The fluidic power of the microvalve consequently increases appreciably, it also being possible to achieve high dynamics since only relatively small masses have to be moved. This pressure-compensated construction is suitable, in particular, for production with micromechanical technologies so that, in addition to low unit costs, a high-precision manufacture and reproducibility of the parts is possible even with small dimensions. The construction of the microvalve can be ideally tailored to the possibilities of the different micromechanical manufacturing technologies. Furthermore, such microvalves can be interconnected as desired and can also be combined to form so-called valve series.
The pressure loaded area of the membrane and the pressure-compensating area can be essentially equally large. The size of the pressure-compensating area can be limited by the valve seat. The diameter of the valve seat can correspond approximately to the effective diameter of the membrane. These features make various directions of movement of the closure member, it being possible for the closure member to open both in the flow direction and also against the flow direction, and also various types of electrical actuation.
The area and the closure member loaded by the pressure in the outlet connection can be at least approximately as large as the area at the ring membrane loaded by the pressure in the recess and determined by the effective diameter of the membrane. This embodiment, as a result of which a pressure compensation can be achieved not only on the inlet side but also on the outlet side is extremely beneficial. In accordance with another embodiment of the present invention, the movable component of the microvalve can be formed as a double annular membrane. This embodiment which is particularly well suited for both flow directions, is furthermore advantageous. A drive in both directions can be achieved. When the actuating means are disposed symmetrically above and below the movable component with double annular membrane as a result of which power and dynamics can be increased further.
The novel features which are considered as characteristic for the invention are set forth in particular in the appended claims. The invention itself, however, both as to its construction and its method of operation, together with additional objects and advantages thereof, will be best understood from the following description of specific embodiments when read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a longitudinal section through a microvalve in a simplified representation and on an enlarged scale,
and FIGS. 2 to 5 show a second to fifth exemplary embodiment of a microvalve.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows a longitudinal section through a single microvalve 10 with a multilayer structure in a considerably enlarged and simplified representation, the individual layers being built up from different materials. At the same time, manufacturing technologies are used for the production of this multilayer structure such as are known per se from semiconductor technology, in particular under the name of silicon technology, thin-film technology or thick-film technology. These technologies for producing certain three-dimensional shapes in a multilayer structure and their potential for constructing mechanical elements determined by structural details are here assumed to be known.
The microvalve 10 has essentially a base layer 11, an intermediate layer 12 and a covering layer 13. At the same time, an annular space 15 which is bounded in the upward direction by the covering layer 13 and communicates with an inlet connection 17 via a channel 16 running in the intermediate layer 12 is formed in the intermediate layer 12 by a recess 14 in the form of an annular groove. The relatively thin-walled base of the recess 14 forms a resilient annular membrane 18 which surrounds a centrally situated layer region 19 which is thick compared with the latter. The annular membrane 18 is consequently integrated into the intermediate layer 12 and bounded by the space 15 formed by the recess 14.
The covering layer 13 has an outlet connection 21 which expands in the inward direction to form a shallow, disc-shaped recess 22. The recess 22 forms an annular valve seat 23 on the side facing the intermediate layer 12. In the unactuated position of the microvalve 10 shown, a plate-type closure member 24 which is attached to the layer region 19 by an area 25 which is substantially reduced compared with the diameter of the valve seat 23 rests against the valve seat 23. At the same time, the plate-type closure member 24 consists of a layer additional to the intermediate layer 12 and made of the same or different material. In this connection, the thicknesses of the layer region 19 and the closure member 24 are so chosen that together they correspond to the thickness of the intermediate layer 12.
With this construction of the microvalve 10, the movable component consisting of the annular membrane 18, the layer region 19 and the closure member 24 has a pressure area 26 whose size is essentially determined by the size of the ring membrane 18. At the same time, on the movable component 18, 19, 24 a pressure compensation area 27 is provided. The pressure compensation are loaded in the opposite direction and its size is limited, on the one hand, by the valve seat 23 and, on the other hand, by the area 25. These two areas 26 and 27 are matched to one another in such a way that they are essentially equally large.
An area 30 on top of the plate-type closure member 24 and loaded with the return pressure p2 is limited by the valve seat 23. An area 31 on the bottom of the movable component 18, 19, 24, which area is loaded with the pressure p0, is determined by the effective diameter 32 of the annular membrane 18.
For as complete as possible a pressure compensation at the movable component 18, 19, 24, the areas 30 and 31 must be essentially equally large. This assumes that the pressures p0 beneath and p2 above the movable component are essentially equally large. The spaces 22 above and 28 beneath the movable component 18, 19, 24 do not, however, necessarily have to contain the same medium: for example, the space 22 may contain a liquid, whereas the space 28 is filled with air, under which circumstances ambient pressure may prevail in both spaces so that p0 is essentially equal to p2.
Disposed in the base layer 11 in a shallow recess 28 facing the intermediate layer 12 is an electrode 29. It serves as electrical actuating means for the closure member 24 and, in addition, forms an electrostatically acting drive.
The mode or operation of the microvalve 10 is explained as follows: the pressurised medium flowing in from an inlet connection 17 not shown in more detail via the channel 16 reaches, with the microvalve 10 not actuated, the space 15 in which the inlet pressure can build up correspondingly. This pressure in the space 15 acts, on the one hand, downwards on the pressure area 26 at the membrane 18 and simultaneously on the annular pressure-compensation area 27 at the closure member 24. Since these two pressure areas 26, 27 are constructed so as to be substantially equally large, the movable component 18, 19, 24 is correspondingly statically pressure-compensated. Under the influence of the restoring force of the resilient annular member 18, the closure member 24 is in close contact with the valve seat 23 and blocks the link to the outlet connection 21. This restoring force of the annular membrane 18 may be very small as a consequence of the pressure-compensated construction of the microvalve 10.
To open the microvalve 10, the electrode 29 is connected to voltage. As a result, an electrostatic drive for the movable component 19, 24 acts in a manner known per se and the closure member 24 moves downwards, in which process it is lifted off the valve seat 23. Pressurised medium can now flow out of the space 15 to the outlet connection 21.
To close the microvalve 10, the electrostatic drive 29 is switched off. As a result, the closure member 24 again rests on the valve seat 23 under the influence of the restoring force of the resilient annular membrane 18 and consequently blocks the pressurised-medium link. At the same time, it is assumed that the pressures p2 and p0 on the areas 30 and 31 respectively are essentially equally large and consequently a pressure compensation also exists in relation to the said areas.
As a result of the pressure-compensated construction of the microvalve 10, it is possible that pressures substantially higher than hitherto can now be controlled and that a relatively weak, and consequently inexpensive and space-saving drive can be used as electrical actuating means. The microvalve 10 is therefore suitable for controlling substantially larger hydraulic or pneumatic pressures and, in addition, makes higher dynamics possible. At the same time, the pressure-compensation area 31 can also be matched relative to the size of the pressure area 30 in such a way that only a partial pressure compensation is achieved. The pressure areas 30, 31 can also be matched to one another in such a way that, in addition to the residual static pressure forces, dynamic forces resulting from the flow can also be allowed for and affect the switching behaviour of the microvalve 10.
FIG. 2 shows a second microvalve 40 which differs from the microvalve 10 according to FIG. 1 as follows, identical reference symbols being used for identical components.
In the second microvalve 40, the valve seat 41 is disposed at the outside of the cover plate 13, that is to say downstream of the opening 42 in the cover plate 13. The closure member 43 has a stud-type section 44 which corresponds to the area 25 and by means of which it passes through the opening 42 and is firmly joined at the central layer region 19 of the intermediate layer 12. The thickness of the central layer region 19 may at the same time be as large as the thickness of the intermediate layer 12. The intermediate layer 12 and the covering layer 13 are furthermore held at a distance from one another by an additional separating layer 45. An annular piezoelectric coating 46 is provided inside the recess 28 on the ring membrane 18 as electrical actuating means for the closure member 43. In the second microvalve 40, on the one hand, the pressure area 26 at the ring membrane 18 and, on the other hand, the pressure-compensation area 27 at the closure member 43 and the areas 30 and 31 are constructed for a static pressure compensation at the movable component, and the space 15 is filled with pressurised medium extending from the intermediate layer 12 through the separating layer 45 and the covering layer 13.
The mode of operation of the second microvalve 40 corresponds in principle to that of the first microvalve 10. The annular membrane 18 is actuated upwards, however, by the piezoelectric coating 46 and the closure member 43 consequently is opened in the flow direction. If the same pressure exists in the recess 28 in this valve construction as the pressure in the outlet, that is to say downstream of valve seat 41, the movable component consisting of annular membrane 18, layer region 19 and closure member 43 is essentially pressure-compensated with respect to the pressures in the inlet and also in the outlet.
FIG. 3 shows a longitudinal section through a third microvalve 50 which differs from the first microvalve 10 only in that a thermoelectric coating 51 which is provided inside the recess 28 in the region of the ring membrane 18 at the intermediate layer 12 is provided as electrical actuating means. The closure member 24 can consequently be actuated in the same direction of movement as in the case of the first microvalve 10, namely downwards from the starting position shown.
FIG. 4 shows a fourth microvalve 60 which differs from the second microvalve 40 shown in FIG. 2 in that a thermofluidic actuation is provided instead of the piezoelectric actuation. For this purpose, there is applied in the recess 28 of the base layer 11 a heating resistance 61 which heats up when an electric current flows through it. In this process, it heats up the fluid (liquid or gas) enclosed in the recess 28 so that the latter expands. As a consequence of the increase in pressure caused thereby in the recess 28, the annular membrane 18 is deflected upwards and the closure member 43 opens in the flow direction.
FIG. 5 shows a fifth microvalve 70 which differs from the microvalve 10 shown in FIG. 1 in that both the annular membrane and the electrical actuating device are present in duplicate. It contains two additional intermediate layers 71 and 72. The movable component 19, 24 from FIG. 1 is linked via a further central layer region 74 to a second annular membrane 73 which is constructed in the intermediate layer 72. Provided above the movable component 19, 24, 74 in the covering layer 13 is a further electrical actuation 75 which is constructed in the same way as the electrical actuation 29 underneath the first annular membrane 18. This achieves a completely symmetrical construction of the microvalve 70. In particular, a complete pressure compensation is ensured at the movable component 19, 24, 74 in this construction even if the pressures p0 and p2 differ fairly considerably from one another.
In the case of the microvalve 10, it is assumed on the other hand, that the possible difference between p0 and p2 is small, which may possibly not be guaranteed in every application case.
The electrical actuating means 75 or 29, respectively, present above or below the movable component 19, 24, 74 has, in addition, the advantage that the valve can be both opened and closed by electrical actuation. In the case of the microvalve 10, on the other hand, closure takes place as a result of the resilient restoring action of the annular membrane 18.
It will be understood that each of the elements described above, or two or more together, may also find a useful application in other types of constructions differing from the types described above.
While the invention has been illustrated and described as embodied in a microvalve with multilayer structure, it is not intended to be limited to the details shown, since various modifications and structural changes may be made without departing in any way from the spirit of the present invention.
Without further analysis, the foregoing will so fully reveal the gist of the present invention that others can, by applying current knowledge, readily adapt it for various applications without omitting features that, from the standpoint of prior art, fairly constitute essential characteristics of the generic or specific aspects of this invention.
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A microvalve has at least two pressurized-medium connections means forming a valve seat between the connections, a closure member cooperating with the valve seat, an electrical actuating unit deflecting the closure member, and a membrane which moves the closure member in opposition to he electrical actuating unit and adjoins a space which can be loaded with pressurized medium. The membrane has an area which is substantially reduced relative to the valve seat and is firmly joined to the membrane and also has a pressure-loaded area. The closure member has a ring-shaped pressure-compensation area which is opposite to the membrane and extends radially outwardly of the reduced surface of the membrane and counteracts the pressure loaded area of the membrane, the pressure-loaded area of the membrane and the pressure-compensation area of the closure member are essentially equally large.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] This invention relates to the use of a protic solvent in nucleophilic displacement reactions.
[0003] 2. Description of the Related Art
[0004] Nucleophilic substitution of alkyl halides is perhaps one of the most useful reactions in organic chemistry. The nucleophilic displacement of chloride ion and similar leaving groups (e.g. bromide ion, sulfonate ion) is usually performed under anhydrous conditions using polar aprotic solvents or alcoholic solvents, or heterogeneous phase transfer conditions. This is especially true for very reactive substrates, since protic solvents (or water) might lead to solvolysis of these substrates.
[0005] One such example of very reactive intermediates is the sulfonium ion that forms in nucleophilic displacement reactions of β-chlorosulfides. As fast as it is formed, this intermediate reacts with water to yield the corresponding solvolysis product. Thus, known procedures for the nucleophilic displacement of such compounds typically employ aprotic solvents (THF, DMF, DMSO, MeCN), or alcoholic solvents (EtOH), phase transfer conditions or no solvent (Ohsawa et al., J. Org. Chem. 1983 48, 3644; Tolstikov et al., Khim-Farm. Zh. 1997 31 (8), 26-29; Krivonogov et al., Khim-Farm. Zh. 1995 29 (4), 38-40). Usually these procedures require harsh conditions (e.g. temperatures over 100° C.) and, as such, products are isolated in poor to moderate yields. A procedure that reduces reaction time and increases reaction yield is desired.
SUMMARY OF THE INVENTION
[0006] This invention provides for a process of using water as solvent/promotor in the nucleophilic displacement of halogens. Specifically, water is used as a co-solvent in nucleophilic halide displacement reactions of β-halosulfides. It is believed that water facilitates the formation of the intermediate sulfonium ion, which subsequently reacts with the desired nucleophile to form the desired product.
DETAILED DESCRIPTION OF THE INVENTION
[0007] According to Scheme 1, a preferred embodiment of the present invention relates to a method for the formation of a β-substituted sulfide III by reacting a β-halosulfide I with a desired nucleophile II in water, and optionally, another solvent or other solvents.
[0008] In Scheme 1:
[0009] R, R′, R 1 , and R 2 independently are hydrogen or
[0010] R, R′, R 1 , R 2 and R 3 independently are
[0011] lower alkyl optionally substituted with one, two or three groups independently selected from halogen, lower alkoxy, —C(O)-alkyl, aryl, —C(O)NH-alkyl, C(O)N-dialkyl, —C(O)O-alkyl, —SO 2 NR 4 R 5 , cyano, alkenyl or alkynyl, or
[0012] aryl, arylalkyl, heteroaryl or heteroarylalkyl wherein the ring portion of each is optionally substituted with one, two or three groups independently selected from halogen, lower alkyl, lower alkoxy, —C(O)-alkyl, —C(O)NH-alkyl, C(O)N-dialkyl, —C(O)O-alkyl, —SO 2 NR 4 R 5 , cyano, alkenyl or alkynyl; or
[0013] R 1 and R 2 together with the carbon atom to which they are attach form a 3, 4, 5, 6, or 7 membered carbocyclic ring up to two of which members are optionally hetero atoms selected from oxygen, sulfur and nitrogen, where the carbocyclic group is optionally substituted with one or two groups halogen, lower alkoxy, —C(O)-alkyl, hydroxy, —C(O)NH-alkyl, C(O)N-dialkyl, —C(O)O-alkyl, —SO 2 NR 4 R 5 , cyano, alkenyl or alkynyl; and
[0014] R 4 and R 5 independently are hydrogen or lower alkyl.
[0015] By “alkyl”, “lower alkyl”, and “C 1 -C 6 alkyl” in the present invention is meant straight or branched chain alkyl groups having 1-6 carbon atoms, such as, methyl, ethyl, propyl, isopropyl, n-butyl, sec-butyl, tert-butyl, pentyl, 2-pentyl, isopentyl, neopentyl, hexyl, 2-hexyl, 3-hexyl, and 3-methylpentyl. These groups may be substituted with up to four groups mentioned below for substituted aryl.
[0016] By “alkoxy”, “lower alkoxy”, and “C 1 -C 6 alkoxy” in the present invention is meant straight or branched chain alkoxy groups having 1-6 carbon atoms, such as, for example, methoxy, ethoxy, propoxy, isopropoxy, n-butoxy, sec-butoxy, tert-butoxy, pentoxy, 2-pentyl, isopentoxy, neopentoxy, hexoxy, 2-hexoxy, 3-hexoxy, and 3-methylpentoxy. These groups may be substituted with up to four groups mentioned below for substituted aryl.
[0017] By the term “halogen” in the present invention is meant fluorine, bromine, chlorine, and iodine.
[0018] A “carbocyclic group” or “cycloalkyl” is a nonaromatic cyclic ring or fused rings having from 3 to 7 ring members. Examples include cyclopropyl, cyclobutyl, and cycloheptyl. These rings may be substituted with one or more of the substituent groups mentioned below for aryl, for example alkyl, halo, and alkoxy. Typical substituted carbocyclic groups include 2-chlorocyclopropyl, 2,3-diethoxycyclopentyl, and 2,2,4,4-tetrafluorocyclohexyl. The carbocyclic group may contain one or two heteroatoms selected from oxygen, sulfur, and nitrogen, and such ring systems may be referred to as “heterocyclyl” or “heterocyclic”. Examples include pyranyl, tetrahydrofuranyl, and dioxanyl. These heterocyclyl groups may be substituted with up to four of the substituent groups mentioned for aryl to give groups such as 3-chloro-2-dioxanyl, and 3,5-dihydroxymorpholino. In addition, the carbocyclic or heterocyclic group may also contain one or more internal double bonds, as long as having such double bonds does not make the carbocycle or hererocycle aromatic.
[0019] By heteroaryl is meant one or more aromatic ring systems of 5-, 6-, or 7-membered rings containing at least one and up to four heteroatoms selected from nitrogen, oxygen, or sulfur. Such heteroaryl groups include, for example, thienyl, furanyl, thiazolyl, imidazolyl, (is)oxazolyl, pyridyl, pyrimidinyl, (iso)quinolinyl, napthyridinyl, benzimidazolyl, benzoxazolyl. The heteroaryl group is optionally substituted with up to four groups mentioned below for substituted aryl.
[0020] 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, anthryl, or phenanthryl), which is optionally mono-, di-, or trisubstituted with, e.g., halogen, lower alkyl, lower alkoxy, trifluoromethyl, trifluoromethoxy, lower acyloxy, aryl, heteroaryl, and nitro.
[0021] Certain of the compounds of the present invention possess one or more chiral centers and each center may exist in the R or S configuration. The present invention includes all diastereomeric, enantiomeric, and epimeric forms as well as the appropriate mixtures thereof. Additionally, the compounds of the present invention may exist as geometric isomers. The present invention includes all cis, trans, syn, anti, entgegen (E), and zusammen (Z) isomers as well as the appropriate mixtures thereof.
[0022] In a preferred embodiment, the β-halosulfide I and the desired nucleophile II are reacted together in water and an additional suitable co-solvent. The reaction mixture in such a solvent can be homogenous or heterogenous. Examples of suitable solvents for the present method include, but are not limited to, one or more of the following: a protic solvent such as methanol, ethanol, n-propanol, or n-butanol; or aprotic solvents such as tetrahydrofuran (THF), acetonitrile, dimethylsulfoxide, dimethylformamide or hexamethylphosphorotriamide. In an even more preferred embodiment, the solvent is an aprotic solvent, and most preferably, THF.
[0023] In another preferred embodiment, the method of the present invention is carried out at temperatures of from between 20° C. and 200° C. More preferably, the reaction temperature is from between 60° C. and 150° C. and even more preferably the reaction temperature is from between 75° C. and 100° C.
[0024] In yet another preferred embodiment, a suitable base is present in the reaction mixture. Examples of acceptable bases used in the present method are those with alkali metals or alkaline earth metals such as sodium, potassium, calcium and magnesium, and those with organic bases including, but not limited to, amines. Preferred bases are organic bases, such as, for example, triethyl amine. In an even more preferred embodiment, the base is present in a molar excess amount.
[0025] The disclosures in this application of all articles and references, including patents, are incorporated herein by reference.
[0026] The invention is illustrated further by the following examples which are not to be construed as limiting the invention in scope or spirit to the specific procedures described in them.
[0027] The starting materials and various intermediates may be obtained from commercial sources, prepared from commercially available organic compounds, or prepared using well known synthetic methods.
EXAMPLE 1
Synthesis of Iso-butyl(2-phenylthiocyclopentyl)Amine
[0028] [0028]
[0029] 1-Chloro-2-phenylthiocyclopentane (10 g, 47 mmol) and iso-butyl amine (4.13 g, 56.4 mmol) are dissolved in 50 ml of THF. Triethylamine (13.1 ml) and water (10 ml) are added to the reaction and the resulting mixture is refluxed at 80° C. overnight. The reaction mixture is cooled down to room temperature and 200 ml of dichloromethane is added to dilute the reaction mixture. The reaction mixture is then dried over K 2 CO 3 (K 2 CO 3 also neutralizes the triethylamine/HCl salt, which is generated during the reaction). Removal of the solvent gives crude product as a viscous oil, which is purified by distillation to give pure product 7.1 g (Compound 1) (yield: 53%).
EXAMPLE 2
[0030] The following compounds are prepared essentially according to the procedures described in Example 1 (10 g scale) and shown in Scheme 1:
[0031] (a) Benzyl(2-phenylthiocyclopentyl)amine (58% yield) (Compound 2);
[0032] (b) n-Propyl(2-phenylthiocyclopentyl)amine (45% yield) (Compound 3);
[0033] (c) (2-Methoxyethyl)-(2-phenylthiocyclopentyl)amine (62% yield) (Compound 4);
[0034] (d) Methyl(2-phenylthiocyclopentyl)amine (65% yield) (Compound 5);
[0035] (e) (3-Imidazol-1-ylpropyl)-(2-phenylthiocyclopentyl)amine (55% yield) (Compound 6).
[0036] The invention and the manner and process of making and using it, are now described in such full, clear, concise and exact terms as to enable any person skilled in the art to which it pertains, to make and use the same. It is to be understood that the foregoing describes preferred embodiments of the present invention and that modifications may be made therein without departing from the spirit or scope of the present invention as set forth in the claims. To particularly point out and distinctly claim the subject matter regarded as invention, the following claims conclude this specification.
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Disclosed is a one step method for preparing a β-substituted sulfide by treating a β-halosulfide with a nucleophile in water.
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The invention was made with Government support under Contract AR21-96MC-33089 awarded by the Department of Energy. The Government has certain rights in the invention.
FIELD OF THE INVENTION
The present invention pertains to substantially spherical, monodisperse sorptive particles, a method therefor, and a method of using the particles in loose form, in a column, or enmeshed in a web or membrane for extraction of metal ions, particularly radioactive forms of these ions, from solution. The method and particles are particularly useful in the remediation of nuclear wastes.
BACKGROUND OF THE INVENTION
The conventional method of preparing titanate particles suffers from two significant drawbacks. First, grinding the dried solids must be done carefully so as to minimize formation of unusable fines. Second, since a wide range of particle sizes results from grinding, the particulate must be sized through sieves. These operations are time-consuming and inevitably cause loss of product. Sized titanates can then be loaded into columns in order to remove metals from radioactive waste solutions.
Spray-drying of solid materials is a method known in the art for preparation of useful solids, including titanates, pigments, and food stuffs. See, for example, Kirk-Othmer Encyclopedia of Chemical Technology, 4th Ed., John Wiley & Sons, New York, 1993; Vol. 8, p. 475-519, particularly pp. 505-508; C. Strumillo and T. Kudra, "Drying: Principles, Applications and Design," Gordon and Breach, New York, 1986, pp. 352-359; and Masters, K., Spray Drying Handbook, 4 th Ed., John Wiley & Sons, New York, 1985; pp. 548-567, particularly pp. 549, 550 and 565.
Crystalline sodium nonatitanate has been disclosed as an ion exchanger for strontium in WO 97/14652. Certain binders are stated to be useful for binding the sodium nonatitanate into larger particles. Spray-drying is not disclosed.
In U.S. Pat. Nos. 4,138,336 and 5,128,291 spray-drying of porous titania in the presence of an inorganic binder is disclosed. Crystalline silicotitanates as ion exchangers have been disclosed in WO94/19277 and in Pacific Northwest National Laboratories publication PNL-8847, UC-510 (October 1993).
SUMMARY OF THE INVENTION
Briefly, the present invention provides a method of removing metal ions from solution comprising the steps of:
providing titanate particles by spray-drying a solution or slurry comprising titanate particles, preferably having a particle size up to 20 micrometers, optionally in the presence of an organic binder free of cellulose functionality, to produce monodisperse, substantially spherical sorbent titanate particles in a yield of at least 70 percent of theoretical yield and having an average particle size in the range of 1 to 100 micrometers, said titanate sorbents being active towards metals in Periodic Table (CAS version) Groups IA, IIA, IB, IIB, IIIB, and VIII, and
introducing the spray-dried titanate particles into a metal ion containing solution wherein the metal ions are as mentioned above, preferably any of Sr, Cs, Am, Pu, and U, equilibrated with the solution, and then separated from the sorbed and/or exchanged metal ions. The spray-dried particles can be in a loose form, or in agglomerated form, in a cartridge, or enmeshed in a porous membrane, matrix or web. The particles preferably are any of crystalline silicotitanate and sodium titanate particulates. Preferably, the web or matrix is porous.
The binder is preferably selected from polymers of olefins or acrylates. Preferably the sorbents are selected from the group consisting of silicotitanates and metal titanates, wherein the metal preferably is selected from Periodic Table (CAS version) Groups IA or IIA. More preferably, the sorbents are selected from the group consisting of cystalline silicotitanate (CST), and sodium titanate particles. The liquid in the solution or slurry can be aqueous or organic liquid.
In a further aspect, there are disclosed substantially spherical sorbent particles having an average particle size in the range of 1 to 100 micrometers, the particles being sorptive towards metals from Periodic Table (CAS version) Groups IA, IIA, IB, IIB, IIIB, and VIII. Preferably, the spherical particles can be crystalline silicotitanate, and sodium nonatitanate. The particles can be used in columns or beds to selectively remove heavy metal ions from Periodic Table Groups IA, IIA, IB, IIB, IIIB, and VIII, preferably any of Cs, Sr, Ag, Co, Cr, Au, Hg, U, Pu, Am, more preferably Sr, Cs, Am, Pu, and U, and other transuranic ions from aqueous solutions.
In a still further aspect, the spherical sorptive particles that have been spray-dried, optionally in the presence of olefin or acrylate polymeric binder, can be enmeshed in a nonwoven, fibrous web, matrix, or membrane. The webs or matrices or membranes, which preferably are porous, can be used in solid phase extraction (SPE) procedures to selectively remove metal ions from aqueous solutions by passing a solution of the metal ion through or by the particle loaded web, matrix, or membrane.
In yet another aspect, the invention provides an SPE device, such as a cartridge which in preferred embodiments can be pleated or spirally wound, comprising a fibrous non-woven SPE web comprising spherical, monodisperse particles which, in preferred embodiments, can be crystalline silicotitanate or sodium titanate particulate. In particular, the particulate can be enmeshed in the SPE web which preferably can comprise poly(m- or p-terephthalamide) fibers enclosed in the cartridge device. Preferably, the web is porous.
In another embodiment, the invention provides a method of removing the specified metal ions from an aqueous solution comprising passing the aqueous solution through an SPE column comprising spherical, monodisperse sorptive particles made by the method of this invention, the particles preferably being crystalline silicotitanate or sodium titanate particulate.
In this application:
"crystalline silicotitanate" can be designated CST;
"drain time" means the time required to dewater a slurry of particles and fibers when making a sheet;
"monodisperse" means a monomodal particle size distribution (i.e., particles of uniform size in a dispersed phase) about a mean in a range of 1 up to about 500 micrometers, preferably 1 to about 60 micrometers, as illustrated in FIG. 1;
"particles" and "particulate" are used interchangeably;
"size" means the diameter of a spherical particle or the largest dimension of an irregularly shaped particle;
"sodium titanate" includes "sodium nonatitanate";
"sorptive" or "sorb" means by one or both of absorption and adsorption and includes ion exchange;
"substantially spherical" means particles that are spherical, ovoid (having an elliptical cross-section), or toroidal, that are free of sharp corners; and
"web", "matrix", and "membrane" are used interchangeably and each term includes the others.
The overall process yield in making particles of the invention using a spray-dryer with a diameter of at least 1 m is at least 70 percent, preferably 80-90 percent or more, compared to a yield of about 60 percent or less when using prior art ground and sieved particles. Preferably, the resulting particles are free of submicron size particles, with not more than 15 percent of particles being <5 μm in size. The spray-drying process substantially eliminates product particles having submicron sizes.
Additionally, free-flowing spherical particles or agglomerates thereof will pack with point contact in columns, resulting in less channeling and a lower pressure drop during extraction compared with, for example, irregularly shaped prior art particles having the same average size. Irregularly shaped prior art particles, particularly those less than 5 micrometers in size can pack tightly and lead to a high pressure drop in extraction applications. When irregularly shaped prior art particles are greater than 50 micrometers in size, channeling can result as liquids pass through, resulting in poor separations.
It has been found that compacting the spray dried particles with low pressure (as by hand pressure) and then heating to about 130° C. for 72 hours results in a sponge-like (porous) shaped article having excellent separating ability without building back-pressure.
Further, the advantages of the particles of the invention in webs, matrices, or membranes include reduced drain time by a factor of at least three compared to non-spherical, irregularly shaped, prior art particles typically obtained from a grinding process, when incorporated in a sheet article.
Further, sheet articles can be made using particles of this invention, whereas in many cases sheet articles cannot be made in a timely fashion from prior art ground and sieved particles because of excessive drain time or inability to control the sheet forming process. The sheet articles formed from spray-dried particles often have lower flow resistance than sheet articles made from ground and screened particles and are therefor more efficient in use.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a graph of a monodisperse particle size distribution for typical spray-dried particles of the invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
In preferred embodiments, sorptive particles useful in the present invention include substantially spherical sorptive titanate particles of crystalline silicotitanate (CST), (available from UOP, Tarrytown, N.Y.) or sodium nonatitanate (available from AlliedSignal, Inc., Morristown, N.J.). These particles can be useful to sorb metal ions, preferably strontium (Sr), cesium (Cs), americium (Am), plutonium (Pu), uranium (U), and other transuranic elements which may be in their radioactive forms.
The commercially available CST or sodium titanate, which comprise particles of irregular shapes can be slurried with liquid, preferably water, and then spray-dried, optionally in the presence of an organic binder that is free of cellulose functionality and preferably is selected from olefin or acrylate polymers, preferably using a spinning disk atomizer, and then collecting the resulting substantially spherical titanate particles having a size distribution in the range of about 1 to 500 micrometers, preferably about 1 to 100 micrometers, more preferably 1 to 60 micrometers, and most preferably 5 to 20 micrometers. Spherical particles in the size range of about 100 to 500 micrometers can be useful in industrial separations.
In the process for providing a slurry of the sorptive particles of the invention, an organic binder, wherein more preferably the binder is selected from styrene butadiene copolymer, a vinylidene halide emulsion, an acrylic (co)polymer of acrylates and/or methacrylates, and an acrylic colloidal dispersion. The binder may facilitate production of the desired particles. An organic binder such as styrene polybutadiene copolymer (e.g., Goodrite™ 1800×73, from B. F. Goodrich Company, Brecksville, Ohio) preferably can be used.
Organic binders can be present in the slurry in an amount in the range of 5-50 weight percent, preferably 15-25 weight percent of the particles present.
In some instances the slurry can be sonicated to reduce or maintain particles in a submicron size range. It is preferred that the particles in the slurry not be dried prior to subjecting them to the spray drying technique. In addition, particles in a slurry that contain a binder can also desirably be mechanically agitated and preferably also sonicated as the slurry is pumped into the spray drying unit.
Spray-drying of the slurry can be accomplished using well-known techniques which include the steps of:
1) atomization, using a spinning disk, of the material introduced into the dryer;
2) removing of moisture as, for example, by contact of the material with hot gas; and
3) separation of dry product from the exhaust drying agent.
The slurry preferably has a solids content in the range of 3 to 15 percent by weight, more preferably 5 to 10 percent by weight, most preferably 5 to 7.5 percent by weight, to ensure smooth operation of the apparatus.
After spray-drying, the particles are free-flowing with most preferred average diameters in the range of 5-20 micrometers. The particle can be evaluated for its Ion exchange capacity (see Brown, G. N., Carson, K. J., DesChane, J. R., Elovich, R. J., and P. K. Berry. September 1996. Chemical and Radiation Stability of a Proprietary Cesium Ion Exchange Material Manufactured from WWL Membrane and Superlig™ 644. PNNL-11328, Pacific Northwest National Laboratory, Richland, Wash.) by testing for the batch distribution coefficient or K d which is described as follows:
The batch distribution coefficient, K d is an equilibrium measure of the overall ability of the solid phase ion exchange material to remove an ion from solution under the particular experimental conditions that exist during the contact. The batch K d is an indicator of the selectivity, capacity, and affinity of an ion for the ion exchange material in the presence of a complex matrix of competing ions. In most batch K d tests, a known quantity of ion exchange material is placed in contact with a known volume of solution containing the particular ions of interest. The material is allowed to contact the solution for a sufficient time to achieve equilibrium at a constant temperature, after which the solid ion exchange material and liquid supernate are separated and analyzed.
In this application, the batch K d values were determined in one procedure by contacting 0.10 g of the particle with 20 mL of TAN matrix, for 20 hours with shaking (see formulation below).
______________________________________TAN* Waste Simulant Composition Species Molarity (M)______________________________________ Ba 6.39E-7 Ca 1.36E-2** Cu 1.01E-6 Cr 8.11E-4 Fe 1.16E-6 Mg 3.87E-3** Na 6.10E-6 Pb 3.13E-5 Zn 1.20E-7 Sr 3.42E-5**______________________________________ *TAN means Test Area North, INEEL Department of Energy Installation, Idah Falls, ID **The concentration values for Sr and Ca in the Table above are for the determination of K.sub.d values only. For breakthrough curve data the concentrations for Sr, Ca, and Mg ions were changed to 3.42E-6, 1.36E-3, and 3.87E-4, respectively, see Example 27, below. Concentrations for othe ions remained constant in the solution.
In a second procedure, the batch K d values were determined by contacting 0.02 g of particle with 20 mL of liquid (Solution A) for 24 hours with shaking. Solution A comprised 0.1 M sodium hydroxide admixed with 5 M sodium nitrate containing 55 ppm Sr ion in deionized water.
The equation for determining the K d can be simplified by determining the concentration of the analyte before and after contact and calculating the quantity of analyte on the ion exchanger by difference. ##EQU1## Where: C I is the initial amount or activity of the ion of interest in the feed solution prior to contact,
C f is the amount or activity after contact,
V is the solution volume,
M is the exchanger mass,
F is the mass of dry ion exchanger divided by the mass of wet ion exchanger (F-factor).
K d (normal units are mL/g) represents the theoretical volume of solution (mL) that can be processed per mass of exchanger (dry weight basis) under equilibrium conditions.
More preferably, the experimental equipment that was required to complete the batch K d determinations included an analytical balance, a constant temperature water bath, an oven for F-factor determinations, a variable speed shaker table, 20-mL scintillation vials, 0.45 μm syringe filters, the appropriate ion exchanger, and simulant solutions. The particles were all dried thoroughly prior to testing. Approximately (0.10 g) or (0.02 g) of each material, respectively, was contacted with 20 mL of the TAN matrix or Solution A (respectively). The sample bottles were placed into a 25° C. constant temperature bath and shaken lightly for 20 hours or 24 hours, respectively. The samples were then filtered with a 0.45 micrometer syringe filter to separate the resin material from the solution and the resulting liquid was analyzed for strontium content by ICP (inductively coupled plasma).
The particles of the invention can be enmeshed in various fibrous, nonwoven webs or matrices, which perferably are porous. Types of webs or matrices include fibrillated polytetrafluoroethylene (PTFE), microfibrous webs, macrofibrous webs, and polymer pulps.
1. Fibrillated PTFE
The PTFE composite sheet material of the invention is prepared by blending the particulate or combination of particulates employed with a PTFE emulsion until a uniform dispersion is obtained and adding a volume of process lubricant up to approximately one half the volume of the blended particulate. Blending takes place along with sufficient process lubricant to exceed sorptive capacity of the particles in order to generate the desired porosity level of the resultant article. Preferred process lubricant amounts are in the range of 3 to 200 percent by weight in excess of that required to saturate the particulate, as is disclosed in U.S. Pat. No. 5,071,610, which are incorporated herein by reference. The aqueous PTFE dispersion is then blended with the particulate mixture to form a mass having a putty-like or dough-like consistency. The sorptive capacity of the solids of the mixture is noted to have been exceeded when small amounts of water can no longer be incorporated into the mass without separation. This condition should be maintained throughout the entire mixing operation. The putty-like mass is then subjected to intensive mixing at a temperature and for a time sufficient to cause initial fibrillation of the PTFE particles. Preferably, the temperature of intensive mixing is up to 90° C., preferably it is in the range of 0° to 90° C., more preferably 20° to 60° C. Minimizing the mixing at the specified temperature is essential in obtaining extraction media and chromatographic transport properties.
Mixing times will typically vary from 0.2 to 2 minutes to obtain the necessary initial fibrillation of the PTFE particles. Initial mixing causes partial disoriented fibrillation of a substantial portion of the PTFE particles.
Initial fibrillation generally will be noted to be at an optimum within 60 seconds after the point when all components have been fully incorporated into a putty-like (dough-like) consistency. Mixing beyond this point will produce a composite sheet of inferior extraction medium and chromatographic properties.
Devices employed for obtaining the necessary intensive mixing are commercially available intensive mixing devices which are sometimes referred to as internal mixers, kneading mixers, double-blade batch mixers as well as intensive mixers and twin screw compounding mixers. The most popular mixer of this type is the sigma-blade or sigma-arm mixer. Some commercially available mixers of this type are those sold under the common designations Banbury mixer, Mogul mixer, C. W. Brabender Prep mixer and C. W. Brabender sigma blade mixer. Other suitable intensive mixing devices may also be used.
The soft putty-like mass is then transferred to a calendering device where the mass is calendered between gaps in calendering rolls preferably maintained at a temperature up to 125° C., preferably in the range of 0° to about 100° C., more preferably in the range of 20° C. to 60° C., to cause additional fibrillation of the PTFE particles of the mass, and consolidation while maintaining the water level of the mass at least at a level of near the sorptive capacity of the solids, until sufficient fibrillation occurs to produce the desired extraction medium. Preferably the calendering rolls are made of a rigid material such as steel. A useful calendering device has a pair of rotatable opposed calendering rolls each of which may be heated and one of which may be adjusted toward the other to reduce the gap or nip between the two. Typically, the gap is adjusted to a setting of 10 millimeters for the initial pass of the mass and, as calendering operations progress, the gap is reduced until adequate consolidation occurs. At the end of the initial calendering operation, the resultant sheet is folded and then rotated 90° to obtain biaxial fibrillation of the PTFE particles. Smaller rotational angles (e.g., 20° to less than 90°) may be preferred in some extraction and chromatographic applications to reduce calender biasing, i.e., unidirectional fibrillation and orientation. Excessive calendering (generally more than two times) reduces the porosity which in turn reduces the solvent wicking in thin layer chromatography (TLC) and the flow-through rate in the filtration mode.
During calendering, the lubricant level of the mass is maintained at least at a level of exceeding the absorptive capacity of the solids by at least 3 percent by weight, until sufficient fibrillation occurs and to produce porosity or void volume of at least 30 percent and preferably 40 to 70 percent of total volume. The preferred amount of lubricant is determined by measuring the pore size of the article using a Coulter Porometer as described in the Examples below. Increased lubricant results in increased pore size and increased total pore volume as is disclosed in U.S. Pat. No. 5,071,610, the process of which is incorporated herein by reference.
The calendered sheet is then dried under conditions which promote rapid drying yet will not cause damage to the composite sheet or any constituent therein. Preferably drying is carried out at a temperature below 200° C. The preferred means of drying is by use of a forced air oven. The preferred drying temperature range is from 20° C. to about 70° C. The most convenient drying method involves suspending the composite sheet at room temperature for at least 24 hours. The time for drying may vary depending upon the particular composition, some particulate materials having a tendency to retain water more than others.
The resultant composite sheet preferably has a tensile strength when measured by a suitable tensile testing device such as an Instron (Canton, Mass.) tensile testing device of at least 0.5 MPa. The resulting composite sheet has uniform porosity and a void volume of at least 30 percent of total volume.
The PTFE aqueous dispersion employed in producing the PTFE composite sheet of the invention is a milky-white aqueous suspension of minute PTFE particles. Typically, the PTFE aqueous dispersion will contain about 30 percent to about 70 percent by weight solids, the major portion of such solids being PTFE particles having a particle size in the range of about 0.05 to about 0.5 micrometers. The commercially available PTFE aqueous dispersion may contain other ingredients, for example, surfactant materials and stabilizers which promote continued suspension of the PTFE particles.
Such PTFE aqueous dispersions are presently commercially available from Dupont de Nemours Chemical Corp., for example, under the trade names Teflon™ 30, Teflon™ 30B or Teflon™ 42. Teflon™ 30 and Teflon™ 30B contain about 59 percent to about 61 percent solids by weight which are for the most part 0.05 to 0.5 micrometer PTFE particles and from about 5.5 percent to about 6.5 percent by weight (based on weight of PTFE resin) of non-ionic wetting agent, typically octylphenol polyoxyethylene or nonylphenol polyoxyethylene. Teflon™ 42 contains about 32 to 35 percent by weight solids and no wetting agent but has a surface layer of organic solvent to prevent evaporation. A preferred source of PTFE is FLUON™, available from ICI Americas, Inc. Wilmington, Del. It is generally desirable to remove, by organic solvent extraction, any residual surfactant or wetting agent after formation of the article.
In other embodiments of the present invention, the fibrous membrane (web) can comprise non-woven, macro- or microfibers preferably selected from the group of fibers consisting of polyamide, polyolefin, polyester, polyurethane, glass fiber, polyvinylhalide, or a combination thereof. The fibers preferably are polymeric. (If a combination of polymers is used, a bicomponent fiber may be obtained.) If polyvinylhalide is used, it preferably comprises fluorine of at most 75 percent (by weight) and more preferably of at most 65 percent (by weight). Addition of a surfactant to such webs may be desirable to increase the wettability of the component fibers.
2. Macrofibers
The web can comprise thermoplastic, melt-extruded, large-diameter fibers which have been mechanically-calendered, air-laid, or spunbonded. These fibers have average diameters in the general range of 50 μm to 1,000 μm.
Such non-woven webs with large-diameter fibers can be prepared by a spunbond process which is well known in the art. (See, e.g., U.S. Pat. Nos. 3,338,992, 3,509,009, and 3,528,129, the fiber preparation processes of which are incorporated herein by reference.) As described in these references, a post-fiber spinning web-consolidation step (i.e., calendering) is required to produce a self-supporting web. Spunbonded webs are commercially available from, for example, AMOCO, Inc. (Napierville, Ill.).
Non-woven webs made from large-diameter staple fibers can also be formed on carding or air-laid machines (such as a Rando-Webber™ Model 12BS made by Curlator Corp., East Rochester, N.Y.), as is well known in the art. See, e.g., U.S. Pat. Nos. 4,437,271, 4,893,439, 5,030,496, and 5,082,720, the processes of which are incorporated herein by reference.
A binder is normally used to produce self-supporting webs prepared by the air-laying and carding processes and is optional where the spunbond process is used. Such binders can take the form of resin systems which are applied after web formation or of binder fibers which are incorporated into the web during the air laying process.
Examples of common binder fibers include adhesive-only type fibers such as Kodel™ 43UD (Eastman Chemical Products, Kingsport, Tenn.) and bicomponent fibers, which are available in either side-by-side form (e.g., Chisso ES Fibers, Chisso Corp., Osaka, Japan) or sheath-core form (e.g., Melty™ Fiber Type 4080, Unitika Ltd., Osaka, Japan). Application of heat and/or radiation to the web "cures" either type of binder system and consolidates the web.
Generally speaking, non-woven webs comprising macrofibers have relatively large voids. Therefore, such webs have low capture efficiency of small-diameter particulate (reactive supports) which is introduced into the web. Nevertheless, particulate can be incorporated into the non-woven webs by at least four means. First, where relatively large particulate is to be used, it can be added directly to the web, which is then calendered to actually enmesh the particulate in the web (much like the PTFE webs described previously). Second, particulate can be incorporated into the primary binder system (discussed above) which is applied to the non-woven web. Curing of this binder adhesively attaches the particulate to the web. Third, a secondary binder system can be introduced into the web. Once the particulate is added to the web, the secondary binder is cured (independent of the primary system) to adhesively incorporate the particulate into the web. Fourth, where a binder fiber has been introduced into the web during the air laying or carding process, such a fiber can be heated above its softening temperature. This adhesively captures particulate which is introduced into the web. Of these methods involving non-PTFE macrofibers, those using a binder system are generally the most effective in capturing particulate. Adhesive levels which will promote point contact adhesion are preferred.
Once the particulate (reactive supports) has been added, the loaded webs are typically further consolidated by, for example, a calendering process. This further enmeshes the particulate within the web structure.
Webs comprising larger diameter fibers (i.e., fibers which average diameters between 50 μm and 1,000 μm) have relatively high flow rates because they have a relatively large mean void size.
3. Microfibers
When the fibrous web comprises non-woven microfibers, those microfibers provide thermoplastic, melt-blown polymeric materials having active particulate dispersed therein. Preferred polymeric materials include such polyolefins as polypropylene and polyethylene, preferably further comprising a surfactant, as described in, for example, U.S. Pat. No. 4,933,229, the process of which is incorporated herein by reference. Alternatively, surfactant can be applied to a blown microfibrous (BMF) web subsequent to web formation. Polyamide can also be used. Particulate can be incorporated into BMF webs as described in U.S. Pat. No. 3,971,373, the process of which is incorporated herein by reference.
Microfibrous webs of the present invention have average fiber diameters up to 50 μm, preferably from 2 μm to 25 μm, and most preferably from 3 μm to 10 μm. Because the void sizes in such webs range from 0.1 μm to 10 μm, preferably from 0.5 μm to 5 μm, flow through these webs is not as great as is flow through the macrofibrous webs described above.
4. Cast Porous Membranes
Solution-cast porous membranes can be provided by methods known in the art. Such polymeric porous membranes can be, for example, polyolefin including polypropylene, polyamide, polyester, polyvinyl chloride, and polyvinyl acetate fibers.
5. Fibrous Pulps
The present invention also provides a solid phase extraction sheet comprising a porous fibrous pulp, preferably a polymeric pulp, comprising a plurality of fibers that mechanically entrap active particles, and preferably a polymeric hydrocarbon binder, the weight ratio of particles to binder being at least 13:1 and the ratio of average uncalendered sheet thickness to effective average particle diameter being at least 125:1.
Generally, the fibers that make up the porous polymeric pulp of the SPE sheet of the present invention can be any pulpable fiber (i.e., any fiber that can be made into a porous pulp). Preferred fibers are those that are stable to radiation and/or to a variety of pHs, especially very high pHs (e.g., pH=14) and very low pHs (e.g., pH=1). Examples include polyamide fibers and those polyolefin fibers that can be formed into a pulp including, but not limited to, polyethylene and polypropylene. Particularly preferred fibers are aromatic polyamide fibers and aramid fibers because of their stability to both radiation and highly caustic fluids. Examples of useful aromatic polyamide fibers are those fibers of the nylon family. Polyacrylic nitrile, cellulose, and glass can also be used. Combinations of pulps can be used.
Examples of useful aramid fibers are those fibers sold under the trade name Kevlar™ (DuPont, Wilmington, Del.). Kevlar™ fiber pulps are commercially available in three grades based on the length of the fibers that make up the pulp. Regardless of the type of fiber(s) chosen to make up the pulp, the relative amount of fiber in the resulting SPE sheet (when dried) ranges from about 12.5 percent to about 30 percent (by weight), preferably from about 15 percent to 25 percent (by weight).
Useful binders in the SPE sheet of the present invention are those materials that are stable over a range of pHs (especially high pHs) and that exhibit little or no interaction (i.e., chemical reaction) with either the fibers of the pulp or the particles entrapped therein. Polymeric hydrocarbon materials, originally in the form of latexes, have been found to be especially useful. Common examples of useful binders include, but are not limited to, natural rubbers, neoprene, styrene-butadiene copolymer, acrylate resins, and polyvinyl acetate. Preferred binders include neoprene and styrene-butadiene copolymers. Regardless of the type of binder used, the relative amount of binder in the resulting SPE sheet (when dried) is about 3 percent to about 7 percent, preferably about 5 percent. The preferred amount has been found to provide sheets with nearly the same physical integrity as sheets that include about 7 percent binder while allowing for as great a particle loading as possible. It may be desirable to add a surfactant to the fibrous pulp, preferably in small amounts up to about 0.25 weight percent of the composite.
In some cases the binder present in or on the particles from the spray-drying process was sufficient and no additional binder was necessary to make the SPE sheet.
Because the capacity and efficiency of the SPE sheet depends on the amount of particles included therein, high particle loading is desirable. The relative amount of particles in a given SPE sheet of the present invention is preferably at least about 65 percent (by weight), more preferably at least about 70 percent (by weight), and most preferably at least about 75 percent (by weight). Additionally, the weight percentage of particles in the resulting SPE sheet is at least 13 times greater than the weight percentage of binder, preferably at least 14 times greater than the weight percentage of binder, more preferably at least 15 times greater than the weight percentage of binder.
Regardless of the type or amount of the particles used in the SPE sheet of the present invention, they are mechanically entrapped or entangled in the fibers of the porous pulp. In other words, the particles are not covalently bonded to the fibers.
Objects and advantages of this invention are further illustrated by the following examples. The particular materials and amounts thereof, as well as other conditions and details, recited in these examples should not be used to unduly limit this invention.
EXAMPLES
Example 1
Crystalline Silicotitanate (CST) Bound with a Styrene Butadiene Emulsion (Goodrite™ 1800×73)
The material was prepared as follows: 0.80 g nonionic surfactant (Tergitol™ TMN-06, Union Carbide Corp., Danbury, Conn.) was dispersed in 2743 g deionized water with an air mixer. To this was then added 1282.8 g of ground crystalline silicotitanate (IONSIV IE 910™, UOP, Tarrytown, N.J.) (150 g, 11.7% solids) with agitation. Slowly to this was added 150.9 g of a styrene butadiene emulsion (Goodrite™ 1800×73 B. F. Goodrich, Brecksville, Ohio) (39% solids, 58.5 g) with stirring. This mixture was mixed for 1 hour with an air mixer. This slurry was then sonicated using a Branson Sonifier E Module™ ultrasonic generator Model EMW50-16 with sonication module Model WF-316 (Branson Ultrasonics Corporation, Danbury, Conn.) with a flow through rate of 175 mL/min. The material was then fed into the spray drier (Niro Atomizer, Serial number #2402, Model 68, Order No. 093-1413-00, Niro Atomizer, Inc., Columbia, Md.) at 35 mL/min. Spray drying conditions were as follows:
Inlet air temperature: 196° C.
Outlet Temperature: 74.5° C.
Slurry feed rate: 35 mL/min, 2.1 L/hour
Spinning disc air motor pressure: 400 KPa, (58 psig)
Cyclone Magnahelic pressure: 0.47 in H 2 O (1.19×10 -3 kg/cm 2 )
After spray drying the particle was dried in a vacuum oven for 24 hours at 130° C. and 709 Torr (28 inches Mercury vacuum) to remove all moisture. Recovered dried CST/Goodrite 1800×73 was observed under a scanning electron microscope (Cambridge model S240, LEO Electromicroscopy Inc., Thornwood, N.Y.,) to be mostly spherical in shape with some large agglomerates formed. Measurement of the particles using a Horiba Model LA-900 particle size analyzer (Horiba Instruments, Inc., Irvine, Calif.), showed the average particle size of approximately 29.78 micrometers with 0 percent of the particles less than 5 micrometers. The yield of bound CST was 72 percent.
Example 2
CST Bound with Styrene Butadiene Emulsion (Goodrite 1800×73)
The material was prepared by dispersing 0.80 g Tergitol TMN-06 in 1481 g deionized water with an air mixer. To this was then added 1159 g of ground crystalline silicotitanate (150 g, 13.0% solids) (IONSIV IE 910) with agitation. Slowly to this was added 150.1 g Goodrite 1800×73 (39% solids, 58.5 g) with stirring. This mixture was mixed for 1 hour with an air mixer. The slurry was spray dried using a Niro Atomizer, (Serial number #2402) at 35 mL/min. Spray drying conditions were as follows:
Inlet air temperature: 197° C.
Outlet Temperature: 81.1° C.
Slurry feed rate: 35 mL/min, 2.1 L/hour
Spinning disc air motor pressure: 400 KPa, (58 psig)
Cyclone Magnahelic pressure: 0.47 in H 2 O (1.19×10 -3 kg/cm 2 )
After spray drying the particle was dried in a vacuum oven for 24 hours at 130° C. and 709 Torr to remove all moisture. Recovered dried CST/Goodrite 1800×73 was observed under a scanning electron microscope (Cambridge model S240) to be spherical in shape with some large agglomerates formed. Measurement of the particles using a Horiba Model LA-900 particle size analyzer showed the average particle size of approximately 86.8 micrometers with 4.3 percent of the particles less than 5 micrometers. The yield of bound CST was 79 percent.
Example 3
CST
The material, 317 g crystalline silicotitanate powder (Ionsiv IE 910), was ground with 600 mL deionized water in a ball mill using zirconia media for 4 hours it was then reduced to 5% solids with 5740 mL deionized water. This mixture was mixed for 1 hour with a air mixer. The slurry was spray dried using a Niro Atomizer, (Serial number #2402) at 35 mL/min. Spray drying conditions were as follows:
Inlet air temperature: 200° C.
Outlet Temperature: 67.1° C.
Slurry feed rate: 35 mL/min, 2.1 L/hour
Spinning disc air motor pressure: 400 KPa, (58 psig)
Cyclone Magnahelic pressure: 0.47 in H 2 O (1.19×10 -3 kg/cm 2 )
After spray drying the particle was dried in a vacuum oven for 24 hours at 130° C. and 709 Torr to remove all moisture. Measurement of the particles using a Horiba Model LA-900 particle size analyzer showed the average particle size of approximately 15 micrometers with 5.5 percent of the particles less than 5 micrometers. The yield of CST was 93 percent.
Example 4
CST (Comparative)
Crystalline silicotitanate (Ionsiv IE 910, UOP, Tarrytown, N.J.) as received from the supplier had an average particle size (as determined using a Horiba LA-900 particle size analyzer) of 0.394 micrometers with 81% of the particle less than 5 micrometers. The particles as examined by scanning electron microscope (SEM) were predominately irregular in shape and consisted of particles and agglomerates.
Example 5
Sodium Titanate Bound with Styrene Butadiene Emulsion (Goodrite 1800×73)
This particle was prepared by dispersing 0.80 g Tergitol TMN-06 in 2743 g deionized water with an air mixer. To this was then added 1468.9 g of sodium nonatitanate (AlliedSignal, Morristown, N.J.) (150 g, 9.9% solids) with agitation. Slowly to this was added 150.1 g Goodrite 1800×73 (39% solids, 58.5 g) with stirring. This mixture was mixed for 1 hour with a air mixer. This slurry was then sonicated using a Branson Sonifier with a flow through rate of 175 mL/min. The material was then fed into the spray drier (Niro Atomizer, Serial number #2402) at 40 mL/min. Spray drying conditions were as follows:
Inlet air temperature: 196° C.
Outlet Temperature: 68.5° C.
Slurry feed rate: 40 mL/min, 2.4 L/hour
Spinning disc air motor pressure: 380 KPa, (55.1 psig)
Cyclone Magnahelic pressure: 0.47 in H 2 O (1.19×10 -3 kg/cm 2 )
After spray drying the particle was dried in a vacuum oven for 24 hours at 130° C. and 709 Torr to remove all moisture. Recovered dried sodium titanate/Goodrite 1800×73 was observed under a scanning electron microscope (Cambridge model S240) to be spherical in shape with some agglomerates formed. Measurement of the particles using a Horiba Model LA-900 particle size analyzer, showed the average particle size of approximately 41.2 micrometers with 14 percent of the particles less than 5 micrometers. The yield of bound sodium titanate was 84 percent.
Example 6
Sodium Titanate
A slurry of sodium nonatitanate purchased from AlliedSignal was mixed for 12 hour with a low shear air mixer. The material was then fed into the spray drier (Niro Atomizer, Serial number #2402) at 40 mL/min. Spray drying conditions were as follows:
Inlet air temperature: 200° C.
Outlet Temperature: 73.5° C.
Slurry feed rate: 40 mL/min, 2.4 L/hour
Spinning disc air motor pressure: 400 KPa, (58 psig)
Cyclone Magnahelic pressure: 0.47 in H 2 O (1.19×10 -3 kg/cm 2 )
After spray drying the particle was dried in a vacuum oven for 24 hours at 130° C. and 709 Torr to remove all moisture. Recovered dried sodium nonatitanate was observed under a scanning electron microscope (Cambridge model S240) to be spherical in shape. Measurement of the particles using a Horiba Model LA-900 particle size analyzer, showed the average particle size of approximately 11.8 micrometers with 8 percent of the particles less than 5 micrometers. The yield of sodium titanate was 91 percent.
Example 7
Sodium Titanate (Comparative)
Sodium nonatitanate (AlliedSignal, Morristown, N.J.) as received from the supplier had an average particle size (as determined using a Horiba LA-900 particle size analyzer) of 3.0 micrometers with 70% of the particle less than 5 micrometers in largest diameter. The particles as examined by scanning electron microscope were predominately irregular in shape with particles and agglomerates.
Example 8
Sodium Titanate Bound with a Heat Reactive Acrylic Copolymer Latex (Hycar™ 26138)
The particle was prepared by adding 1.21 g Tergitol TMN-06 into 2985 g sodium nonatitanate slurry (200 g, 6.7% solution) with an air mixer. Slowly to this was added 156 g Hycar 26138 (B. F. Goodrich, Cleveland, Ohio) a heat reactive acrylic copolymer latex (78 g, 50% solids) with stirring. This mixture was mixed until it was spray dried. The slurry was spray dried using a Niro Atomizer, (Serial number #2402) at 45 mL/min. Spray drying conditions were as follows:
Inlet air temperature: 200° C.
Outlet Temperature: 72.6° C.
Slurry feed rate: 45 mL/min, 2.7 L/hour
Spinning disc air motor pressure: 380 KPa, (55 psig)
Cyclone Magnahelic pressure: 0.43 in H 2 O (1.09×10 -3 kg/cm 2 )
After spray drying the particle was dried in a vacuum oven for 24 hours at 130° C. and 709 Torr to remove all moisture. Recovered dried sodium nonatitanate/Hycar 26138 was observed under a scanning electron microscope (Cambridge model S240) to be textured spheres which are mostly agglomerated together and some bonding between the particles. Measurement of the particles using a Horiba Model LA-900 particle size analyzer, showed the average particle size of approximately 38.7 micrometers with 0.5 percent of the particles less than 5 mircrometers. The yield of bound sodium titanate was 72 percent.
Example 9
Sodium Titanate Bound with a Vinylidene Chloride Emulsion (Permax™ 801)
The particle was prepared by adding 1.4 g Tergitol TMN-06 into 2985 g sodium nonatitanate slurry (200 g, 6.7% solution) with an air mixer. Slowly to this was added 135 g Permax 801 (B. F. Goodrich, Cleveland, Ohio) a vinylidene chloride emulsion (78 g, 57.5% solids) with stirring. This mixture was mixed until it was spray dried. The slurry was spray dried using a Niro Atomizer (Serial number #2402) at 45 mL/min. Spray drying conditions were as follows:
Inlet air temperature: 200° C.
Outlet Temperature: 72.2° C.
Spinning disc air motor pressure: 400 KPa, (58 psig)
Cyclone Magnahelic pressure: 0.47 in H 2 O (1.19×10 -3 kg/cm 2 )
After spray drying the particle was dried in a vacuum oven for 24 hours at 130° C. and 709 Torr to remove all moisture. Recovered dried sodium titanate/Permax 801 was observed under a scanning electron microscope (Cambridge model S240) to be agglomerates of smooth spheres with some particles bonded together. Measurement of the particles using a Horiba Model LA-900 particle size analyzer showed an average particle size of approximately 48.3 micrometers with 0 percent of the particles less than 5 micrometers. The yield of bound sodium titanate was 72 percent.
Example 10
Sodium Titanate Bound with a Waterborne Acrylic Resin (Maincote™ HG-54D
The particle was prepared by adding 1.2 g Tergitol TMN-06 into 3333 g sodium nonatitanate slurry (223 g, 6.7% solution) with an air mixer. Slowly to this was added 190.24 g Maincote HG-54D (Rohm and Haas, Philadelphia, Pa.) a waterborne acrylic resin (78 g, 41% solids) with stirring. This mixture was mixed until it was spray dried. The slurry was spray dried using a Niro Atomizer, (Serial number #2402) at 45 mL/min. Spray drying conditions were as follows:
Inlet air temperature: 200° C.
Outlet Temperature: 71.5° C.
Slurry feed rate: 45 mL/min, 2.7 L/hour
Spinning disc air motor pressure: 390 KPa, (57 psig)
Cyclone Magnahelic pressure: 0.47 in H 2 O (1.19×10 -3 kg/cm 2 )
After spray drying the particle was dried in a vacuum oven for 24 hours at 130° C. and 709 Torr to remove all moisture. Recovered dried sodium nonatitanate/Maincote HG-54D was observed under a scanning electron microscope (Cambridge model S240) to be textured spheres with some agglomeration with little bonding between the spheres. Measurement of the particles using a Horiba Model LA-900 particle size analyzer showed an average particle size of approximately 36.7 micrometers with 0 percent of the particles less than 5 micrometers. The yield of bound sodium titanate was 85 percent.
Example 11
Sodium Titanate Bound with an Acrylic Emulsion (Rhoplex™ Multilobe™ 200)
The particle was prepared by adding 1.2 g Tergitol TMN-06 into 3333 g sodium nonatitanate slurry (224 g, 6.7% solution) with an air mixer. Slowly to this was added 145.8 g Rhoplex Multilobe 200 (Rohm and Haas, Philadelphia, Pa.) an acrylic emulsion (78 g, 53.5% solids) with stirring. This mixture was mixed until it was spray dried. The slurry was spray dried using a Niro Atomizer, (Serial number #2402) at 45 mL/min. Spray drying conditions were as follows:
Inlet air temperature: 200° C.
Outlet Temperature: 75.1° C.
Slurry feed rate: 45 mL/min, 2.7 L/hour
Spinning disc air motor pressure: 390 KPa, (57 psig)
Cyclone Magnahelic pressure: 0.43 in H 2 O (1.09×10 -3 kg/cm 2 )
After spray drying the particle was dried in a vacuum oven for 24 hours at 130° C. and 709 Torr to remove all moisture. Recovered dried sodium titanate/Rhoplex Multilobe 200 was observed under a scanning electron microscope (Cambridge model S240) to be textured spheres that are mostly agglomerated together with bonding between the spheres. Measurement of the particles using a Horiba Model LA-900 particle size analyzer showed an average particle size of approximately 34.3 micrometers with 1 percent of the particles less than 5 micrometers. The yield of bound sodium titanate was 81 percent.
Example 12
Sodium Titanate Bound with Styrene Butadiene Emulsion (Goodrite 1800×73)
The particle was prepared by adding 1.92 g Tergitol TMN-06 into 6312 g sodium titanate slurry (278 g, 4.4% solution) with an air mixer. Slowly to this was added 278.5 g Goodrite 1800×73 a styrene butadiene emulsion (108.7 g, 39% solids) with stirring. This mixture was mixed until it was spray dried. The slurry was spray dried using a Niro Atomizer, (Serial number #2402) at 45 mL/min. Spray drying conditions were as follows:
Inlet air temperature: 200° C.
Outlet Temperature: 71.0° C.
Slurry feed rate: 45 mL/min, 2.7 L/hour
Spinning disc air motor pressure: 390 KPa, (57 psig)
Cyclone Magnahelic pressure: 0.47 in H 2 O (1.19×10 -3 kg/cm 2 )
After spray drying the particle was dried in a vacuum oven for 24 hours at 130° C. and 709 Torr to remove all moisture. Recovered dried sodium nonatitanate/Goodrite 1800×73 was observed under a scanning electron microscope (Cambridge model S240) to be spherical in shape with some agglomerates formed. Measurement of the particles using a Horiba Model LA-900 particle size analyzer, showed the average particle size of approximately 27.3 micrometers with 1.3 percent of the particles less than 5 micrometers. The yield of bound sodium titanate was 90 percent.
Example 13
(Comparative)
A particle filled porous web was prepared from the CST particles (unprocessed particles), as described in Example 4. Into a 4 L Waring™ Blendor™ was added 2000 ml of hot water, 0.25 g Tamol 850™ nonionic dispersant (Rohm and Haas Co, Philadelphia, Pa.); this was mixed for 30 seconds on low speed. Into the Blendor was then added 14.35 g of Kevlar™ 1F306 aramid pulp (83.5% solids, 12 g dry weight Dupont, Wilmington, Del.) and again this was mixed for 30 seconds. To this mixture was then added 169.2 g CST particles from Example 4 (26.6% solids, 45 g dry weight) and again mixed for 30 seconds. Next, 7.69 g Goodrite 1800×73 was added (39% solids, 3 g dry weight), and again mixed for 30 seconds. Then 20 g of 25% alum (aluminum sulfate in water) was added with mixing on low for an additional minute, to this was then added 1.2 g of an acrylamide modified cationic copolymer (1% Solution of Nalco™ 7530, Nalco Chemical Co, Chicago, Ill.) with mixing continuing for 4 seconds. The mixture was then poured into a Williams sheet mold (Williams Apparatus Co, Watertown, N.Y.) equipped with a 413 cm 2 porous screen having pores size 0.171 mm (80 mesh) at the bottom and allowed to drain, drain time was 135 seconds. The resulting wet sheet was pressed in a pneumatic press (Air Hydraulics Inc., Jackson, Mich.) at approximately 551 KPa for 5 minutes to remove additional water. Finally the porous web was dried on a Williams handsheet dryer (Williams Apparatus Co, Watertown, N.Y.) for 90 minutes at 100° C. Tensile strength was determined using a Thwing Albert Model QCII-XS electronic tensile tester (Thwing Albert Instrument Company, Philadelphia, Pa.) equipped with a 227 Kg load cell at 10% load range. The tensile strength was determined to be 6130 KPa with 133% elongation without break.
Example 14
A particle filled porous web was prepared as described in Example 13 using CST/Goodrite 1800×73 particles from Example 1. The drain time was 40 seconds. The tensile strength was determined with the Thwing Albert model QCII-XS electronic tensile tester to be 797 psig (5495 KPa) with 134% elongation without break.
Example 15
A particle filled porous web was prepared as described in Example 13 using CST particles from Example 2. The drain time was 135 seconds. The tensile strength was determined with the Thwing Albert model QCII-XS electronic tensile tester to be 697 psig (4805 KPa) with 95% elongation without break. Preferably, the CST particles are combined with a binder (see Example 14) to optimize the drain time of the web.
Example 16
A particle filled porous web was prepared from the CST/Goodrite 1800×73 particles from Example 2. Into a 4 L Waring™ Blendor™ was added 2000 ml of hot water and 0.25 g Tamol 850™ which was mixed for 30 seconds on low. Into the Waring Blendor was then added 14.35 g of Kevlar 1F306 aramid pulp (83.5% solids, 12 g dry weight) and again this was mixed for 30 seconds. To this mixture was then added 45 g CST/Goodrite 1800×73 particles from Example 2 (100% solids) and again mixed for 30 seconds. No additional binder, other than that in or on the particles, was used. The mixture was then poured into a Williams sheet mold equipped with a 413 cm 2 porous screen having pores size 0.171 mm (80 mesh) at the bottom and allowed to drain, drain time was 25 seconds. The resulting wet sheet was pressed in an Air Hydraulics pneumatic press at approximately 551 KPa for 5 minutes to remove additional water. Finally the porous web was dried on a Williams handsheet dryer for 90 minutes at 100° C. The strength tensile was determined with the Thwing Albert model QCII-XS electronic tensile tester to be 129 psig (889 KPa).
Example 17
(Comparative)
A particle filled porous web was prepared as described in Example 13 from the sodium titanate particles described in Example 7. The drain time was 720 seconds. The tensile strength was determined with the Thwing Albert model QCII-XS electronic tensile tester to be 1283 psig (8845 KPa) with 159% elongation without break.
Example 18
A particle filled porous web was prepared as described in Example 13 from the sodium titanate particles described in Example 6. The drain time was 20 seconds. The tensile strength was determined with the Thwing Albert model QCII-XS electronic tensile tester to be 110 psig (758 KPa).
Example 19
A particle filled porous web was prepared as described in Example 13 from the sodium titanate/Goodrite 1800×73 particles described in Example 5. The drain time was 35 seconds. The tensile was determined with the Thwing Albert model QCII-XS electronic tensile tester to be 910 psig (6247 KPa) with 136% elongation without break.
Example 20
A particle filled porous web was prepared using the sodium titanate/Goodrite 1800×73 particles described in Example 5. Into a 4 L Waring Blendor was added 2000 ml of hot water and 0.25 g Tamol 850™ which was mixed for 30 seconds on low. Into the Blendor was then added 14.35 g of Kevlar 1F306 aramid pulp (83.5% solids, 12 g dry weight) and again this was mixed for 30 seconds. To this mixture was then added 45 g sodium titanate/Goodrite 1800×73 particle (100% solids) and again mixed for 30 seconds. No additional binder, other than that in or on the particles, was used. The mixture was then poured into a Williams sheet mold equipped with a 413 cm 2 porous screen having pores size 0.171 mm (80 mesh) at the bottom and allowed to drain, drain time was 15 seconds. The resulting wet sheet was pressed in an Air Hydraulics pneumatic press at approximately 551 KPa for 5 minutes to remove additional water. Finally the porous web was dried on a Williams handsheet dryer for 90 minutes at 100° C. The tensile strength was determined with the Thwing Albert model QCII-XS electronic tensile tester to be 59 psig (406 KPa).
Example 21
A particle filled porous web was prepared using the sodium titanate/Goodrite 1800×73 particles described in Example 5. Into a 4 L Waring™ Blendor was added 2000 ml of hot water and 0.25 g Tamol 850™ which was mixed for 30 seconds on low. Into the Blendor was then added 14.35 g of Kevlar 1F306 aramid pulp (83.5% solids, 12 g dry weight) and again this was mixed for 30 seconds. To this mixture was then added 45 g sodium titanate/Goodrite 1800×73 particle (100% solids) and again mixed for 60 seconds. No additional binder, other than that in or on the particles, was used. To this was then added 20 g of 25% alum (aluminum sulfate in water useful as a coelescing) and mixed for 30 seconds. The mixture was then poured into a Williams sheet mold equipped with a 413 cm 2 porous screen having pores size 0.171 mm (80 mesh) at the bottom and allowed to drain, drain time was 40 seconds. The resulting wet sheet was pressed in an Air Hydraulics pneumatic press at approximately 551 KPa for 5 minutes to remove additional water. Finally the porous web was dried on a Williams handsheet dryer for 90 minutes at 100° C. The tensile strength was determined with the Thwing Albert model QCII-XS electronic tensile tester to be 220 psig (1516 KPa) with 153% elongation without break.
Example 22
A particle filled porous web was prepared as described in Example 13 from the sodium titanate/Hycar 26138 particles described in Example 8. The drain time was 180 seconds. The tensile strength was determined with the Thwing Albert model QCII-XS electronic tensile tester to be 592 psig (4081 KPa) with 98% elongation without break.
Example 23
A particle filled porous web was prepared as described in Example 13 from the sodium titanate/Permax 801 particles described in Example 9. The drain time was 40 seconds. The tensile strength was determined with the Thwing Albert model QCII-XS electronic tensile tester to be 504 psig (3475 KPa) with 103% elongation without break.
Example 24
A particle filled porous web was prepared as described in Example 13 from the sodium titanate/Maincote HG-54D particles described in Example 10. The drain time was 180 seconds. The tensile strength was determined with the Thwing Albert model QCII-XS electronic tensile tester to be 797 psig (5500 KPa) with 83% elongation without break.
Example 25
A particle filled porous web was prepared as described in Example 13 from the sodium titanate/Rhoplex Multilobe 200 particles described in Example 11. The drain time was 90 seconds. The tensile strength was determined with the Thwing Albert model QCII-XS electronic tensile tester to be 890 psig (6136 KPa) with 99% elongation without break.
Example 26
A particle filled porous web was prepared as described in Example 13 from the sodium titanate/Goodrite 1800×73 particles described in Example 12. The drain time was 35 seconds.
Example 27
Into a 8.3 cm by 3.1 cm diameter tube capped at one end with a rubber stopper was placed approximately 50 g of sodium titanate/Goodrite 1800×73 particle from Example 12, which had not been vacuum dried. The particle was compacted as much as possible using hand pressure and then placed in the vacuum oven and dried at 130° C. and 709 Torr for 72 hours. When the material was cooled and removed from the oven, the material retained the cylindrical shape and did stick together to form a sponge-like mass. The tube was then used as a column with the cylindrical dried particle being used in the column for separation. The cylindrical dried particles were preconditioned with 0.1 M NaOH/5M NaNO 3 with a flow rate of 30 mL/min for 30 min. Deionized water was then passed through the column at 30 mL for 10 min. The TAN matrix was then passed through the column at 30 mL/min. for 4 hours. This column was very efficient in removing Ca, Mg, and Sr ions from the TAN matrix: pressure was about 7 KPa There were no detectable Ca, Sr, or Mg ions in the effluent. It was unexpected that the small average particle size (27 μm) resulted in low back pressure without channeling and with excellent separation.
Example 28
Capacity data was obtained by running K d determination using two different solutions: 1) TAN matrix with 3 ppm Sr, 545 ppm Ca, and 195 ppm Mg; and 2) a solution of 55 ppm Sr in 0.1 molar sodium hydroxide and 5 molar sodium nitrate. Data are as follows:
TABLE 1______________________________________Tan Matrix (2.5 ppm Sr) Example Capacity K.sub.dParticle Id Number (g Sr/g particle) (mLg particle)______________________________________CST IE 910 (comparative) 4 0.000436 43200CST/Goodrite 1800 × 73 1 0.000454 45400CST/Goodrite 1800 × 73 2 0.000445 44500Sodium Titanate (compar- 7 0.000380 1600ative)Sodium Titanate/Goodrite 5 0.000359 7251800 × 73______________________________________
Capacities determined using Tan Matrix as in Table 1 and Table 2 show that the capacity of the spray dried particles as evaluated by K d determination did not deviate significantly from the starting material.
TABLE 2______________________________________Capacity and K.sub.d determination with TAN matrix (4 ppm Sr) Example Capacity K.sub.dParticle Id Number (g Sr/g particle) (mL/g particle)______________________________________CST IE 910 (comparative) 4 0.000766 7710CST/Goodrite 1800 × 73 2 0.000775 7750Sodium Titanate (compar- 7 0.000657 963ative)Sodium Titanate/Goodrite 5 0.000641 8591800 × 73Sodium Titanate/Hycar 8 0.000590 56326138Sodium Titanate/Permax 9 0.000493 328801Sodium Titanate/HG-54D 10 0.000620 689Sodium Titanate/ML-200 11 0.000625 738______________________________________
TABLE 3______________________________________Capacity and K.sub.d determination with 0.1M NaOH/5M NaNO.sub.3 (54 ppmSr) % Retention Capacity K.sub.d K.sub.d with Example (g Sr/g (mL/g binder/K.sub.dParticle Id No. Particle) particle) without binder______________________________________CST IE 910 4 0.0199 600(comparative)CST/Goodrite 2 0.00856 191 31.81800 × 73Sodium Titanate/ 5 0.00972 220 10Goodrite 1800 ×73Sodium Titanate 7 0.0363 2256(comparative)Sodium Titanate/ 8 0.0158 412 18Hycar 26138Sodium Titanate/ 9 0.01746 487 22Permax 801Sodium Titanate/ 10 0.0205 638 28HG-54DSodium Titanate/ 11 0.0125 306 13.6ML-200Sodium Titanate/ comparative 16,000no binder*Sodium Titanate/ comparative <300 <1.8cellulose acetate*Sodium Titanate/ comparative 1600 9.5processedcellulose acetate*______________________________________ *comparative sample as prepared in WO97/14652, Example 21.
TABLE 4______________________________________Capacity and K.sub.d determination with 0.1M NaOH/5M NaNO.sub.3 (57 ppmSr) % Retention Capacity K.sub.d K.sub.d spray Example (g Sr/g (mL/g dried/K.sub.d notParticle Id No. Particle) particle) spray dried______________________________________Sodium Titanate 7 0.0357 2820 --(comparative)Sodium Titanate 6 0.0432 4380 155(spray-dried, nobinder)______________________________________
The data of Tables 3 and 4 show that sodium titanate particles with binders according to the present invention retained more sorptive capacity towards strontium than comparative sodium titanate after processing particles with cellulose acetate as binder as disclosed in WO97/14652. (WO97/14652 discloses a multi-step process to increase porosity and % retention from 1.8 to 9.5.) The data of Table 4 also show an increase in sorptive capacity for the spray dried material without binder (Example 6) compared with sodium titantate that has not been spray dried.
Example 29
Tensile strengths were determined both wet and dry. The wet tensile was evaluated in two ways. The first evaluation involved soaking the sample for 7 days in deionized water, removing the sample from the water and blotting the surface dry prior to testing. The second wet tensile evaluation involved soaking the sample for 7 days in NCAW (neutralized current acid waste from Hanford, Wash., see formulation below). The sample was removed from the NCAW and rinsed with deionized water twice; the surface was then blotted dry prior to testing. The tensile strength was determined using a Thwing Albert Model QCII-XS electronic tensile tester (Thwing Albert Instrument Company, Philadelphia, Pa.) equipped with a 227 Kg load cell at 10% load range.
TABLE 5__________________________________________________________________________Tensile Strengths Dry versus Wet Wet Tensile strength Wet Tensile Dry Tensile (soaked 1 week (soaked 1 week Strength in deionized water) in NCAW waste) Example Tensile Strength Tensile Strength Tensile StrengthParticle Id No. (KPa) (KPa) (KPa)__________________________________________________________________________Sodium Titanate (compar- 17 8845 3373 2153ative)Sodium Titanate/Goodrite 19 6274 3192 29041800 × 73Sodium Titanate/Goodrite 20 406 209 1901800 × 73Sodium Titanate/Goodrite 21 1516 N/A N/A1800 × 73__________________________________________________________________________
The wet tensile strength, as expected, was lower than the dry tensile strength. The wet tensile strengths were very similar for both the deionized and NCAW samples. The most significant difference was for the sodium titanate comparative which had a difference of 64% between the two wet tensile strengths. The difference for the sodium titanate/Goodrite 1800×73 samples were both 91%. It is important to note that the retained strength even in NCAW, was sufficient for the material to perform as a usable SPE disk or cartridge.
______________________________________NCAW Waste Simulant Composition Species Molarity (M)______________________________________ Na 5.00 K 0.12 Rb 5.00E-5 Al 0.43 SO.sub.4 0.15 OH (total) 3.40 OH (free) 1.68 CO.sub.3 0.23 NO.sub.2 0.43 NO.sub.3 1.67 F 0.089 PO.sub.4 0.025 Cs 0.00051______________________________________
NCAW (Neutralized current acid waste) simulant is considered to be representative of Hanford (Wash.) tank wastes. In actual tanks the concentration of Cs ranges from 1.0E-2 to 1.0E-5 M as Cesium nitrate.
Various modifications and alterations of this invention will become apparent to those skilled in the art without departing from the scope and intent of this invention, and it should be understood that this invention is not to be unduly limited to the illustrative embodiments set forth herein.
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A method for removing metal ions from solution comprises the steps of providing titanate particles by spray-drying a solution or slurry comprising sorbent titanates having a particle size up to 20 micrometers, optionally in the presence of polymer free of cellulose functionality as binder, said sorbent being active towards heavy metals from Periodic Table (CAS version) Groups IA, IIA, IB, IIB, IIIB, and VIII, to provide monodisperse, substantially spherical particles in a yield of at least 70 percent of theoretical yield and having a particle size distribution in the range of 1 to 500 micrometers. The particles can be used free flowing in columns or beds, or entrapped in a nonwoven, fibrous web or matrix or a cast porous membrane, to selectively remove metal ions from aqueous or organic liquid.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application is based on and claims priority under 35 USC 119 from Japanese Patent Application No. 2013-169250 filed Aug. 16, 2013.
BACKGROUND
(i) Technical Field
The present invention relates to a data processing apparatus, a data processing method, and a non-transitory computer readable medium.
(ii) Related Art
In recent years, reconfigurable devices in which an internal circuit configuration may be dynamically reconfigured (dynamic reconfiguration devices) have been developed, and data processing apparatuses using a reconfigurable device have also been proposed.
SUMMARY
According to an aspect of the invention, there is provided a data processing apparatus including:
a reconfigurable circuit that has a dynamically-reconfigurable circuit configuration to execute data processing with the reconfigured circuit configuration;
a loading processor that loads reconfiguration data to a reconfiguration memory based on set loading information;
a reconfiguration processor that reconfigures the circuit configuration with the reconfiguration data loaded to the reconfiguration memory in response to a request from the reconfigurable circuit; and
a controller that executes a process of setting the loading information with respect to the loading processor while inhibiting the reconfiguration by invalidating the request, and validates the request after terminating the setting process to permit the reconfiguration.
BRIEF DESCRIPTION OF THE DRAWINGS
Exemplary embodiments of the present invention will be described in detail based on the following figures, wherein:
FIG. 1 is a diagram showing an appropriate data processing apparatus according to an exemplary embodiment of the invention;
FIG. 2 is a schematic diagram of a process related to the reconfiguration in the data processing apparatus of FIG. 1 ;
FIG. 3 is a timing chart of the reconfiguration by the data processing apparatus of FIG. 1 ;
FIG. 4 is a timing chart showing a process having scheduling of the reconfiguration by the data processing apparatus of FIG. 1 ;
FIG. 5 is a flowchart showing a control process executed by a control processor;
FIG. 6 is a flowchart showing a setting process executed by the control processor;
FIG. 7 is a diagram showing a specific example of a setting state of a self register; and
FIG. 8 is a diagram showing comparison results related to data processing time.
DETAILED DESCRIPTION
FIG. 1 is a diagram showing a configuration of an appropriate data processing apparatus according to an exemplary embodiment of the invention. The data processing apparatus of FIG. 1 (the present data processing apparatus) is provided with a reconfigurable circuit 10 , a reconfiguration memory 20 , a DRAM 30 , a self loader 40 , an autonomous reconfiguration controller 50 , an interrupt controller 60 , and a control processor 70 , and executes data processing necessary for processing target data.
The present data processing apparatus is realized by, for example, a dynamic reconfigurable processor (DRP) or the like. For example, when the present data processing apparatus is realized by DRP, FIG. 1 is a functional block diagram in the DRP.
The reconfigurable circuit 10 is a circuit in which an internal logic circuit configuration may be reconfigured dynamically, that is, during the operation of the circuit, and is provided with, for example, a circuit configuration part provided with many circuit elements (processor elements (PE)). The connection configuration between the circuit elements may be relatively rapidly reconfigured (recombined) according to reconfiguration data (configuration data), and the reconfigured circuit configuration part functions as a data processing circuit.
The circuit configuration part in the reconfigurable circuit 10 is reconfigured based on the reconfiguration data stored in the reconfiguration memory 20 . The reconfiguration memory 20 may store one or more pieces of reconfiguration data. In the specific example shown in FIG. 1 , three pieces of reconfiguration data are stored in the reconfiguration memory 20 .
Many pieces of reconfiguration data used in the present data processing apparatus are stored in the DRAM 30 , and the reconfiguration data stored in the DRAM 30 is loaded to the reconfiguration memory 20 by the self loader 40 .
The self loader 40 is provided with a self register, and the reconfiguration data stored in the DRAM 30 is loaded to the reconfiguration memory 20 based on the information necessary for loading set in the self register (loading information).
The autonomous reconfiguration controller 50 reconfigures the circuit configuration part of the reconfigurable circuit 10 with the reconfiguration data loaded to the reconfiguration memory 20 in response to a request from the reconfigurable circuit 10 , that is, an interrupt signal for requesting the reconfiguration. The interrupt signal output from the reconfigurable circuit 10 is sent to the autonomous reconfiguration controller 50 through the interrupt controller 60 .
The control processor 70 performs intensive control in the present data processing apparatus. The control processor 70 is composed of, for example, hardware that realizes a calculation function and the like and software (control program) that regulates the operation of the hardware, and realizes control related to the present data processing apparatus with cooperation between the hardware and the software.
The function of the control processor 70 may be realized by a computer. In that case, a data processing program (control program) corresponding to the function of the control processor 70 is stored in a computer readable storage medium such as a disk and a memory, and is provided to a computer through the storage medium. The program may be provided to a computer through a telecommunication line such as the internet. In addition, the same function as the control processor 70 is realized with cooperation between a hardware resource such as a CPU and a memory of a computer and the provided program (software). Furthermore, the function may be partially or completely realized with a computer using, for example, a program corresponding to some or all of the functions of the self loader 40 , the autonomous reconfiguration controller 50 , and the interrupt controller 60 .
Favorable specific examples of the data processed by the present data processing apparatus include image data. For example, image data is provided from an external apparatus such as a computer to the present data processing apparatus, and is sent to the reconfigurable circuit 10 through a device and the like (not shown). The present data processing apparatus may be assembled in an image processing apparatus having an image reading function (scan function) and the like to process, with the reconfigurable circuit 10 , image data obtained from a medium such as paper through the function. An image corresponding to the image data after the process may be printed on paper or the like, or the image data after the process may be provided to an external apparatus.
The image data is just an appropriate specific example that may be processed in the present data processing apparatus, and it is obvious that the present data processing apparatus may process data other than the image data. For example, the present data processing apparatus may be equipped in an information processing apparatus, an information processing terminal, audio/visual equipment, an electric appliance, a vehicle, or the like so as to be used in various data processings, controls, and the like.
The outline of the present data processing apparatus is as described above. Next, a process and the like to be executed by the present data processing apparatus will be described in detail. Regarding the configuration (part) shown in FIG. 1 , the reference numerals in FIG. 1 will be used in the following description.
FIG. 2 is a schematic diagram of a process related to the reconfiguration in the present data processing apparatus. The present data processing apparatus reconfigures a data processing circuit necessary for processing of data in the reconfigurable circuit 10 , and processes the data using the reconfigured data processing circuit. The timing chart of FIG. 2 shows the outline of the process related to the reconfiguration in the present data processing apparatus.
In the timing chart shown in FIG. 2 , first, the control processor 70 performs setting of a self register SR, change of a parameter P, and setting of an interrupt register IR as initial setting before start of data processing.
The self register SR is a register of the self loader 40 , and information necessary for loading of reconfiguration data from the DRAM 30 to the reconfiguration memory 20 by the self loader 40 (loading information) is set in the self register SR. The self loader 40 is provided with, for example, eight self registers SR#0 to SR#7, and for each self register SR, loading information of reconfiguration data corresponding to the self register SR is set. The loading information of the reconfiguration data includes, for example, information such as an address of the reconfiguration data, a data size of the reconfiguration data, and a loading order of the reconfiguration data. In the specific example shown in FIG. 2 , loading information is set in each of three self registers SR#0 to SR#2 among the eight self registers SR#0 to SR#7 in the initial setting.
The number of the self registers SR may not be eight. In addition, the number of the self registers SR to be initially set is also not limited to three. However, for example, the number of the self registers SR to be initially set is desirably the same as the number of pieces of reconfiguration data that may be loaded to the reconfiguration memory 20 .
The parameter P is information related to processing target data of a data processing circuit that is realized by reconfiguration data. For example, an address of the processing target data, a size of the data, and the like are set as the parameter P. The parameter P is set for each reconfiguration data set in the self register SR. For example, in the initial setting, when loading information of reconfiguration data #0 to #2 is set in the respective self registers SR#0 to SR#2, parameters P#0 to P#2 corresponding to the respective pieces of reconfiguration data #0 to #2 are set.
The interrupt register IR is a register of the interrupt controller 60 , and mask setting (interrupt inhibition) and mask release (interrupt permission) are registered in the interrupt register IR with respect to an interrupt signal output from the reconfigurable circuit 10 . Mask registration is performed for each reconfiguration data set in the self register SR in the interrupt register IR. For example, in the initial setting, when loading information of reconfiguration data #0 to #2 is set in the respective self registers SR#0 to SR#2, mask setting (interrupt inhibition) is set with respect to interrupt registers IR#0 to IR#2 corresponding to the respective pieces of reconfiguration data #0 to #2. Accordingly, the reconfiguration from the circuit configuration corresponding to the respective pieces of reconfiguration data #0 to #2 to the next circuit configuration is temporarily inhibited.
In the initial setting, when completing the setting of the self register SR, the change of the parameter P, and the setting of the interrupt register IR, the control processor 70 issues an instruction to start the execution of data processing by the reconfigurable circuit 10 .
When an instruction is issued to start the execution of data processing, the self loader 40 loads reconfiguration data from the DRAM 30 to the reconfiguration memory 20 in accordance with the loading information set in the self register SR. In the specific example shown in FIG. 2 , in the initial setting, since the loading information is set in the three self registers SR#0 to SR#2, the self loader 40 executes loading #0 to #2 in accordance with the respective pieces of loading information in order of the self registers SR#0 to SR#2, and thus three pieces of reconfiguration data #0 to #2 are sequentially loaded to the reconfiguration memory 20 . When loading information, of which the number is the same as the number of pieces of reconfiguration data that may be loaded to the reconfiguration memory 20 , is initially set in the self register SR, the self loader 40 may sequentially load, to the reconfiguration memory 20 , all of the pieces of reconfiguration data initially set.
When the loading #0 is executed by the self loader 40 and the reconfiguration data #0 is loaded to the reconfiguration memory 20 , the circuit configuration part of the reconfigurable circuit 10 is reconfigured as a data processing circuit #0 of the reconfiguration data #0, and the data processing circuit #0 executes data processing #0.
When the data processing #0 by the data processing circuit #0 is terminated, the reconfigurable circuit 10 outputs an interrupt signal requesting the reconfiguration. The interrupt signal output from the reconfigurable circuit 10 is sent to the autonomous reconfiguration controller 50 through the interrupt controller 60 . However, in the initial setting, since the interrupt register IR#0 corresponding to the reconfiguration data #0 is subjected to mask setting (interrupt inhibition), the interrupt signal associated with the termination of the data processing #0 corresponding to the reconfiguration data #0 is subjected to mask processing, and thus the interrupt signal is not sent to the autonomous reconfiguration controller 50 , and the reconfiguration is temporarily inhibited.
The control processor 70 performs setting of the self register SR, change of the parameter P, and setting of the interrupt register IR in a period in which the interrupt associated with the termination of the data processing #0 is inhibited, that is, a #0 interrupt inhibition period shown in FIG. 2 .
That is, with respect to reconfiguration data #3 following the reconfiguration data #0 to #2 set previously in the initial setting, the control processor 70 sets loading information of the reconfiguration data #3 in the self register SR#3, sets a parameter P#3 of the reconfiguration data #3, and registers mask setting (interrupt inhibition) of the reconfiguration data #3 in an interrupt register IR#3.
When the setting of the self register SR, the change of the parameter P, and the setting of the interrupt register IR related to the reconfiguration data #3 are terminated, the control processor 70 releases the mask of the interrupt register IR#0 related to the reconfiguration data #0. Accordingly, the mask of the interrupt signal associated with the termination of the data processing #0 corresponding to the reconfiguration data #0 is released.
After the release of the mask of the interrupt signal associated with the termination of the data processing #0, when an interrupt signal is output from the reconfigurable circuit 10 , that is, when an interrupt signal requesting the reconfiguration is output from the reconfigurable circuit 10 in a #0 interrupt permission period shown in FIG. 2 , the interrupt signal is sent to the autonomous reconfiguration controller 50 through the interrupt controller 60 .
When the interrupt signal is sent, the autonomous reconfiguration controller 50 reconfigures the circuit configuration part of the reconfigurable circuit 10 with the reconfiguration data #1 loaded to the reconfiguration memory 20 in response to the request from the reconfigurable circuit 10 . Accordingly, the circuit configuration part of the reconfigurable circuit 10 is reconfigured as a data processing circuit #1 corresponding to the reconfiguration data #1, and the data processing circuit #1 executes data processing #1.
In addition, when the circuit configuration part of the reconfigurable circuit 10 is reconfigured as the data processing circuit #1, the self loader 40 loads the reconfiguration data #3 from the DRAM 30 to a region where the reconfiguration data #0 of the reconfiguration memory 20 has been stored, that is, a region that may be set in association with the termination of the data processing #0.
Although the circuit configuration part of the reconfigurable circuit 10 is reconfigured as the data processing circuit #1 and the data processing circuit #1 executes the data processing #1, the interrupt register IR#1 corresponding to the reconfiguration data #1 is subjected to mask setting (interrupt inhibition) in the initial setting. Accordingly, the interrupt signal associated with the termination of the data processing #1 corresponding to the reconfiguration data #1 is subjected to mask processing, and thus the interrupt signal is not sent to the autonomous reconfiguration controller 50 , and the reconfiguration is temporarily inhibited.
The control processor 70 performs setting of the self register SR, change of the parameter P, and setting of the interrupt register IR in a period in which the interrupt associated with the termination of the data processing #1 is inhibited, that is, a #1 interrupt inhibition period shown in FIG. 2 .
That is, with respect to reconfiguration data #4 following the reconfiguration data #3 set previously, the control processor 70 sets loading information of the reconfiguration data #4 in the self register SR#4, sets a parameter P#4 of the reconfiguration data #4, and registers mask setting (interrupt inhibition) of the reconfiguration data #4 in an interrupt register IR#4.
When the setting of the self register SR, the change of the parameter P, and the setting of the interrupt register IR related to the reconfiguration data #4 are terminated, the control processor 70 releases the mask of the interrupt register IR#1 related to the reconfiguration data #1. Accordingly, the mask of the interrupt signal associated with the termination of the data processing #1 corresponding to the reconfiguration data #1 is released.
After the release of the mask of the interrupt signal associated with the termination of the data processing #1, when an interrupt signal is output from the reconfigurable circuit 10 , that is, when an interrupt signal requesting the reconfiguration is output from the reconfigurable circuit 10 in a #1 interrupt permission period shown in FIG. 2 , the interrupt signal is sent to the autonomous reconfiguration controller 50 through the interrupt controller 60 . When the interrupt signal is sent, the autonomous reconfiguration controller 50 reconfigures the circuit configuration part of the reconfigurable circuit 10 in response to the request from the reconfigurable circuit 10 .
Although omitted in the drawing, data processings #2, #3, #4, etc. corresponding to the reconfiguration data #2, #3, #4, etc., respectively, are sequentially executed after the data processing #1. In addition, an interrupt signal associated with the termination of each data processing is subjected to mask setting to inhibit the reconfiguration, and the control processor 70 performs setting of the self register SR, change of the parameter P, and setting of the interrupt register IR during the execution of each data processing.
FIG. 3 is a timing chart of the reconfiguration (dynamic autonomous reconfiguration) by the present data processing apparatus. First, the control processor 70 performs setting of the self registers SR#0 to SR#2, change of the parameters P#0 to P#2, and setting of the interrupt registers IR#0 to IR#2 as initial setting before start of data processing. In the setting of the interrupt registers IR#0 to IR#2, interrupt mask (#0 to #2) setting is performed for each of the registers (IR#0 to IR#2). When the initial setting is terminated, the control processor 70 issues an instruction to start the data processing.
When the instruction is issued to start the data processing, the self loader 40 loads reconfiguration data #0 to #2 in this order from the DRAM 30 to the reconfiguration memory 20 , based on the loading information set in each of the self registers SR#0 to SR#2.
When the reconfiguration data #0 is loaded to the reconfiguration memory 20 , the circuit configuration part of the reconfigurable circuit 10 is reconfigured as the data processing circuit #0 corresponding to the reconfiguration data #0, and the data processing circuit #0 executes the data processing #0. When the data processing #0 is started, the reconfigurable circuit 10 outputs a processing start signal indicating the start. The processing start signal is sent to the control processor 70 through the interrupt controller 60 .
The control processor 70 receiving the processing start signal sets information related to the reconfiguration data #3 following the reconfiguration data #0 to #2 set previously in the initial setting. That is, the control processor 70 sets loading information of the reconfiguration data #3 in the self register SR#3, sets a parameter P#3 of the reconfiguration data #3, and sets an interrupt mask #3 in the interrupt register IR#3. When the setting of the information related to the reconfiguration data #3 is terminated, the control processor 70 releases the interrupt mask #0 of the interrupt register IR#0.
When the data processing #0 is terminated, the reconfigurable circuit 10 outputs, to the interrupt controller 60 , an interrupt signal indicating the termination. The interrupt controller 60 subjects the interrupt signal to mask processing so that the interrupt signal of the data processing #0 is not output to the autonomous reconfiguration controller 50 in a period in which the interrupt mask #0 corresponding to the data processing #0 is set. When the interrupt mask #0 corresponding to the data processing #0 is released, the interrupt controller 60 outputs the interrupt signal of the data processing #0 to the autonomous reconfiguration controller 50 .
In the specific example shown in FIG. 3 , since the interrupt mask #0 is released at the time when the reconfigurable circuit 10 outputs an interrupt signal 1 of the data processing #0, the interrupt signal 1 is sent from the interrupt controller 60 to the autonomous reconfiguration controller 50 without being subjected to mask processing.
The autonomous reconfiguration controller 50 receiving the interrupt signal 1 of the data processing #0 reconfigures the circuit configuration part of the reconfigurable circuit 10 as the data processing circuit #1 corresponding to the reconfiguration data #1 with the reconfiguration data #1 loaded to the reconfiguration memory 20 . The reconfigured data processing circuit #1 executes data processing #1. When the data processing #1 is started, the reconfigurable circuit 10 outputs a processing start signal indicating the start. The processing start signal is sent to the control processor 70 through the interrupt controller 60 .
The control processor 70 receiving the processing start signal sets information related to the reconfiguration data #4 following the reconfiguration data #3 set previously. That is, the control processor 70 sets loading information of the reconfiguration data #4 in the self register SR#4, sets a parameter P#4 of the reconfiguration data #4, and sets an interrupt mask #4 in the interrupt register IR#4. When the setting of the information related to the reconfiguration data #4 is terminated, the control processor 70 releases the interrupt mask #1 of the interrupt register IR#1.
When the data processing #1 is terminated, the reconfigurable circuit 10 outputs, to the interrupt controller 60 , an interrupt signal indicating the termination. The interrupt controller 60 subjects the interrupt signal to mask processing so that the interrupt signal of the data processing #1 is not output to the autonomous reconfiguration controller 50 in a period in which the interrupt mask #1 corresponding to the data processing #1 is set. When the interrupt mask #1 corresponding to the data processing #1 is released, the interrupt controller 60 outputs the interrupt signal of the data processing #1 to the autonomous reconfiguration controller 50 .
In the specific example shown in FIG. 3 , since the interrupt mask #1 is set at the time when the reconfigurable circuit 10 outputs a first interrupt signal 1 and a second interrupt signal 2 related to the data processing #1, the interrupt signal 1 and the interrupt signal 2 are subjected to mask processing. At the time when a third interrupt signal 3 related to the data processing #1 is output, the interrupt mask #1 is released, and thus the interrupt signal 3 is sent from the interrupt controller 60 to the autonomous reconfiguration controller 50 without being subjected to mask processing.
Although omitted in FIG. 3 , the reconfiguration and data processing based on data subsequent to the reconfiguration data #2 are sequentially executed.
According to the process shown in FIG. 3 , for example, in a period in which the control processor 70 executes setting of the self register SR of the self loader 40 and change of the parameter P, the interrupt signal from the reconfigurable circuit 10 is subjected to mask processing, and thus the reconfiguration during the setting of the self register SR and the change of the parameter P is avoided. Therefore, for example, in the execution of plural data processings, during the execution of each data processing, the setting of the self register SR and the change of the parameter P related to the next data processing may be performed. Accordingly, for example, in the initial setting before the execution of plural data processings, a change in the order of the data processings, the change of the parameter P, and the like are dealt with flexibly, compared to a case in which the setting of the self register SR and the change of the parameter P are performed in relation to all of the data processings.
In addition, according to the process shown in FIG. 3 , for example, even when the number of the self registers SR is limited (for example, to eight), self registers SR that may be reset after the use of the loading information may be cyclically used. Therefore, the reconfiguration may be continued plural times (without limitation in theory) without being limited by the number of the self registers SR.
FIG. 4 is a timing chart showing a process having scheduling of the reconfiguration by the present data processing apparatus. As described above using FIG. 3 , the control processor 70 performs setting of the self registers SR#0 to SR#2, change of the parameters P#0 to P#2, and setting of the interrupt registers IR#0 to IR#2 as initial setting before start of data processing. When the initial setting is terminated, the control processor 70 issues an instruction to start the data processing. The timing chart of FIG. 4 shows a process after the control processor 70 issues an instruction to start the data processing.
When the instruction is issued to start the data processing, the self loader 40 loads reconfiguration data #0 to #2 in this order from the DRAM 30 to the reconfiguration memory 20 , based on the loading information set in each of the self registers SR#0 to SR#2.
When the reconfiguration data #0 is loaded to the reconfiguration memory 20 , the circuit configuration part of the reconfigurable circuit 10 is reconfigured as the data processing circuit #0 corresponding to the reconfiguration data #0, and the data processing circuit #0 executes the data processing #0. When the data processing #0 is started, the reconfigurable circuit 10 outputs a processing start signal indicating the start. The processing start signal is sent to the control processor 70 through the interrupt controller 60 .
The control processor 70 receiving the processing start signal related to the data processing #0 predicts a processing time of the data processing #0, and determines whether the completion of the setting of information related to reconfiguration data #3 is possible within the processing time. When determining that the completion of the setting is possible, the control processor 70 sets loading information of the reconfiguration data #3 in the self register SR#3, sets a parameter P#3 of the reconfiguration data #3, and sets an interrupt mask #3 in the interrupt register IR#3.
When the setting of the information related to the reconfiguration data #3 is terminated, the control processor 70 determines whether the completion of the setting of information related to reconfiguration data #4 is possible within the processing time of the data processing #0. When determining that the completion of the setting is possible, the control processor 70 sets loading information of the reconfiguration data #4 in the self register SR#4, sets a parameter P#4 of the reconfiguration data #4, and sets an interrupt mask #4 in the interrupt register IR#4.
When the setting of the information related to the reconfiguration data #4 is terminated, the control processor 70 determines whether the completion of the setting of information related to reconfiguration data #5 is possible within the processing time of the data processing #0. When determining that the completion of the setting is not possible, the control processor 70 does not set the information related to the reconfiguration data #5, but temporarily terminates the setting process to release the interrupt mask #0 of the interrupt register IR#0.
In the process shown in FIG. 4 , when it is determined that the completion of the setting of information related to reconfiguration data is possible within the processing time of the data processing, the information related to the reconfiguration data is set (setting of the self register SR and the like), and thus the setting may be completed within the processing time of the data processing. In addition, when it is determined that the setting is possible within the processing time of the data processing, information related to plural pieces of reconfiguration data (for example, self registers SR#3, SR#4, and the like) may be set.
When the data processing #0 is terminated, the reconfigurable circuit 10 outputs, to the interrupt controller 60 , an interrupt signal indicating the termination. The interrupt controller 60 subjects the interrupt signal to mask processing so that the interrupt signal of the data processing #0 is not output to the autonomous reconfiguration controller 50 in a period in which the interrupt mask #0 corresponding to the data processing #0 is set. When the interrupt mask #0 corresponding to the data processing #0 is released, the interrupt controller 60 outputs the interrupt signal of the data processing #0 to the autonomous reconfiguration controller 50 .
In the specific example shown in FIG. 4 , since the interrupt mask #0 is released at the time when the reconfigurable circuit 10 outputs the interrupt signal of the data processing #0, the interrupt signal is sent from the interrupt controller 60 to the autonomous reconfiguration controller 50 without being subjected to mask processing.
The autonomous reconfiguration controller 50 receiving the interrupt signal of the data processing #0 reconfigures the circuit configuration part of the reconfigurable circuit 10 as the data processing circuit #1 corresponding to the reconfiguration data #1 with the reconfiguration data #1 loaded to the reconfiguration memory 20 . Then, the reconfigured data processing circuit #1 executes data processing #1. When the data processing #1 is started, the reconfigurable circuit 10 outputs a processing start signal indicating the start. The processing start signal is sent to the control processor 70 through the interrupt controller 60 .
The control processor 70 receiving the processing start signal related to the data processing #1 predicts a processing time of the data processing #1, and determines whether the completion of the setting of the information related to the reconfiguration data #5 is possible within the processing time. When determining that the completion of the setting is not possible, the control processor 70 does not set the information related to the reconfiguration data #5, but temporarily terminates the setting process to release the interrupt mask #1 of the interrupt register IR#1.
When the data processing #1 is terminated, the reconfigurable circuit 10 outputs, to the interrupt controller 60 , an interrupt signal indicating the termination. In the specific example shown in FIG. 4 , since the interrupt mask #1 is released at the time when the reconfigurable circuit 10 outputs the interrupt signal of the data processing #1, the interrupt signal is sent from the interrupt controller 60 to the autonomous reconfiguration controller 50 without being subjected to mask processing, and the next reconfiguration is immediately executed.
In the process shown in FIG. 4 , when it is determined that the completion of the setting of loading information and the like related to reconfiguration data is not possible within the processing time of the data processing, the setting related to the reconfiguration data is not performed, and the setting process is temporarily terminated to release the interrupt mask so that the reconfiguration is permitted. Therefore, the standby time of the reconfigurable circuit 10 that is generated due to the inhibition of the reconfiguration is shortened, compared to a case in which the loading information and the like are set regardless of the fact that the setting of the loading information and the like may not be completed within the processing time of the data processing.
FIG. 5 is a flowchart showing the control process executed by the control processor 70 (the process realized by a control program). The control processor 70 is composed of, for example, hardware that realizes a calculation function and the like and software (control program) that regulates the operation of the hardware, and executes the control process shown in the flowchart of FIG. 5 with cooperation between the hardware and the software. Hereinafter, processes in the respective steps in the flowchart of FIG. 5 will be described.
The control processor 70 performs setting of the self registers SR#0 to SR#2, change of the parameters P#0 to P#2, and setting of the interrupt masks #0 to #2 as initial setting (S 501 ). When the initial setting is terminated, the control processor 70 issues an instruction to start data processing (S 502 ).
When the instruction is issued to start the data processing, the self loader 40 loads reconfiguration data, and the circuit configuration part of the reconfigurable circuit 10 is reconfigured to start the data processing. When the data processing started, the reconfigurable circuit 10 outputs a processing start signal indicating the start (see FIGS. 3 and 4 ).
When the output of the processing start signal is confirmed (S 503 ), the control processor 70 executes a setting process related to the reconfiguration data (S 504 ).
FIG. 6 is a flowchart showing the setting process (process in S 504 of FIG. 5 ) executed by the control processor 70 .
In the setting process, first, the control processor 70 confirms a setting state of the self register SR (S 601 ). That is, the control processor 70 confirms a number (#X) of a self register SR in which the setting is completed and a number (#Y) of a self register SR that is currently being executed, and initializes a variable i to 1.
FIG. 7 is a diagram showing a specific example of the setting state of the self register SR. In the specific example shown in FIG. 7 , the number of the self registers SR is eight (SR#0 to SR#7), and the number of pieces of reconfiguration data capable of being loaded to the reconfiguration memory 20 is three.
In the specific example shown in FIG. 7 , the self register SR#3 is currently being executed. That is, reconfiguration data corresponding to the loading information set in the self register SR#3 is loaded to the reconfiguration memory 20 , and the reconfigurable circuit 10 is reconfigured with the reconfiguration data.
In addition, the setting of the self registers SR#4 and SR#5 is completed. That is, loading information is previously set in each of the self registers SR#4 and SR#5, and reconfiguration data corresponding to the loading information is being loaded (is being loaded or has been loaded) to the reconfiguration memory 20 .
The setting of other self registers SR#0 to SR#2, SR#6, and SR#7 is possible. That is, no loading information is set or loading information used previously is set in each of the self registers SR#0 to SR#2, SR#6, and SR#7, and the setting of new loading information therein is possible.
In the setting state shown in FIG. 7 , the number (#X) of a self register SR in which the setting is completed is #5 (X=5), and the number (#Y) of a self register SR that is currently being executed is #3 (Y=3).
When the data processing related to the reconfiguration data corresponding to the self register SR#3 is terminated, the reconfigurable circuit 10 is reconfigured with the reconfiguration data corresponding to the self register SR#4. The self register SR#4 becomes currently executed, and the setting of the self register SR#3 becomes possible. Furthermore, when the data processing related to the reconfiguration data corresponding to the self register SR#4 is terminated, the reconfigurable circuit 10 is reconfigured with the reconfiguration data corresponding to the self register SR#5. The self register SR#5 becomes currently executed, and the setting of the self register SR#4 becomes possible. In addition, new loading information is sequentially set in a self register SR in which the setting is possible. Accordingly, although the number of the self registers SR is limited (for example, to eight), self registers SR that may be reset after the use of the loading information may be cyclically used. Therefore, the reconfiguration may be continued plural times (without limitation in theory) without being limited by the number of the self registers SR.
Returning to FIG. 6 , when confirming the setting state of the self register SR, the control processor 70 confirms whether there is a setting margin (S 602 ). The setting margin is a numerical value that decides a safety factor C that is used later in the calculation of a prediction processing time A. For example, the number of self registers SR in which the setting is completed corresponds to the setting margin. For example, in the setting state shown in FIG. 7 , the number of self registers SR in which the setting is completed is two, and the setting margin is two.
In S 602 of FIG. 6 , when the setting margin is confirmed and there is no setting margin (the setting margin is zero), the control processor 70 executes a setting process related to reconfiguration data #X+1 with respect to the self register SR (S 603 ). When there is no setting margin, there is no self register SR#X in which the setting is completed. Thus, for example, the number #Y of a self register SR that is currently being executed is changed into #X, and the setting process related to the reconfiguration data #X+1 is executed for the next self register SR#X+1 (X=Y). The setting process related to the reconfiguration data #X+1 includes setting of loading information of the reconfiguration data #X+1 in the self register SR#X+1, setting of a parameter P#X+1 of the reconfiguration data #X+1, and setting of an interrupt mask #X+1 in an interrupt register IR#X+1.
When the setting process related to the reconfiguration data #X+1 is executed, the control processor 70 confirms whether an interrupt signal is output from the reconfigurable circuit 10 (S 604 ). When the interrupt signal is output, that is, when the reconfigurable circuit 10 requests the reconfiguration, the setting process shown in FIG. 6 is terminated, and the process proceeds to S 505 of FIG. 5 to release the mask related to the interrupt signal. Accordingly, the reconfiguration of the reconfigurable circuit 10 is permitted.
In S 604 of FIG. 6 , when the interrupt signal is not output, the control processor 70 predicts a processing time of the data processing that is currently being executed by the reconfigurable circuit 10 (S 605 ). That is, the control processor 70 calculates a prediction processing time A based on the following expression.
Prediction Processing Time( clk )=output data(byte)×circuit performance( clk /byte)×safety factor C Expression 1
The output data represents the size (byte) of data that is a target of the data process that is currently being executed, and the circuit performance represents a time (clk) for processing 1-byte data by the circuit that is currently executing the data processing.
The safety factor C is a factor set according to the setting margin, that is, the number of self registers SR in which the setting is completed. The larger the setting margin, the smaller the safety factor C, and a short prediction processing time A is estimated. Specifically, for example, when the setting margin is 4, the safety factor C is 0.6, when the setting margin is 3, the safety factor C is 0.7, when the setting margin is 2, the safety factor C is 0.8, when the setting margin is 1, the safety factor C is 0.9, and when the setting margin is 0, the safety factor C is 1.0.
When the safety factor C is used, for example, in a case in which the setting margin is relatively large, and thus the number of self registers SR in which the setting is completed is relatively large, the safety factor C is reduced, and thus a relatively short prediction processing time A is estimated, whereby a setting process (S 610 ) related to reconfiguration data #X+i to be described later is not forcibly performed. In contrast, when the setting margin is relatively small, and thus the number of self registers SR in which the setting is completed is relatively small, the safety factor C is increased, and thus a relatively long prediction processing time A is estimated, whereby the setting process (S 610 ) related to the reconfiguration data #X+i is performed as frequently as possible within the processing time of the data processing by the reconfigurable circuit 10 .
When calculating the prediction processing time A, the control processor 70 predicts a remaining processing time based on the calculated prediction processing time A (S 606 ). That is, the control processor 70 subtracts a setting time B (X+1) from the prediction processing time A to modify the prediction processing time A to a remaining processing time A. The setting time (X+1) is a time required for the setting related to the reconfiguration data #X+1 in S 603 .
Next, the control processor 70 increases the variable i by 1, and further predicts a remaining processing time (S 608 ). That is, the control processor 70 subtracts a setting time B(X+i), that is, a setting time B(X+2) from the remaining processing time A obtained in S 606 to modify the remaining processing time A. The setting time B(X+i) is a time required for the setting related to the reconfiguration data #X+i that will be set next time.
The control processor 70 determines whether to continue the setting process based on the remaining processing time A obtained in S 608 (S 609 ). When the value of the remaining processing time A obtained in S 608 is a negative value (A<0), the control processor 70 determines that the setting process will not be continued, and when the value of the remaining processing time A obtained in S 608 is not a negative value (A≧0), the control processor 70 determines that the setting process will be continued.
Regardless of the value of the remaining processing time A obtained in S 608 , the control processor 70 determines that the setting process will not be continued when the interrupt signal is output from the reconfigurable circuit 10 , and even when there is no self register SR in which the setting is possible (that is, when X+i=Y), the control processor 70 determines that the setting process will not be continued. When the setting process is not continued, the setting process shown in FIG. 6 is terminated and the process proceeds to S 505 of FIG. 5 .
When the setting process is continued, the control processor 70 executes the setting process related to the reconfiguration data #X+i with respect to the self register SR (S 610 ). The setting process related to the reconfiguration data #X+i includes setting of loading information of the reconfiguration data #X+i in the self register SR#X+i, setting of a parameter P#X+i of the reconfiguration data #X+i, and setting of an interrupt mask #X+i in an interrupt register IR#X+i.
Next, after increasing the variable i by 1, the control processor 70 returns to S 608 to further predict a remaining processing time. That is, the control processor 70 subtracts a setting time B(X+i) from the remaining processing time A obtained in the previous S 608 to modify the remaining processing time A. The setting time B(X+i) is a time required for the setting related to the reconfiguration data #X+i that will be set next time. Furthermore, the control processor 70 determines whether to continue the setting process in S 609 . Until determining that the setting process will not be continued in S 609 , the control processor 70 repeatedly executes the setting related to the reconfiguration data #X+i of S 610 to perform the setting as many times as possible in relation to plural pieces of reconfiguration data within the processing time of the data processing that is currently being executed by the reconfigurable circuit 10 .
Returning to S 602 , when the setting margin is confirmed and there is a setting margin (the setting margin is 1 or larger), the control processor 70 predicts a processing time of the data processing that is currently being executed by the reconfigurable circuit 10 (S 607 ). That is, the control processor 70 calculates a prediction processing time A based on the Expression 1 used also in S 605 .
Furthermore, the control processor 70 predicts a remaining processing time based on the calculated prediction processing time A (S 608 ). That is, the control processor 70 subtracts a setting time B (X+i) from the prediction processing time A to modify the prediction processing time A to a remaining processing time A. The setting time B (X+i) is a time required for the setting related to the reconfiguration data #X+i that will be set next time.
The control processor 70 executes processes after S 609 described above. That is, in S 609 , until determining that the setting process will not be continued, the control processor 70 repeatedly executes the setting related to the reconfiguration data #X+i of S 610 to perform the setting as many times as possible in relation to plural pieces of reconfiguration data within the processing time of the data processing that is currently being executed by the reconfigurable circuit 10 .
Returning to FIG. 5 , when the setting process (see FIG. 6 ) in S 504 is terminated, the control processor 70 releases the interrupt mask related to the data processing that is currently being executed by the reconfigurable circuit 10 (S 505 ). Accordingly, when the reconfiguration of the reconfigurable circuit 10 is permitted and an interrupt signal is output from the reconfigurable circuit 10 , the autonomous reconfiguration controller 50 reconfigures the circuit configuration part of the reconfigurable circuit 10 , and thus a state in which the next data processing is possible is obtained.
The control processor 70 confirms whether data processing for final data of the processing target data is completed (S 506 ). When the data processing is not completed, the control processor 70 executes the processes after S 503 again. When the data processing for the final data of the processing target data is completed, the control process shown in FIG. 5 is terminated.
FIG. 8 is a diagram showing comparison results related to the data processing time. FIG. 8 illustrates a graph of simulation results related to the processing time when dynamic autonomous reconfiguration (see FIG. 3 ) is performed in the present data processing apparatus and illustrates a graph of simulation results related to the processing time when dynamic autonomous reconfiguration (see FIGS. 4 to 6 ) with scheduling is performed.
As a comparative example, a graph of measured values related to the processing time when reconfiguration control by the control processor is performed without performing dynamic autonomous reconfiguration is provided. The reconfiguration control by the control processor is control for performing the reconfiguration data loading and the reconfiguration of the reconfigurable circuit 10 by the control processor 70 without using neither the self loader 40 nor the autonomous reconfiguration controller 50 .
In each graph, “reconfigurable circuit” represents a processing time of the reconfigurable circuit 10 , “control processor” represents a processing time of the control processor 70 , and “others” represents a time for processes other than the processes of the reconfigurable circuit 10 and the control processor 70 . In each graph, the sum of “reconfigurable circuit”, “control processor”, and “others” is a total processing time.
Processing target data and data processing are common to all of the three graphs respectively corresponding to the comparative example, the dynamic autonomous reconfiguration, and the dynamic autonomous reconfiguration with scheduling. Accordingly, the processing time (actual operation time) of the reconfigurable circuit 10 is the same in the three graphs.
Regarding the processing time of the control processor 70 , marked differences are shown in the three graphs. That is, in the reconfiguration control by the control processor, the control processor 70 performs a reconfiguration process every when the circuit configuration of the reconfigurable circuit 10 is changed, whereby the processing time of the control processor 70 is relatively long.
In the dynamic autonomous reconfiguration, the autonomous reconfiguration controller 50 performs a reconfiguration process, and thus the processing time of the control processor 70 is greatly reduced (reduced substantially by half in the example of FIG. 8 ), compared to the reconfiguration control by the control processor.
In the dynamic autonomous reconfiguration, it is necessary to perform setting of the self register SR, change of the parameter P, and setting of the interrupt register IR. However, a time for both of the setting of the self register SR and the setting of the interrupt register IR is just 1 microsecond (μs) or shorter, and a time for the change of the parameter P is approximately 10 μs, whereby these are extremely shorter than the total processing time (for example, several tens of seconds). Particularly, in the dynamic autonomous reconfiguration with scheduling, since setting of the self register and the like (setting of the self register SR, change of the parameter P, and setting of the interrupt register IR) are performed within the processing time of the reconfigurable circuit 10 , an increase in the processing time associated with the setting of the self register and the like is suppressed, and the total processing time is further shortened.
The appropriate exemplary embodiments of the invention have been described as above. However, the above-described exemplary embodiments are just examples in all respects, and the scope of the invention is not limited thereto. The invention includes various modifications without departing from the gist of the invention.
The foregoing description of the exemplary embodiments of the present invention has been provided for the purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise forms disclosed. Obviously, many modifications and variations will be apparent to practitioners skilled in the art. The embodiments were chosen and described in order to best explain the principles of the invention and its practical applications, thereby enabling others skilled in the art to understand the invention for various embodiments and with the various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the following claims and their equivalents.
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Provided is a data processing apparatus including a reconfigurable circuit that has a dynamically-reconfigurable circuit configuration to execute data processing with the reconfigured circuit configuration, a loading processor that loads reconfiguration data to a reconfiguration memory based on set loading information, a reconfiguration processor that reconfigures the circuit configuration with the reconfiguration data loaded to the reconfiguration memory in response to a request from the reconfigurable circuit, and a controller that executes a process of setting the loading information with respect to the loading processor while inhibiting the reconfiguration by invalidating the request, and validates the request after terminating the setting process to permit the reconfiguration.
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This invention relates to an electrical apparatus and system for training an animal to remain confined within a defined area without human interference.
BACKGROUND OF THE INVENTION
One known method for training an animal not to leave a prescribed area is to give the animal an electric shock as the animal approaches the boundary line defining the perimeter of the prescribed area. There are several known devices which apply an electric shock to train an animal. Some operate manually under the direct supervision of a trainer and others operate under radio control or in response to a particular behavior of the animal.
A system which operates to apply an electric shock to an animal based upon sensing the intensity of an electric field generated about a current carrying wire conductor surrounding the area in which the animal is to be confined is taught in U.S. Pat. No. 3,753,421. In accordance with the teaching in this patent, an electric antenna in the form of a wire is used to define the perimeter of the restricted area. AC current is passed through the wire to generate an electromagnetic field around the wire at sub-broadcast band frequency. A receiver is attached to the collar of the animal tuned to the frequency of this field. The receiver has an electric circuit which senses the intensity of the electromagnetic field and generates a high voltage when the detected signal strength exceeds a predetermined level corresponding to a desired fixed distance from the wire. The high voltage causes an electric shock.
The system described in the aforementioned patent suffers from a number of significant deficiencies which restrict its usefulness in terms of both its operation and practicality. One principal drawback of the system places a limitation on the geometry of the restricted area to basically that of a circle. The reason for this is due to how the system operates. The receiver circuit senses the level of field strength, i.e., the intensity of the field at the location of the receiver. Since the receiver is attached to the animal an electric shock will be generated each time the detected intensity is above a predetermined magnitude. Accordingly, the system is very sensitive to the magnitude of the electric current in the wire. If the area defined by the electrical wire is not circular but is rather of an irregular shape, the electromagnetic field intensity will not be uniform along the wire. As a result, the field strength will vary in magnitude particularly around sharp turns and corners or where the wire is looped close to itself. Since the receiver operates in response to field intensity, a variation in signal strength will vary the distance at which the receiver generates the electric shock. For a rectangular geometry, the electromagnetic field from the sides are additive thereby substantially doubling the signal strength near the corners. The field strength is thus shape dependent and for some irregular shapes the field may be caused to subtract near the wire conductor. Equally significant is the fact that the signal strength will also vary due to interference from any metal object lying in the vicinity of the wire. Moreover, since the magnitude of the electrical current in the wire controls the intensity of the field, the operator must also be careful to maintain the applied power to the wire at a constant level.
In addition, the system taught in the aforementioned patent operates to exponentially increase the generated voltage as the animal continues to approach the wire which exponentially increases the shock level. In practice, the animal almost momentarily receives a full power shock unless the animal is slowly walking toward the wire. A sudden application of a full shock operates as a severe punishment which bewilders the animal and leads to a confused state of behavior.
OBJECTS OF THE INVENTION
It is accordingly, the principal object of the present invention to provide a training apparatus and system for restricting the freedom of movement of an animal without human interference by the controlled application of an electric shock preferably in combination with a high pitched signal at a frequency audible to the animal.
It is a further object of the present invention to provide the electric shock in response to an electrical signal proportional to the position of the animal relative to the perimeter of the area in which the animal is to be confined with the electrical signal being substantially independent of the current intensity in the wire generating the electromagnetic field.
SUMMARY OF THE INVENTION
In accordance with the preferred embodiment of the present invention, the system operates to control the movement of an animal relative to an area defined by the location of an electrical conductor through which an AC current is passed by generating an electric shock from a receiver mounted upon the animal when the animal approaches the conductor with the receiver comprising first coil means for sensing the strength of the magnetic field generated about the electrical conductor along a first plane substantially parallel to the ground second coil means for sensing the strength of the magnetic field generated about the electrical conductor along a second plane vertically intersecting the first plane; control signal means for comparing the signal strength in said first and second coil means and means responsive to said control signal means for generating a high voltage when the signals received in said first and second coil are related to each other in a given proportion. Accordingly, the receiver operates independent of the absolute value of the current intensity in the electrical conductor and avoids all of the problems indicated above relative to sensing the field directly from the intensity of current in the wire.
In a second embodiment of the present invention the system operates to control the movement of an animal relative to an area defined by the location of an electrical conductor through which an AC current is passed with the system including means for generating an electric shock in response to a given position of the animal relative to the perimeter of the defined area and/or means for generating a high pitched sound audible to the animal as the animal approaches the electrical conductor.
DRAWINGS
Other objects and advantages of the present invention will become apparent from the following detailed description of the present invention when read in conjunction with the accompanying drawings of which:
FIG. 1 is a perspective view of a residential home bounded by a current carrying wire conductor which defines a controlled area for confining a dog by means of a receiver attached to the dog and responsive to a magnetic field generated about the current carrying wire conductor;
FIG. 2 is a diagrammatic view, in side elevation, illustrating the relationship of the magnetic field generated from the current carrying wire conductor of FIG. 1 and a pair of coil means in the receiver of FIG. 1 for detecting the position of the receiver relative to the wire conductor in accordance with the present invention;
FIG. 3 is a graphical illustration of the relationship between the induced signals received in each coil in the receiver of FIG. 1 and the position of each coil relative to the position of the wire conductor; and
FIG. 4 is an electrical circuit diagram of the receiver of FIG. 1.
DETAILED DESCRIPTION OF THE INVENTION
To control the freedom of movement of an animal in accordance with the present invention, a receiver with means for generating a high pitched sound and/or a high voltage is mounted on the animal. The receiver operates to detect the position of the animal relative to the position of a current carrying conductor for activating the high pitched sound and/or the high voltage in a predetermined manner.
Referring now to FIG. 1 of the drawings in which a dog 5 is shown having a receiver 16 affixed to the dog 5 preferably by attaching it to the dog's collar 4 preferably below the neck of the dog 5. An AC power transmitter (not shown) may be located in any convenient indoor location such as the garage of a house 1. The transmitter is powered from a household AC outlet of, e.g., 115 volts AC. A current carrying wire conductor with two ends 9 and 10 is connected from the house transmitter with the ends 9 and 10 laid out around the house to form a closed loop of any desired shape or geometry in which the dog 5 is to be confined. The two ends 9 and 10 of the wire are preferably interwound in a twisted arrangement along the front walk of the house for the purpose of effectively cancelling out the magnetic field generated around each conductor 9 and 10 along the front walk area. At a desired boundary point 11 the two conductors 9 and 10 separate to encircle the house 1. The conductors 9 and 10 are laid above ground level or are buried beneath the surface to a shallow depth. The AC transmitter generates an AC current through each conductor 9 and 10 at a suitable transmitting frequency generally in the sub-broadcast range.
The receiving device 16 is a miniature compact battery operated electronic device which senses the magnetic field generated by the current carrying wire conductors 9 and 10 in such a way as to be independent of the absolute value of the intensity of the current through either conductor. This is accomplished using two sensing coils 18 and 20 which are oriented transverse to each other. Sensing coil 18 is preferably aligned along a substantially horizontal plane parallel to ground level whereas sensing coil 20 is aligned substantially vertically. The position of the coils 18 and 20 shown in FIG. 2 at an arbitrary position of the dog 5 relative to the wire conductor 10. Since the receiver 16 is mounted on the collar of the dog 5 it is above ground at a level based on the height of the dog 5.
The wire conductor 10 generates an electromagnetic field 22 indicated by concentric circles which intersect the coils 18 and 20 and induce signals which vary in amplitude from one another based upon their respective orientation and their position relative to the wire conductor. A graphical display of the amplitude versus distance for each coil is shown in FIG. 3.
The magnitude of the signal induced in each coil 18 and 20 is proportional to the strength of the magnetic field at a given distance and to the amount of magnetic flux intersecting its cross section. At a fixed distance the signal is maximum when the magnetic field is perpendicular to its cross section and zero when it is tangential. In the position shown in FIG. 2, the horizontal coil 18 picks up a larger signal than the vertical coil 20. When the two coils 18 and 20 are exactly above the wire 10, the induced signal V in the vertical coil 20 as indicated in FIG. 3 is at maximum while the induced signal H in the horizontal coil 18 is zero. The signal H induced in the horizontal coil 18 is zero. The signal H induced in the horizontal coil 18 increases slowly and gradually as the receiver 16 is brought closer to the wire 10 and then, abruptly, drops to zero when the coil 18 is exactly above the wire. Conversely, the signal V induced in the vertical coil 20 will not be detectable until the device is brought relatively close to the wire 10 and then it will increase steeply, reaching its maximum value when the receiver 16 is exactly above the wire 10. Although the amplitude of each signal received by the coils 18 and 20 is proportional to the intensity of the current in the wire, their relative relationship, such as their ratio, will be independent of the current intensity in the wire. For instance, the point where the two curves intersect will always be at point A. At this point, the horizontal and vertical distance from the receiver 16 to the wire 10 are equal. At this location, each coil 18 and 20 in the receiver 16 makes an included angle with the wire 10 of 45 degrees.
The signals received by the coils 18 and 20 may be used in a variety of ways to generate a high pitched sound and to control the application of an electric shock to the animal 12 independent of the absolute value of the current intensity in the wire 10. Preferably, the electric shock should be applied within region B of FIG. 3 which can be varied by changing the proportion between the signals induced in coils 18 and 20. Once again, this is independent of the current intensity in the wire 10. The relationship between the signals induced in coils 18 and 20 determines when the electric shock is delivered corresponding to a desired location from the wire 10.
The coils 18 and 20 are in an electrical circuit 25 mounted in the receiver 16 for generating the electric shock. The schematic diagram for the electric circuit 25 is shown in FIG. 4. The circuit 25 is powered by a 6-volt miniature battery 26.
The magnetic field generated about the wire conductor 10 is sensed simultaneously by the horizontal coil 18 and the vertical coil 20 respectively. The coils 18 and 20 are tuned to respond to a desired frequency by capacitors C-1 and C-10. The induced signal in coil 18 is amplified in amplifier circuits 27 and 28 containing transistors Q-1 and Q-2 and the induced signal in coil 20 is amplified in amplifier circuits 29 and 30, containing transistors Q-8 and Q-9. The amplifiers 29 and 30 for coil 20 are substantially identical to amplifiers 27 and 28 for coil 18. A voltage doubler circuit 32 is formed by transistor Q-3 diode D-1 and capacitors C-4 and C-6.
A second voltage doubler 34 is formed by transistor Q-4 with diode D-2 and capacitors C-5 and C-7. The output of the first voltage doubler 32 at the emitter 33 of transistor Q-3 drives transistor Q-5. Transistor Q-5 operates as a power switch for turning "on" or "off" a voltage to frequency converter 36. The voltage to frequency converter 36 is a conventional circuit which includes transistors Q-6 and Q-7. A speaker S is disposed between the collectors of transistors Q-6 and Q-7 for generating an audible sound of high pitch which varies in frequency in proportion to the control voltage at the emitter output 37 of voltage doubler 34. When the voltage to frequency converter is turned on the control voltage is about 1.5 volts and the frequency of oscillation is about 1 KH z . As the animal approaches wire 10 the control voltage increases and so does the frequency of oscillation causing the emission of a higher pitched sound from the speaker. The frequency increases up to 3 KH z providing about one and a half octave variation from minimum to maximum.
The horizontal coil 18 was selected to control the output of the variable frequency converter 36 because of its more linear output. Alternatively, the vertical coil 20 may have been used which would have provided a continually increasing audible output right to the location directly above the wire conductor 10.
The induced signal in the vertical coil 20 is amplified by amplifier circuit 29 and 30 and doubled through a voltage doubler circuit 38. The output of the voltage doubler circuit 38 is fed as one input to a comparator circuit 40. The output of the voltage doubler circuit 32 is fed as a second input to the comparator circuit 40. The comparator circuit 40 includes transistors Q-11 and Q-12 to provide an output 42 which is proportional to the difference between its input signals. Accordingly, when the vertical signal becomes larger than the horizontal signal transistor Q-13 is turned on which, in turn, turns on a square wave generator 44, such as integrated circuit ICM 7555, which operates at about 1 KH z . The output of the square wave generator 44 drives a high voltage inverter 45 for generating an electric shock. The high voltage inverter 45 includes two field effect transistors Q-14 and Q-15 and a transformer T-1. The secondary coil of the transformer T-1 applies the electric shock. The electric shock is applied at a fixed voltage which will not harm the animal or bewilder the animal.
If the animal passes over the wire conductor, the electric shock will decrease as the animal moves further away from the controlled perimeter. This can happen if the animal runs through at high speed. The animal may eventually learn to do this which can minimize the physiological effect of the control system of the present invention. This may readily be overcome in accordance with the present invention by timing the application of the electric shock, i.e., once the electric shock is initiated, a timer circuit (not shown) is triggered to cause the electric shock to continue to be applied for a fixed duration of time such as two or three seconds independent of further movement of the animal. The timer circuit (not shown) may be a conventional solid state timer, the output of which keeps transister Q-13 turned on until it times out.
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Apparatus and system for training an animal to remain confined in a prescribed area defined by an electrical wire conductor through which A.C. current is passed. A receiver is used having two coils disposed at substantial right angles to each other and includes a control circuit for applying a high voltage to the animal in the form of an electrical shock when the signals induced in the coils are related to each other in a given proportion corresponding to a predetermined distance between the animal and the wire conductor.
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FIELD OF THE INVENTION
The invention relates to a connecting rod extending between the heddle frame of a weaving machine and the heddle frame actuating lever of a shed-forming machine which controls same, which connecting rod has at least one pivot joint arranged transversely with respect to the longitudinal direction and which consists preferably of two partial bolts which can be moved into one another and which rest on one another, wherein each partial bolt is secured to a plate which can be moved at least partially axially with respect to the pivot joint, and which is designated to be received in an opening of the heddle frame or the heddle frame actuating lever.
BACKGROUND OF THE INVENTION
In the case of form-lockingly operating weaving machines, the heddle frames are both during lifting and also during lowering operated directly by the shed-forming machine. This requires a rigid connection between the lifting units of the shed-forming machine and the weaving frame. Connecting elements are known, among others from Swiss Pat. No. 538 559, which are inserted into the heddle frame actuating device, in particular between the heddle frame and the free arm of a lever of the heddle frame actuating device. These connecting elements can carry out various functions. They create the hinged connection to the heddle frame and permit a problem-free exchange of the heddle frame during a changing of the fabric article on the weaving machine. They permit furthermore by changing their length, an adjustment of the basic position of the heddle frame. The connecting element achieves a play-free power transmission and if necessary an easy exchange in the case of a defect, while maintaining the power transmission both during the pull or draw cycle and also during the push cycle.
Such connecting elements have usually at least one pivot joint which rests between two sheet-metal plates, which bolt is connected to the free arm of a lever or with the heddle frame. Since modern weaving machines operate at high speeds, there exists the demand that these connecting elements are of a very low mass and yet still very strong. The heretofore used weldable material has proven to be of insufficient strength at high operating speeds and stresses.
The purpose of the invention is to provide a connecting element of a light, simple, however, strong structure, of a highly solid material, without using welding or soldering points during assembly. The requirement remains that the pivot joints for facilitating a quick exchange of the heddle frame can be installed and removed easily in axial direction out of the opening in the heddle frame or in the lever. Of course, the connecting element must be arranged within the heddle frame division and may not have any parts which project toward adjacent heddle frames. That is, the width of thickness of the heddle frame is to be equal to or less than the heddle frames.
SUMMARY OF THE INVENTION
The objects and purposes of this invention are met by providing a connecting rod of the above-mentioned type, which is characterized inventively by two clamping rails which are arranged spaced from one another corresponding with the width of the plates, which clamping rails are connected by at least one operable clamping member, wherein each clamping rail has on each side a groove extending along the longitudinal edge, the profile of which corresponds with the edge profile of the plates and the plates are arranged in pairs between the clamping rails.
BRIEF DESCRIPTION OF THE DRAWING
Exemplary embodiments of the invention are illustrated in the drawing, in which:
FIG. 1 is a perspective view of a connecting rod embodying the invention;
FIG. 2 is a side view of said rod in a released condition and engaged with a heddle frame and actuating lever;
FIG. 3 is a top view of the same rod;
FIG. 4 illustrates in an enlarged scale a cross-sectional view of said rod; and
FIG. 5 is a perspective view of a modified embodiment.
DETAILED DESCRIPTION
The connecting rod according to FIGS. 1 to 4 consists of four plates 1,2 and 3,4, which cooperate with each other in pairs. One plate 1,3 of each plate pair has on one free end thereof a pivot bolt part which is a hollow bushing structure 10,30; each of the other plates 2,4 of each plate pair has a pivot bolt part which is a pin 20,40 which is received in the opening in the bushing. The plates are engaged on their edges by two elongated profiled rails 5,6 made of a springy material and clamped therebetween. Each profiled rail has an elongated groove 50,60 therein extending along the longitudinal side edges thereof. The cross sectional shape of the grooves corresponds with the shape of the edges of the plates, for example a V-shaped groove form and a V-shaped edge form. The rails 5,6 are clamped with the plates 1 to 4 positioned therebetween by means of several screws 7.
To install the connecting rod, for example in an opening in a heddle frame 21 (FIG. 2), at least one screw 7 is loosened. The springy clamping rails 5,6 are lifted or spread apart, as is illustrated in FIG. 2. The plate 4 can, as is illustrated in FIG. 1, be moved laterally in the axial direction of the pin 40 so that the bushing structure 30 can be introduced into a not-illustrated opening in the heddle frame 21. A fastening of the connecting rod to the heddle frame 21 occurs in a reversed sequence. The connecting rod can be connected to an actuating lever 22 by introducing the bushing 10 into an opening 23 in the lever 22 in a similar manner, as also shown in FIG. 2.
Two pairs of plates 1,3 or 2,4 are clamped in a single groove 50,60 in the clamping rails 5,6. To adjust the length of the connecting rod, it is sufficient to loosen at least one screw and to move the two plates which are connected together through a pin-bushing connection. With this, the length of the connecting rod and simultaneously the basic position of the heddle frame can be adjusted.
If the connecting rod is to be unchangeable in its length, the plates 1,3 or 2,4 can be made in one piece. FIG. 4 does not show the rails 5,6 cross hatched for reasons of clarity in illustration.
FIG. 5 illustrates a modified embodiment. Two of the side plates and the two clamping rails are connected to one single tubelike part 8 of rectangular cross section. A slot 90 exists between the clamping parts 9. However, one will recognize from the drawing that the grooves 50,60 and a bushing structure 10 are within the tubelike part 8. Reference numeral 3 identifies one of the two plates to be inserted. The plates 3 are in turn clamped between the grooves 50,60 by a not-illustrated screw received in slot openings 70. The part 8 may have continuous grooves 50,60 extending lengthwise of the connecting rod. The bushing 10 and pin 20 in FIG. 5 are similar to and cooperate in the same manner as the bushings 10 and 30 and pins 20 and 40 described hereinabove with respect to the embodiment of FIG. 1. The plates supporting the bushing 10 and pin 20 in FIG. 5 are flexible, so that the free ends thereof can be pulled away from each other to separate the pin 20 from engagement with the bushing 10.
Although particular preferred embodiments of the invention have been disclosed in detail for illustrative purposes, it will be recognized that variations or modifications of the disclosed apparatus, including the rearrangement of parts, lie within the scope of the present invention.
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A connecting rod having two clamping rails between which are clamped plates extending in a plane perpendicular to the plane of the clamping rails. The clamping is accomplished by screws. The plates have pivot joints which can be moved into one another at their ends. The connecting rod is adjustable in length.
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BACKGROUND OF THE INVENTION
The present invention relates to a thermoengine with a displacement element analogous to piston strokes and operating particularly by converting thermal energy into mechanical energy.
The internal combustion engine is a type of engine which generates thermal energy through combustion and converts that energy into mechanical energy. Generally speaking, these engines are reciprocating pistons, rotary pistons or turbines. The conversion of thermal energy into mechanical energy as such is, however, independent from the actual construction of the machine. These machines use the phenomenon known as internal combustion according to which fuel burns at an accellerated rate producing pressure energy which is in one way or another converted into mechanical movement. It is known, however, that all of these machines are more or less noisy, produce pollutants and contaminants and run relatively inefficiently. Since the production of combustion is the modus operandi of these machines, the fuel must be used under conditions in which the generation and sustaining of combustion is the primary prerequisite. All other factors are secondary. While improvements on isolated aspects are still conceivable, the known internal combustion engine cannot be considered an optimum type of machine for converting theremal energy into mechanical energy.
DESCRIPTION OF THE INVENTION
It is an object of the present invention to provide a new and improved thermo-engine having a lifting and reciprocating, work-producing element which is highly efficient and can be operated under ecologically advantageous conditions.
In accordance with the preferred embodiment of the present invention, it is suggested to provide a plurality of elongated elements which change length mechanically under exertion of relatively low force in a first temperature range, while restoring their respective original length in a different tremperature range, particularly when exceeding a transition temperature range and under development of significant force. The elements each are exposed alternatingly to heating and cooling fluids, and the elements are elastically coupled to a rotating device or element (e.g. a disk or a crank-shaft) to convert the resulting length expansion and contraction of the elements into rotary motion.
The invention, therefore, is to be seen in eliminating the thermocycle of gas heating and expansion of a combustion engine, and instead thermally produced, periodical length changes of these elongated elements are used.
In the preferred form of practicing the invention, elongated elements are constructed from a Nickel-Titanium alloy of the type disclosed, for example, in British Pat. No. 1,180,782. An elongated element made of such a material is rather easily deformible, such as longitudinal upsetting or compression or extension when below the so-called transition temperature range, while restoring to its original length when heated above that temperature range, resulting in a work producing stroke.
The fluids provide for alternating cooling below and heating above the transition range, whereby preferably the temperature spread of cooling and heating is a multiple of that transition range to permit these alternating contractions and expansions to occur in rapid sequence. The transition range is for instance from 130° to 140°C and the operating range is for instance from 110° to 160°C.
Preferably, one will provide ducts through these elements for alternating passage of heating and cooling fluid. The elastic coupling of the linearly expanding and contracting elements to the rotary output keeps hard impacts from the latter, as the change in longitudinal dimension of such elements occurs quite rapidly when traversing the critical, transition temperature range.
The heat exchange fluid will be heated preferably in a steady heating process that does not need to operate with combustion. Burning of clean fuel under conditions favorable to ecology can become the prime factor operation. Unlike in combustion engines, the requirement here is merely that an exothermic process be used which can be sustained as such. Thus, burning of fuel can readily be optimized as far as BTU output is concerned and/or as far as completeness of burning and avoiding formation of contaminant is concerned. The heat exchange fluid is preferably a liquid such as heat resisting oil.
It can readily be seen that the invention permits complete separation of the development of thermal energy from the mechanical-work producing process. The fluid heating the elements must be heated somehow, or more generally, the elements must be heated periodically in some fashion. It makes no difference where the thermal energy comes from.
As far as cooling is concerned, forced air cooling suffices, While such air could be used as cooling fluid, a heat exchange process with a cooling liquid, such as water, possibly with anti-freeze, is preferred so as to increase the heat exchange rate with the elongated elements. It can also be seen that ambient air readily suffices even under very different climate conditions.
The machine can be expected to have a long life, as the elements on internal tecture change, no outside wear is involved. The resulting internal cycle is such that an element restoring its original length on heating provides the force which causes length change in one or several elements which are cooled in the instant. However, the force developed on restauration is considerably higher than the force needed to compress or extend, as the case may be, one or several cooled elements.
DESCRIPTION OF THE DRAWINGS
While the specification concludes with claims particularly pointing out and distinctly claiming the subject matter which is regarded as the invention, it is believed that the invention, the objects and features of the invention and further objects, features and advantages thereof will be better understood from the following description taken in connection with the accompanying drawings in which:
FIG. 1 is a somewhat schematic and diagrammatic illustration of a first example for practicing the preferred embodiment of the invention;
FIG. 2 is a schematic and diagrammatic detail of FIG. 1;
FIG. 3 is partially a section view, partially diagram of the second example for practicing the preferred embodiment of the invention; and
FIG. 3A is a side view of element 35 of FIG. 3.
Proceeding now to the detailed description of the drawings, FIG. 1 shows three elongated, work-stroke producing elements 10, 11 and 12. Preferably made from a titanium nickel alloy with a temperature dependent memory of the type disclosed in said British patent; it may be assumed that e.g. after annealing these elements have a particular length. They can be rather easily longitudinally compressed, i.e. upset when at a temperature for instance below 130°C. Upon heating these elements above the range, they restore to their original length under development of much greater force than needed for the low temperature upsetting of any such element, so that the force balance permits extraction of a useful output. A length change of about 10 percent is readily available here.
One end of each element is provided, e.g. with a transverse cylindrical configuration received in a corresponding socket in a housing 13. This wall all elements are pivotally connected to the housing. The pivot axes may be coaxial and extend transverse to the elongated extension of each element but parallel to an axis 15' for a rotational output. The other ends of these elements are connected to a crankshaft 15 as output and having that axis 15'. The connection is made in each instance through elastic connectors 14. The connection to the crank-shaft is made so that the points of engagement with the crank-shaft are apart by 120°. Arrow 15a points to an axial front projection of the connections as made relative to the axis 15' of the crank-shaft.
Each of the elements 10, 11, 12 is longitudinally traversed by two parallel bores which are fluid conductively interconnected adjacent the respective elastic connector 14. Rotary slide or disk valves 16, 17 and 18 respectively connect these bores alternatingly (as to each element) to a heating circulation 20 and to a cooling circulation 22, for driving heat exchange fluid through the ducts to obtain heating and cooling of the elements in alternating sequence as to each of them but with a phase among the three. Accordingly, each of the elements 10, 11, 12 is alternatingly cooled and heated, but at a phase shift explained as follows:
Generally speaking, the valves 16, 17, and 18 are under control of a controller 19, having the rotation of the crank-shaft 15 as an input. The operative connection between crank-shaft 15 and the valves is such that cooling cycle and heating cycle is operated for each element 10 to 12 in strict dependency upon the phase angles of rotation as representing the forward and retracted positions of the several elements. As a consequence, heating and cooling fluid is passed through these lements 10, 11, 12 in alternating sequence as to each element and with a 120° phase shift among the several elements causing the elements to alternatingly contract and expand, with the same phase shift.
In the illustrated position, with arrow 15b denoting the desired rotation, rod 10 is supposed to contract. Under the assumption that the elements expand when heated, valve 16 has passed and may still be passing cooling fluid into element 10, so that the element is cold while being upset by the crank-shaft. Element 11 is at maximum expansion and cooling fluid may just begin to be fed into and through its ducts. Element 12 is the one performing work at this point. It is being heated by heating fluid and it is expanding, turning the crank. Accordingly, the crank-shaft is driven by these elements to the extent they expand and contract.
The resulting stroke of expansion and contraction of each element is rather small but may be up to about 10 percent. The small stroke, however, is carried out under development of a significant amount of force. Even though the lever action on the crank-shaft is accordingly small, the resulting torque is of significant magnitude.
The operation could be carried out in the reverse in that the restoration of length of each element 10, 11, 12 involves its contraction on heating, while with comparatively little force they are extended when below the transition temperature range. Under such circumstances element 10 in FIG. 1 would still receive heating fluid to undergo and continue its contraction pursuant to higher temperature restoration of its length, while element 12 is cooled and undergoes extension by the crank-shaft.
The resilient coupler or connector 14 for each expanding and contracting element has a rather important function. It cushions the rather hard pushing and pulling action as provided by the respective element, whenever restoring it original configuration upon traversal of the transition temperature. The resiliency prevents also destruction of the machine in the case of malfunction.
It is of advantage to operate heating and cooling fluids at a temperature differential which is well in excess of the critical temperature range of the transition to obtain rapid traversal of that transition change so as to obtain rapid expansion and contraction in each instance. This permits development of relatively high rotational speeds at the crank-shaft, bearing in mind, however, that this is a low speed high torque machine.
By way of example, the heating fluid should have a temperature of for instance 60 centigrade and the cooling fluid may have room temperature.
FIG. 2 shows a schematic for the heating and cooling circulations for one element (e.g. 11) of FIG. 1. The valve 17 is shown here in two synchronously operating parts or portions 17a and 17b, one for each duct 11a, 11b. In the illustrated valve position, the ducts 11a and 11b are connected into the heating fluid circulation, while the cooling fluid circulation is positively interrupted. This, however, is correct only as to the one particular stroke element. In reality, there may always one element be connected to the heating fluid circulation, one to the cooling fluid circulation, while the third one is in transition of connection and may also be connected to the heating or to the cooling circulation as required. It will be recalled that in FIG. 1 element 10 is connected to the cooling circulation, but may soon be cut off, while element 11 had just been connected also to the cooling circulation.
The heating circulation includes a heating source 20a for heating fluid which is pumped into the circulation by a pump 21. Specifically, hot fluid is pumpsed through valve 17a into duct 11a and returns from duct 11b through valve 17b to the heat source. The source 20a may be a clean fuel steady operating burner with a BTU output sufficient to maintain a particular temperature of the circulating heat exhchange fluid as being pumped by pump 21. The burner 20a is a completely independent unit. It may, for example, be operated in a feedback loop to maintain, approximately at least, constant temperature of the fluid it heats and which is pumped through the system. One can use gaseous or liquid fuel and operate the burner under minimum polluting conditions with maximum use of its latent energy content.
Upon changing the disposition of valves 17a, b (see arrow in FIG. 2), the heating circulation is cut off from element 11, and the cooling circulation 22 is connected to ducts 11a, 11b through valves 17a, b. A cooled fluid is pumped from a cooling source 22a by means of a pump 23 into duct 11a and back from duct 11b.
The prime input of the cooling circulation may be a fan forcing outside air into heat exchange relation with the cooling fluid, so that the latter gives off thermal energy it receives from the respective element or elements. If the air needed for the burner is taken from that cooling circuit, one may achieve still greater efficiency.
It should be noted that speed regulation of the engine may be carried out, for example, by controlling the pump or pumps 21, 23. The pumps are, of course, driven via the crank-shaft, and their volume of pumped fluid may be valvecontrolled, so that the rate of fluid flow is controlled which in turn controlls heating and cooling speeds. These speeds are the primary factor for rotational speed control. One could also control the temperature of the fluids, but that is a slower process.
Turning now to the second example of the preferred embodiment of the invention as shown in FIG. 3, an engine is illustrated here resembling a swash plate machine with axially parallel pistons, except that this particular machine has no pistons but expanding - contracting, stroke producing, tubular elements 30 and 31. These elements are articulated on one end in a follower disk 34, while they are held in a likewise revolving disk 32 at their other end by means of force - dependent, elastic couplers 38 and 39, respectively. Due to the articulated connection, the resilient connection to disk 32 amounts indirectly to a resilient connection to disk 34. Disk 34 revolves about an axis oblique to, but intersecting the axis of rotation of disk 32, while elements 30, 31 extend parallelly to the latter axis. The disks 32, 34 are journalled in appropriate bearings in a housing 40. Housing 40 has two end plates 35 and 36 constructed as stationary control disks provided with appropriate arcuate slots in disk 35.
Analogously, disk 34 revolves in face to face abutment with disk 36, and ducts 34a, 34b alternatingly align with the openings in disk 36. These ducts in disk 34 terminate inside of the disk in sockets which articulate end balls of the elements 30, 31. These end balls are also traversed by a bore to continue the tubular interior of the tubular elements but with slightly flared ends. Thus, as the end balls change directions, the hollow interior remains in fluid conductive alignment with ducts 34a, 34b throughout.
The respective other ends of tubular elements 30, 31 are slidingly held in short flanged sleeves 38, 39 on disk 32 which in turn communicate with the ducts 32a, 32b.
Inlet and outlet of the cooling circulation are permanently connected to one opening or slot in disk 35 and one opening in disk 36, respectively. Inlet and outlet of the heating circulation are connected to the respective other openings in disk 35, 36. Additional valves are not necessary as the relative movement of disk 32 on disk 35 performs e.g. the inlet valving function, while disk 34 as rotating on disk 36 performs the outlet valving function or vice versa.
It can readily be seen that fluid is passed through each stroke producing element in one direction only. The illustrated disposition of the machine in FIG. 3 shows heating fluid to begin to pass through element 31, while cooling fluid begins to pass through element 30.
As can be taken from FIG. 3a, the crosssection of ducts 32a, 32b must be a little smaller than the distance of the arcuate slots at their ends from each other, so that these ducts 32a, 32b will not interconnect the cooling and the heating circulations. On the other hand, as soon as, for example, duct 32a of rotating disk 32 has completely receded from alignment with one of the arcuate slots in disk 35 it will open passage and connection to the other slot.
It is assumed also that the mechanical memory of the elements is such that cooling permits and will produce contraction, while heating beyond the transition temperature will result in expansive restauration of the respective tube, 30 or 31 as the case may be.
For a full cycle, assume that tube 31 is being heated and its temperature exceeds the transition temperature it expands quite forcefully. Resilient coupler 39 attenuates the impact and causes more gradual conversion of the axial push into rotation, thereby imparting torque upon disks 32 and 34. The resilient couplers 38, 39 are shown in an intermediate position in which they are held by elastic forces, tending to restore that disposition upon deflection therefrom in either direction. The couplers 38, 39 may for instance be spring centered mechanisms or hydraulic pressure loaded elements.
Concurrently to heating of tube 31, tube 30 was cooled, so as to assume its upset, shortened configuration. This in turn provides torque upon the assembly in support of the torque as provided by the expansion of tube 31. After 180° rotation the heating and cooling of the tubes is reversed.
The direction of the resulting rotation is simply the one the rotating structure already has. The relative phase of the various openings bores and ducts in relation to the axes can be selected in relation to the tilt angle of disk 34, so that the correct rotation is assumed from the beginning. The starting position is preferably not dead center, but full or partial alignment of the bores (32a etc.) with the respective slots which place the tubes 30, 31 off - dead center.
It can readily be seen that the mode of operation can be reversed. The elements 30, 31 may be extended when cooled but contract on heating; the phases of operation are simply changed by 180° as between rotation on one hand, and valve operation for connection of heating and cooling circulations on the other hand.
The invention is not limited to the embodiments described above, but all changes and modification thereof not constituting departures from the spirit and scope of the invention are intended to be included.
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A machine is constructed from plural elongated elements constructed as tubes or rods with double duct and which are alternatingly cooled and heated past a transition temperature, whereby restauration of the original length occurs during heating under development of force and is effective as work producing stroke, while upon cooling below the transition temperature such element is extended or upset. The elements are resiliently coupled to a crank shaft or to the rotary output of swash plate like machine. Heating and cooling fluid is alternatingly driven through the duct or ducts in the stroke producing elements to obtain periodic extension and contraction which is translated into rotational power.
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[0001] This application is a divisional of U.S. application Ser. No. 11/512,847, filed Aug. 30, 2006, which is a continuation of U.S. application Ser. No. 10/165,204, filed Jun. 6, 2002, now abandoned, the contents of each of which are hereby incorporated herein by reference, which is a continuation in part of International Application Serial No. PCT/GB00/04673, filed Dec. 7, 2000, which International Application was published by the International Bureau in English as WO 01/41679 on Jun. 14, 2001.
FIELD OF THE INVENTION
[0002] The present invention relates to medical implants, particularly cardiac and vascular implants and prostheses. More specifically, the invention relates to a cardiac valve prosthesis comprising a frame and leaflets. Such valves may also be made without rigid frames and may also be used as valves in artificial hearts, whether the latter are intended for permanent implantation or for temporary support of a patient.
BACKGROUND OF THE INVENTION
[0003] In mammals the heart is the organ responsible for maintaining an adequate supply of blood, and hence of oxygen and nutrients, to all parts of the body. Reverse flow of blood through the heart is prevented by four valves which serve as the inlet and outlet of each of the two ventricles, the pumping chambers of the heart.
[0004] Dysfunction of one or more of these valves can have serious medical consequences. Such dysfunction may result from congenital defects, or from disease induced damage. Forms of dysfunction include stenosis (reduction in the orifice of the open valve) and regurgitation (reverse flow through the closing or closed valve), either of which increases the work required by the heart to maintain the appropriate blood flows to the body.
[0005] In many cases the only effective solution is to replace the malfunctioning valve. A valve replacement operation is expensive and requires specialised facilities for open heart surgery. Replacement of failed artificial heart valves carries increased risk over the initial replacement, so there are practical limits on the number of times reoperation can be undertaken. Consequently, the design and materials of an artificial valve must provide for durability of the valve in the patient. The artificial valve must also operate without high pressure gradients or undue reverse flow during closing or when closed, because these are the very reasons for which a replacement of the natural valve is undertaken.
[0006] Mechanical valves, which use a ball or a disc or a pair of pivoting rigid leaflets as the opening member(s) can meet these combined requirements of hemodynamic performance and durability. Unfortunately, a patient who has had a mechanical valve implanted must be treated with anticoagulants, otherwise blood will clot on the valve. Clotting on the valve can either restrict the movement of the valve opening member(s), impairing valve function, or can break free from the valve and obstruct blood vessels downstream from the valve, or both. A patient receiving a mechanical valve will be treated with anticoagulants for life.
[0007] Valves excised from pigs and treated with glutaraldehyde to crosslink and stabilise the tissue are also used for replacement of defective valves. These may be mounted on a more or less rigid frame, to facilitate implantation, or they may be unmounted and sewn by the surgeon directly to the vessel walls at operation. A further type of valve replacement is constructed from natural tissue, such as pericardium, treated with glutaraldehyde and mounted on a frame. Valves from pigs or made from other animal or human tissue are collectively known as tissue valves. A major advantage of tissue valves over mechanical valves is that they are much less likely to provoke the blood to clot, and so patients receiving tissue valves are not normally given anticoagulants other than during the immediate post operative period. Unfortunately, tissue valves deteriorate over time, often as a result of calcification of the crosslinked natural tissue. This deterioration presents a problem, particularly in young patients. Thus, although the recipient of a tissue valve is not required to take anticoagulants, the durability of tissue valves is less than that of mechanical valves.
[0008] In third world countries, where rheumatic fever is still common, the problems of valve replacement in young patients are considerable. Anticoagulants, required for mechanical valves, are impractical and accelerated calcification of tissue valves precludes their use.
[0009] In the Western world, life expectancy continues to increase, and this results in a corresponding rise both in patients requiring cardiac valve replacement, and in those patients needing replacement of deteriorating artificial valves implanted in the past. There is, therefore, a need for a replacement heart valve with good hemodynamics, extended durability and having sufficiently low risk of inducing clotting so that anticoagulants are not necessary.
[0010] The natural heart valves use thin flexible tissue leaflets as the closing members. The leaflets move readily out of the orifice as blood begins to flow through the valve so that flow through the open valve is unrestricted by the leaflets. Tissue valves function similarly, providing a relatively unrestricted orifice when the valve is open. For mechanical valves, on the other hand, the closing member rotates in the orifice, but is not removed from the orifice when the valve opens. This provides some restriction to flow, but more importantly, disturbs the blood flow patterns. This disturbance to the flow is widely held to initiate, or at least to contribute significantly to, the observed tendency of mechanical valves to produce clotting.
[0011] A number of trileaflet polyurethane valve designs have been described.
[0012] A valve design, comprising a leaflet geometry which was elliptical in the radial direction and hyperbolic in the circumferential direction in the closed valve position, with leaflets dip-coated from non-biostable polyurethane solutions onto injection-molded polyurethane frames has attained durabilities in excess of 800 million cycles during in vitro fatigue testing (Mackay T G, Wheatley D J, Bernacca G M, Hindle C S, Fisher A C. New polyurethane heart valve prosthesis: design, manufacture and evaluation. Biomaterials 1996; 17:1857-1863; Mackay T G, Bernacca G M, Wheatley D J, Fisher A C, Hindle C S. In vitro function and durability assessment of a polyurethane heart valve prosthesis. Artificial Organs 1996; 20:1017-1025; Bernacca G M, Mackay T G, Wheatley D J. In vitro function and durability of a polyurethane heart valve: material considerations. J Heart Valve Dis 1996; 5:538-542; Bernacca G M, Mackay T G, Wilkinson R, Wheatley D J. Polyurethane heart valves: fatigue failure, calcification and polyurethane structure. J Biomed Mater Res 1997; 34:371-379; Bernacca G M, Mackay T G, Gulbransen M J, Donn A W, Wheatley D J. Polyurethane heart valve durability: effects of leaflet thickness. Int J Artif Organs 1997; 20:327-331). However, this valve design became unacceptably stenotic in small sizes. Thus, a redesign was effected, changing the hyperbolic angle from the free edge to the leaflet base, and replacing the injection-molded frame with a rigid, high modulus polymer frame. This redesign permitted the use of a thinner frame, thus increasing valve orifice area. This valve design, with a non-biostable polyurethane leaflet material, was implanted in a growing sheep model. Valve performance was good over the six month implant period, but the region close to the frame posts on the inflow side of the valve, at which full leaflet opening was not achieved, suffered a local accumulation of thrombus (Bernacca G M, Raco L, Mackay T G, Wheatley D J. Durability and function of a polyurethane heart valve after six months in vivo. Presented at the XII World Congress of International Society for Artificial Organs and XXVI Congress of the European Society for Artificial Organs, Edinburgh, August 1999. Wheatley D J, Raco L, Bernacca G M, Sim I, Belcher P R, Boyd J S. Polyurethane: material for the next generation of heart valve prostheses? Eur. J. Cardio-Thorac. Surg. 2000; 17; 440-448). This valve design used non-biostable polyurethane, which had tolerable mechanical durability, but which showed signs of polymer degradation after six months in vivo.
[0013] International Patent Application WO 98/32400 entitled “Heart Valve Prosthesis” discloses a similar design, i.e., closed leaflet geometry, comprising essentially a trileaflet valve with leaflets molded in a geometry derived from a sphere towards the free edge and a cone towards the base of the leaflets. The spherical surface, defined by its radius, is intended to provide a tight seal when the leaflets are under back pressure, with ready opening provided by the conical segment, defined by its half-angle, at the base of the leaflets. Were the spherical portion located at the leaflet base it is stated that this would provide an advantage in terms of the stress distribution when the valve is closed and under back pressure.
[0014] U.S. Pat. No. 5,376,113 (Jansen et al.) entitled “Closing Member Having Flexible Closing Elements, Especially a Heart Valve” issued Dec. 27, 1994 to Jansen et al. discloses a method of producing flexible heart valve leaflets using leaflets attached to a base ring with posts extending from this upon which the leaflets are mounted. The leaflets are formed with the base ring in an expanded position, being effectively of planar sheets of polymer, which become flaccid on contraction of the ring. The resulting valve is able to maintain both a stable open and a stable closed position in the absence of any pulsatile pressure, though in the neutral unloaded position the valve leaflets contain bending stresses. As a consequence of manufacturing the valve from substantially planar sheets, the included angle between the leaflets at the free edge where they attach to the frame is 60° for a three leaflet valve.
[0015] U.S. Pat. No. 5,500,016 (Fisher) entitled “Artificial Heart Valve” discloses a valve having a leaflet shape defined by the mathematical equation z 2 +y 2 =2RL (x−g)−α(x−g) 2 , where g is the offset of the leaflet from the frame, RL is the radius of curvature of the leaflet at (g,0,0) and α is the shape parameter and is >0 and <1.
[0016] A valve design having a partially open configuration when the valve is not subject to a pressure gradient, but assuming a fully-open position during forward flow is disclosed in International Patent Application WO 97/41808 entitled “Method for Producing Heart Valves”. The valve may be a polyurethane trileaflet valve and is contained within a cylindrical outer sleeve.
[0017] U.S. Pat. Nos. 4,222,126 (Boretos et al.) and 4,265,694 (Boretos et al.) disclose a trileaflet polyurethane valve with integral polyurethane elastomeric leaflets having their leading edges reinforced with an integral band of polymer and the leaflets reinforced radially with thicker lines of polyurethane.
[0018] The problem of chronic thrombus formation and tissue overgrowth arising from the suture ring of valves has been addressed by extension of the valve body on either side of the suture ring as disclosed in U.S. Pat. No. 4,888,009 (Lederman et al.) entitled “Prosthetic Heart Valve”.
[0019] Current polyurethane valve designs have a number of potential drawbacks. Close coaptation of leaflets, while ensuring good valve closure, limits the wash-out of blood during hemodynamic function, particularly in the regions close to the stent posts at the commissures. This region of stagnation is likely to encourage local thrombogenesis, with further restriction of the valve orifice in the longer term as well as increasing the risk of material embolising into the circulation. Associated with the thrombosis may be material degradation (in non-biostable polyurethanes) and calcification resulting in localised stiffening the leaflets, stress concentrations and leaflet failure. As previously discussed, animal implants of a trileaflet polyurethane valve design have indicated that thrombus does tend to collect in this region, restricting the valve orifice and damaging the structure of the valve.
[0020] Present valve designs are limited by the availability of suitable polyurethanes which possess good mechanical properties as well as sufficient durability to anticipate clinical functionality of up to twenty years or more. Many low modulus materials, which provide good hydrodynamic function, fail during fatigue testing at unacceptably low durations, due to their greater susceptibility to the effects of accumulated strain. Higher modulus polyurethanes may be better able to withstand repeated stress without accumulating significant damage, but are too stiff to provide good hydrodynamic function in conventional almost-closed geometry valve designs. Current design strategies have not been directed towards enabling the incorporation of potentially more durable, higher modulus leaflet materials, nor the creation of a valve design that is able to maintain good hydrodynamic function with low modulus polyurethanes manufactured as thick leaflets.
[0021] The nature of the valve leaflet attachment to the frame is such that, in many valve designs, there is a region of leaflet close to the frame, which is restrained by the frame. This region may extend some distance into the leaflet before it interfaces with the free-moving part of the leaflet, or may be directly at the interface between frame and leaflet. There thus exists a stress concentration between the area of leaflet that is relatively mobile, undergoing transition between fully open and fully closed, and the relatively stationary commissural region. The magnitude of this flexural stress concentration is maximized when the design parameters predicate high bending strains in order for the leaflet to achieve its fully open position.
[0022] U.S. Pat. Nos. 4,222,126 (Boretos et al.) and 4,265,694 (Boretos et al.) disclose a valve which uses thickened leaflet areas to strengthen vulnerable area of the leaflets. However this approach is likely to increase the flexure stress and be disadvantageous in terms of leaflet hydrodynamic function.
[0023] The major difficulties which arise in designing synthetic leaflet heart valves can be explained as follows. The materials from which the natural trileaflet heart valves (aortic and pulmonary) are formed have deformation characteristics particularly suited to the function of such a valve. Specifically, they have a very low initial modulus, and so they are very flexible in bending, which occurs at low strain. This low modulus also allows the leaflet to deform when the valve is closed and loaded in such a way that the stresses generated at the attachment of the leaflets, the commissures, are reduced. The leaflet material then stiffens substantially, and this allows the valve to sustain the closed loads without prolapse. Synthetic materials with these mechanical properties are not available.
[0024] Polyurethanes can be synthesized with good blood handling and good durability. They are available with a wide range of mechanical properties, although none has as low a modulus as the natural heart valve material. Although they show an increase in modulus at higher strains, this does not occur until strains much higher than those encountered in leaflet heart valves.
[0025] Polyurethanes have been the materials of choice for synthetic leaflet heart valves in the last decade or more. More recently, polyurethanes have become available which are resistant to degradation when implanted. They are clearly more suitable for making synthetic leaflet heart valves than non-stable polyurethanes, but their use suffers from the same limitations resulting from their mechanical properties. Therefore, design changes must be sought which enable synthetic trileaflet heart valves to function with the best available materials.
[0026] Key performance parameters which must be considered when designing a synthetic leaflet heart valve include pressure gradient, regurgitation, blood handling, and durability.
[0027] To minimize the gradient across the open valve, the leaflets must open wide to the maximum orifice possible, which is defined by the inside diameter of the stent. This means that there must be adequate material in the leaflets so they can be flexed into a tube of diameter equal to the stent internal diameter. In addition, there has to be a low energy path for this bending because the pressure forces available to open the valve are small, and the lower the gradient, the smaller the pressure becomes. All the leaflets must open for the lowest cardiac output likely to be encountered by that valve in clinical service.
[0028] To minimize closing regurgitation (reverse flow lost through the closing valve) the valve leaflets must be produced at or close to the closed position of the valve. To minimize closed valve regurgitation (reverse flow through the valve once it has closed), the apposition of the leaflets in the commissural region is found to be key, and from this perspective the commissures should be formed in the closed position.
[0029] Proper blood handling means minimising the activation both of the coagulation system and of platelets. The material of construction of the valve is clearly a very important factor, but flow through the valve must also avoid exposing blood either to regions of high shear (velocity gradient) or to regions of relative stasis. Avoiding regions of high shear is achieved if the valve opens fully, and relative stasis is avoided if the leaflet/frame attachment and the commissural region in particular opens wide. This is not achieved with typical synthetic materials when the commissures are molded almost closed, because the stiffness of synthetics is too high.
[0030] Durability depends to a large extent on the material of construction of the valve leaflets, but for any given material, lifetime will be maximized if regions of high stress are avoided. The loads on the closed valve are significantly greater than loads generated during valve opening. Therefore, the focus should be on the closed position. Stresses are highest in the region of the commissures where loads are transmitted to the stent, but they are reduced when the belly of the leaflet is as low as practicable in the closed valve. This means that there must be sufficient material in the leaflet to allow the desired low closing.
SUMMARY OF THE INVENTION
[0031] The present invention provides a cardiac valve prosthesis comprising a frame and two or more leaflets (preferably three) attached to the frame. Two embodiments of the invention are disclosed.
1. First Embodiment
[0032] The leaflets are attached to the frame between posts, with a free edge which can seal the leaflets together when the valve is closed under back pressure. The leaflets are created in a mathematically defined shape allowing good wash-out of the whole leaflet orifice, including the area close to the frame posts, thereby relieving the problem of thrombus deposition under clinical implant conditions.
[0033] The leaflet shape has a second design feature, by which the pressure required to open the valve and the pressure gradient across the valve in the open position is reduced by creating a valve which is partially open in its stable unstressed position. Molding the leaflets in a partially open position permits them to open easily to a wider angle resulting in an increased effective orifice area, for any given polyurethane/elastomeric material. This permits the use of materials from a wider range of mechanical properties to fabricate the leaflets, including those of a relatively stiff nature, and also permits lower modulus materials to be incorporated as thicker and hence more durable leaflets, while retaining acceptable leaflet hydrodynamic function.
[0034] A third design feature is the reduction of a stress concentration in the vicinity of the commissural region of the leaflets. In many valve designs, there exists a region of localised high bending where the opening part of the flexible leaflet merges into the stationary region of the leaflet adjacent to the valve frame. The current design reduces the bending, and hence the local stress concentration, in this region. This feature is designed to enhance the valve durability.
[0035] The wide opening of the leaflet coaptation close to the stent posts improves blood washout, reduces thrombogenesis and minimizes embolic risks to the recipient, by allowing a clear channel for blood flow throughout the whole valve orifice.
[0036] The partially open design acts to reduce the fluid pressure required to open the valve. This in turn results in lower pressure gradients across the valve, allowing the use of durable, stiffer polyurethanes to fabricate the valve which may be better equipped to deal with a cyclic stress application or thicker leaflets of lower modulus polyurethanes, hence achieving good durability with good hydrodynamic function. The position of the leaflet in its stable unstressed state acts to reduce the stress concentration resulting from leaflet bending, hence increasing valve durability.
[0037] In one aspect the invention is a cardiac valve prosthesis comprising a frame defining a blood flow axis and at least two leaflets attached to the frame. The at least two leaflets are configured to be movable from an open to a closed position. The leaflets have a blood inlet side and a blood outlet side and are in the closed position when fluid pressure is applied to the outlet side, and in the open position when fluid pressure is applied to the inlet side. The leaflets are in a neutral position intermediate the open and closed position in the absence of fluid pressure being applied to the leaflets. The at least two leaflets include a first leaflet. The first leaflet has a surface contour such that an intersection of the first leaflet with at least one plane perpendicular to the blood flow axis forms a first composite wave. The first composite wave is substantially defined by a first wave combined with at least a second wave superimposed over the first wave. The first wave has a first frequency and the second wave has a second frequency, different from the first frequency. Alternatively, the first composite wave may be defined by a first wave combined with second and third waves superimposed over the first wave. The third wave has a third frequency which is different from the first frequency.
[0038] Both the first wave and the second wave may be symmetric or asymmetric about a plane parallel to and intersecting the blood flow axis and bisecting the first leaflet. The first composite wave may be symmetric or asymmetric about a plane parallel to and intersecting the blood flow axis and bisecting the first leaflet. The at least two leaflets may include second and third leaflets. An intersection of the second and third leaflets with a plane perpendicular to the blood flow axis forms second and third composite waves. The second and third composite waves are substantially the same as the first composite wave. The first and second waves may be defined by an equation which is trigonometric, elliptical, hyperbolic, parabolic, circular, a smooth analytic function or a table of values. The at least two leaflets may be configured such that they are substantially free of bending stresses when in the neutral position. The frame may be substantially cylindrical having first and second ends, one of the ends defining at least two scalloped edge portions separated by at least two posts, each post having a tip, and wherein each leaflet has a fixed edge joined to a respective scalloped edge portion of the frame and a free edge extending substantially between the tips of two posts. The first and second waves may be symmetric about a plane parallel to and intersecting the blood flow axis and bisecting the first leaflet or at least one of the first and second waves may be symmetric about such plane. The first leaflet may have a surface contour such that when the first leaflet is in the neutral position an intersection of the first leaflet with a plane parallel to and intersecting the blood flow axis and bisecting the first leaflet forms a fourth wave.
[0039] In another aspect the invention is a method of making a cardiac valve prosthesis. The valve prosthesis includes a frame defining a blood flow axis substantially parallel to the flow of blood through the valve prosthesis and at least two flexible leaflets attached to the frame. The method includes providing a forming element having at least two leaflet forming surfaces. The forming element is engaged with the frame. A coating is applied over the frame and engaged forming element. The coating binds to the frame. The coating over the leaflet forming surfaces forms the at least two leaflets. The at least two leaflets are configured to be movable from an open to a closed position. The leaflets have a blood inlet side and a blood outlet side and are in the closed position when fluid pressure is applied to the outlet side, and in the open position when fluid pressure is applied to the inlet side. The leaflets are in a neutral position intermediate the open and closed position in the absence of fluid pressure being applied to the leaflets. The at least two leaflets include a first leaflet. The first leaflet has a surface contour such that the intersection of the first leaflet with at least one plane perpendicular to the blood flow axis forms a first composite wave. The first composite wave is substantially defined by a first wave combined with a second superimposed wave. The first wave has a first frequency and the second wave has a second frequency different from the first frequency. After the coating is applied the forming element is disengaged from the frame. The first composite wave formed in the coating step may be defined by a first wave combined with second and third waves superimposed over the first wave. The third wave has a third frequency which is different from the first frequency.
[0040] The first and second waves formed in the coating step may be either symmetric or asymmetric about a plane parallel to and intersecting the blood flow axis and bisecting the first leaflet. The first composite wave formed in the coating step may be symmetric or asymmetric about a plane parallel to and intersecting the blood flow axis and bisecting the first leaflet. The at least two leaflets formed in the coating step may include second and third leaflets. An intersection of the second and third leaflets with a plane perpendicular to the blood flow axis forms second and third composite waves, respectively. The second and third composite waves are substantially the same as the first composite wave. The first and second waves formed in the coating step may be defined by an equation which is trigonometric, elliptical, hyperbolic, parabolic, circular, a smooth analytic function or a table of values.
[0041] The first and second waves in the coating step may be symmetric about a plane parallel to and intersecting the blood flow axis and bisecting the first leaflet or at least one of the first and second waves may be asymmetric about such plane. The at least two leaflets in the coating step are configured such that they are substantially free of bending stresses when in the neutral position.
[0042] In a further aspect the invention is a cardiac valve prosthesis comprising a frame defining a blood flow axis and at least two leaflets attached to the frame including a first leaflet. The first leaflet has an internal surface facing the blood flow axis and an external surface facing away from the blood flow axis. The first leaflet is configured such that a mean thickness of a first half of the first leaflet is different than a mean thickness of a second half of the first leaflet. The first and second halves are defined by a plane parallel to and intersecting the blood flow axis and bisecting the first leaflet. The first leaflet may be further configured such that a thickness of the first leaflet between the internal and external surfaces along a cross section defined by the intersection of a plane perpendicular to the blood flow axis and the first leaflet changes gradually and substantially continuously from a first end of the cross section to a second end of the cross section.
[0043] In another aspect the invention is a method of making a cardiac valve prosthesis which includes a frame defining a blood flow axis substantially parallel to the flow of blood through the valve prosthesis and at least two flexible leaflets attached to the frame. The method includes providing a mold having a cavity sized to accommodate the frame, inserting the frame into the mold, inserting the mold into an injection molding machine, and injecting molten polymer into the cavity of the mold to form the at least two leaflets. The injection of the molten polymer causes the at least two leaflets to bond to the frame. The cavity is shaped to form the at least two leaflets in a desired configuration. The at least two leaflets are configured to be movable from an open to a closed position. The leaflets have a blood inlet side and a blood outlet side and are in the closed position when fluid pressure is applied to the outlet side, and in the open position when fluid pressure is applied to the inlet side. The leaflets are in a neutral position intermediate the open and closed position in the absence of fluid pressure being applied to the leaflets. The at least two leaflets include a first leaflet having a surface contour such that when the first leaflet is in the neutral position an intersection of the first leaflet with at least one plane perpendicular to the blood flow axis forms a first composite wave. The first composite wave is substantially defined by a first wave combined with at least a second superimposed wave. The first wave may have a first frequency, the second wave may have a second frequency, the first frequency being different from the second frequency.
[0044] In a still further aspect the invention is a method of designing a cardiac valve prosthesis which includes a frame and at least two flexible leaflets attached to the frame. The method includes defining a first desired shape of the leaflets in a first position, defining a second desired shape of the leaflets in a second position different from the first position, and conducting a draping analysis to identify values of adjustable parameters defining at least one of the first and second shapes. The draping analysis ensures that the leaflets are comprised of a sufficient amount and distribution of material for the leaflets to assume both the first and second desired shapes. Either of the first and second positions in the defining steps may be a closed position and the other of the first and second positions may be a partially open position.
2. Second Embodiment
[0045] In one aspect, this invention is a cardiac valve prosthesis comprising a substantially cylindrical frame defining a blood flow axis, the frame having first and second ends, one of the ends defining at least two scalloped edge positions separated by at least two posts, each post having a tip; and at least two flexible leaflets attached to the frame, the at least two leaflets being configured to be movable from an open to a closed position, the at least two leaflets having a blood inlet side and a blood outlet side, the at least two leaflets being in the closed position when fluid pressure is applied to the outlet side, being in the open position when fluid pressure is applied to the inlet side and being in a neutral position intermediate the open and closed position, in the absence of fluid pressure being applied to the leaflets, each leaflet having a fixed edge joined to a respective scalloped edge portion of the frame and a free edge extending substantially between the tips of two posts. The at least two leaflets may include a first leaflet having a surface contour such that when the first leaflet is in the neutral position an intersection of the first leaflet with at least one plane perpendicular to the blood flow axis forms a first composite wave, the first composite wave being substantially defined by a first wave combined with at least a second wave superimposed over the first wave, the first wave having a first frequency, the second wave having a second frequency different than the first frequency, the first wave comprising a circular arc.
[0046] The first wave may be defined by a first wave combined with second and third waves superimposed over the first wave, the third wave having a third frequency which is different from the first and second frequencies. The first composite wave as well as the second wave may be symmetric or asymmetric about a plane parallel to and intersecting the blood flow axis and bisecting the first leaflet. The at least two leaflets may further include second and third leaflets; and an intersection of the second and third leaflets with the plane perpendicular to the blood flow axis may form second and third composite waves, respectively, the second and third composite waves being substantially the same as the first composite wave. The second wave may be defined by an equation which is one of trigonometric, elliptical, hyperbolic, a smooth analytic function and a table of values. The at least two leaflets may be configured such that they are substantially free of bending stresses when in the neutral position. The first leaflet may have a surface contour such that when the first leaflet is in the neutral position an intersection of the first leaflet with a plane parallel to and intersecting the blood flow axis and bisecting the first leaflet forms a fourth wave.
[0047] In a second aspect, this invention is a method of making a cardiac valve prosthesis which includes a substantially cylindrical frame defining a blood flow axis substantially parallel to the flow of blood through the valve prosthesis and at least two flexible leaflets attached to the frame, the method comprising forming at least two scalloped edge portions on the frame, the shape of each scalloped edge portion being defined by the intersection of the frame with a plane inclined with respect to the blood flow axis; treating the frame to raise its surface energy to above about 64 mN/m; providing a forming element having at least two leaflet forming surfaces; engaging the forming element to the frame; applying a coating over the frame and engaged forming element, the coating binding to the frame, the coating over the leaflet forming surfaces forming the at least two flexible leaflets, the at least two leaflets being configured to be movable from an open to a closed position, the at least two leaflets having a blood inlet side and a blood outlet side, the at least two leaflets being in the closed position when fluid pressure is applied to the outlet side, being in the open position when fluid pressure is applied to the inlet side and being in a neutral position intermediate the open and closed position, in the absence of fluid pressure being applied to the leaflets, the at least two leaflets including a first leaflet having a surface contour such that when the first leaflet is in the neutral position an intersection of the first leaflet with at least one plane perpendicular to the blood flow axis forms a first composite wave, the first composite wave being substantially defined by a first wave combined with at least a second superimposed wave, the first wave having a first frequency, the second wave having a second frequency, the first frequency being different from the second frequency, the first wave comprising a circular arc; and disengaging the forming element from the frame.
DESCRIPTION OF DRAWINGS
[0048] FIG. 1 is a diagrammatic view comparing the shape of symmetric (solid line) and asymmetric (dashed line) leaflets.
[0049] FIG. 2 is a perspective view of the valve prosthesis in the neutral or partially open position.
[0050] FIG. 3 is a sectional view similar to the sectional view along line 3 - 3 of FIG. 2 except that FIG. 3 illustrates that view when the leaflets are in the closed position and illustrates the function which is used to define the shape of the closed leaflet belly X Closed (Z).
[0051] FIG. 4A is a front view of the valve leaflet shown in FIG. 2 . FIG. 4B is in the same view as FIG. 4A and is a partial schematic view of the same closed valve leaflet shown in FIG. 3 and illustrates that S(X, Y) n and S(X, Y) n-1 are contours enclosing the leaflet between the function X Closed (Z) and the scallop geometry.
[0052] FIG. 5 is a plot of an underlying function used in defining the valve leaflet in the molded leaflet partially open position P for valves made in accordance with the first embodiment.
[0053] FIG. 6 is a plot of a symmetrical superimposed function used in defining the shape of the valve leaflet of the first embodiment in the molded leaflet position P.
[0054] FIG. 7 is a plot of the composite function used in construction of the molded leaflet position P resulting from combining an underlying function ( FIG. 5 ) and a symmetric superimposed function ( FIG. 6 ) for valves made in accordance with the first embodiment.
[0055] FIG. 8 is a plot of an asymmetric superimposed function used in the construction of the molded leaflet position P for valves made in accordance with the first embodiment.
[0056] FIG. 9 is a plot of the composite function resulting from combining an underlying function ( FIG. 5 ) and an asymmetric function ( FIG. 8 ) for valves made in accordance with the first embodiment.
[0057] FIG. 10 is a sectional view of the valve leaflets in the neutral position along line 3 - 3 in FIG. 2 and illustrates the function which is used to define the shape of the molded leaflet belly X open (Z).
[0058] FIG. 11A is a front view of the valve. FIG. 11B is a partial schematic view of the valve leaflets of FIG. 11A and illustrates that P(X, Y) n and P(X, Y) n-1 are contours enclosing the leaflet between the function X open (Z) and the scallop geometry.
[0059] FIG. 12 is a perspective view of a valve of the first embodiment having symmetric leaflets.
[0060] FIG. 13 is a perspective view of a valve of the first embodiment having asymmetric leaflets.
[0061] FIG. 14 is a side view of a former used in the manufacture of the valve of the present invention.
[0062] FIG. 15 is a plot of an underlying function used in defining the valve leaflet in the molded partially open position P for a valve made in accordance with the second embodiment.
[0063] FIG. 16 is a plot of an asymmetrical superimposed function used in defining the shape of a valve leaflet of the second embodiment in the molded leaflet position P for valves made in accordance with the second embodiment.
[0064] FIG. 17 is a plot of the composite function used in construction of the molded leaflet position P resulting from combining an underlying function ( FIG. 15 ) and an asymmetric superimposed function ( FIG. 16 ) for a valve made in accordance with the second embodiment.
[0065] FIG. 18 is a perspective view of a valve of the second embodiment having asymmetric leaflets.
DESCRIPTION OF THE INVENTION
a. Design Considerations
[0066] Consideration of the factors discussed above results in the identification of certain design goals which are achieved by the prosthetic heart valve of the present invention. First, the prosthetic heart valve must have enough material in the leaflet for wide opening and low closing, but more than this amount increases the energy barrier to opening. To ensure that there is sufficient, but not an excess of material, a draping analysis discussed in more detail below is used. Second, to ensure sufficient material for wide opening and low closing, the valve can only be manufactured in a partially open position: (a) by deforming the stent posts outwards during manufacture; (b) by introducing multiple curves in the leaflet free edge (but see below); (c) by making the closed position asymmetric; and (d) combinations of the above. Third, if there is enough material for low closing and wide opening, the energy barrier to opening may be high enough to prevent opening of all leaflets at low flow. The energy barrier can be minimized by: (a) introducing multiple curves in the leaflet; (b) making the leaflet asymmetric; and combinations of the above. Fourth, open commissures are needed for blood handling and closed commissures are needed for regurgitation, so the valve should have partially open commissures. In particular the included angle between adjacent leaflet free edges at the valve commissures (for example see angle α of the symmetric leaflets shown in FIG. 1 ) should be in the range of 10-55°, preferably in the range 25-55°.
[0067] As discussed above, the use of multiple curves in the leaflet helps assure wide opening and more complete closure of the valve and to minimize the energy barrier to opening of the valve. However, the introduction of multiple curves of more than 1.5 wavelengths to the leaflet can be a disadvantage. While there may be sufficient material in the leaflet to allow full opening, in order for this to happen, the bends in the leaflet must straighten out completely. The energy available to do this arises only from the pressure gradient across the open valve, which decreases as the leaflets becomes more open, i.e., as the valve orifice area increases. This energy is relatively small (the more successful the valve design the smaller it becomes), and does not provide enough energy to remove leaflet curves of more than 1.5 wavelengths given the stiffness of the materials available for valve manufacture. The result is they do not straighten out and the valve does not open fully.
[0068] A draping analysis is used as a first approximation to full finite element analysis to determine if the starting shape of a membrane is such that it will take on a desired final shape when placed in its final position. From a durability standpoint the focus is on the closed position, and the desired shape of the leaflet in its closed position is defined. Draping analysis allows the leaflet to be reformed in a partially open position.
[0069] Draping analysis assumes that very low energy deformation is possible (in reality any form of deformation requires energy). In order for this to occur the bending stiffness of the leaflet/membrane must be small, each element of the membrane should be free to deform relative to its neighbour, and each element should be free to change shape, i.e., the shear modulus of the material is assumed to be very low. In applying the draping analysis, it is assumed that the leaflet can be moved readily from an original defined closed position to a new position in which it is manufactured. When the valve is actually cycled, it is assumed that the leaflet when closing will move from the manufactured position to the originally defined closed position. This allows the closed position to be optimised from a stress distribution aspect, and the manufactured position to be optimised from the point of view of reducing the energy barrier to opening.
[0070] Both symmetric and asymmetric shapes of the leaflet can allow incorporation of sufficient material in the leaflet free edge to allow full opening. FIG. 1 is a diagrammatic view comparing the shape of symmetric (solid line) and asymmetric (dashed line) leaflets and also showing the commissure area 12 where the leaflets connect to the frame. An advantage of the asymmetric shape is that a region of higher radius of curvature 14 is produced than is achieved with a symmetric curve having a lower radius of curvature 16 . This region can buckle more readily and thereby the energy barrier to opening is reduced.
[0071] An asymmetric leaflet also reduces the energy barrier through producing unstable buckling in the leaflet. During opening symmetric leaflets buckle symmetrically i.e., the leaflet buckles are generally mirrored about the centerline of the leaflet thus balancing the bending energies about this centerline. In the asymmetric valve the region of higher radius buckles readily, and because these bending energies are not balanced about the center line, this buckle proceeds to roll through the leaflet producing a sail-like motion producing a low energy path to open.
[0072] An additional feature of the asymmetric valve is that the open position is also slightly asymmetric, as a result of which it offers a somewhat helical flow path, and this can be matched to the natural helical sense of the aorta. Suggested benefits of this helical flow path include reduction of shear stress non-uniformity at the wall, and consequent reduction of platelet activation.
b. The Valve Prosthesis
[0073] First and second embodiments of the valve prosthesis will be described with reference to the accompanying drawings. FIG. 2 is a perspective view of a heart valve prosthesis made in accordance with the present invention. The valve 10 comprises a stent or frame 1 and attached leaflets 2 a , 2 b , and 2 c . The leaflets are joined to the frame at scallops 5 a , 5 b , and 5 c . Between each scallop is post 8 , the most down-stream part of which is known as a stent tip 6 . Leaflets 2 a , 2 b , and 2 c have free edges 3 a , 3 b , and 3 c , respectively. The areas between the leaflets at the stent tips 6 form commissures 4 .
1. First Embodiment of Heart Valve Prosthesis
[0074] The following describes a particular way of designing a first embodiment of a valve of the present invention. Other different design methodology could be utilized to design a valve having the structural features of the valve disclosed herein. Five computational steps are involved in this particular method:
(1) Define the scallop geometry (the scallop, 5 , is the intersection of the leaflet, 2 , with the frame, 1); (2) Geometrically define a valve leaflet in the closed position C; (3) Map and compute the distribution of area across the leaflet in the closed position; (4) Rebuild the leaflet in a partially open position P; and (5) Match the computed leaflet area distribution in the partially open or molded position P to the defined leaflet in the closed position C. This ensures that when an increasing closing pressure is applied to the leaflets, they eventually assume a shape which is equivalent to that defined in closed position C.
[0080] This approach allows the closed shape of the leaflets in position C to be optimised for durability while the leaflets shaped in the molded partially open shape P can be optimised for hemodynamics. This allows the use of stiffer leaflet materials for valves which have good hemodynamics. An XYZ co-ordinate system is defined as shown in FIG. 2 , with the Z axis in the flow direction of blood flowing through the valve.
[0081] The leaflets are mounted on the frame, the shape of which results from the intersection of the aforementioned leaflet shape and a 3-dimensional geometry that can be cylindrical, conical or spherical in nature. A scallop shape is defined through intersecting the surface enclosed by the following equations with a cylinder of radius R (where R is the internal radius of the valve):
[0000]
X
eff
=
E
sO
-
E
sJ
1
-
(
Z
/
E
sN
)
2
H
sJ
=
E
sO
-
E
sJ
(
1
-
(
Z
/
E
sN
)
2
)
-
H
sO
H
sN
(
Z
)
=
H
sJ
·
tan
(
60
)
·
f
(
Z
)
where
f
(
Z
)
is
a
function
changing
with
Z
.
X
hyp
=
H
sO
+
H
sJ
(
1
-
(
Y
/
H
sN
)
2
)
[0082] The shape of the scallop can be varied using the constants E s0 , E s1 , H s0 , f(Z). The definition of parameters used in these and the other equations herein are contained in Table 4.
[0083] The shape of the leaflet under back pressure (i.e., in the closed position C) can be approximated mathematically using elliptical or hyperbolic co-ordinates, or a combination of the above in an XYZ co-ordinate system where XY is the plane of the valve perpendicular to the blood flow and Z is the direction parallel to the blood flow. The parameters are chosen to define approximately the shape of the leaflet under back pressure so as to allow convenient leaflet re-opening and minimize the effect of the stress component which acts in the direction parallel to the blood flow, whilst also producing an effective seal under back pressure.
[0084] The closed leaflet geometry in closed position C is chosen to minimize stress concentrations in the leaflet particularly prone to occur at the valve commissures. The specifications for this shape include:
(1) inclusion of sufficient material to allow a large open-leaflet orifice; (2) arrangement of this material to minimize redundancy (excess material in the free edge, 3 ) and twisting in the centre of the free edge, 3 ; and (3) arrangement of this material to ensure the free edge, 3 , is under low stress i.e., compelling the frame and leaflet belly to sustain the back-pressure.
[0088] FIG. 3 is a partial sectional view (using the section 3 - 3 shown in FIG. 2 ) showing only the intended position of the leaflet in the closed position. The shape of this intended position is represented by the function X Closed (Z). This function can be used to arrange the shape of the leaflet in the closed position C to meet the aforementioned specification. The curve is defined using the following equation and manipulated using the constants E c1 , E cO , Z cO and the functions E cN (Z) and X T (Z).
[0000]
X
Closed
(
Z
)
=
-
[
E
cJ
(
1
-
(
Z
-
Z
c
O
E
c
N
(
Z
)
)
2
)
]
0.5
+
E
cO
-
X
T
(
Z
)
[0000] where E cN is a function changing linearly with Z and X T (Z) is a function changing nonlinearly with Z.
[0089] Thus the scallop shape and the function X Closed (Z) are used to form the prominent boundaries for the closed leaflet in the closed position C. The remaining part of the leaflet is formed using contours S(X, Y) n sweeping from the scallop to the closed leaflet belly function X closed (Z), where n is an infinite number of contours, two of which are shown in FIG. 4B .
[0090] The length of the leaflet (or contours S(X, Y) n ) in the circumferential direction (XY) is calculated and repeated in the radial direction (Z) yielding a function L(Z) which is used later in the definition of the geometry in the partially open position P. The area contained between respective contours is also computed yielding a function K(Z) which is also used in the definition of the geometry in position P. The area contained between contours is approximated using the process of triangulation as shown in FIG. 4B . This entire process can be shortened by reducing the number of contours used to represent the surface (100<n<200).
[0091] The aforementioned processes essentially define the leaflet shape and can be manipulated to optimise for durability. In order to optimise for hemodynamics, the same leaflet is molded in a position P which is intermediate in terms of valve opening. This entails molding large radius curves into the leaflet which then serve to reduce the energy required to buckle the leaflet from the closed to the open position. The large radius curves can be arranged in many different ways. Some of these are outlined herein.
[0092] The leaflet may be molded on a dipping former as shown in FIG. 14 . Preferably the former is tapered with an included angle θ so that the end 29 has a diameter which is greater than the end 22 . (This ensures apposition of the frame and former during manufacture.) In this case, the scallop shape, defined earlier, is redefined to lie on a tapered geometry (as opposed to the cylindrical geometry used in the definition of the closed leaflet shape). This is achieved by moving each point on the scallop radially, and in the same movement, rotation of each point about an X-Y plane coincident with the bottom of the scallop, until each point lies on the tapered geometry.
[0093] The geometry of the leaflet shape can be defined as a trigonometric arrangement (or other mathematical function) preferably sinusoidal in nature in the XY plane, comprising one or more waves, and having anchoring points on the frame. Thus the valve leaflets are defined by combining at least two mathematical functions to produce composite waves, and by using these waves to enclose the leaflet surface with the aforementioned scallop.
[0094] One such possible manifestation is a composite curve consisting of an underlying low frequency sinusoidal wave upon which a second higher frequency sinusoidal wave is superimposed. A third wave having a frequency different from the first and second waves could also be superimposed over the resulting composite wave. This ensures a wider angle between adjacent leaflets in the region of the commissures when the valve is fully open thus ensuring good wash-out of this region.
[0095] The composite curve, and the resulting leaflet, can be either symmetric or asymmetric about a plane parallel to the blood flow direction and bisecting a line drawn between two stent tips such as, for leaflet 2 a , the section along line 3 - 3 of FIG. 2 . The asymmetry can be effected either by combining a symmetric underlying curve with an asymmetric superimposed curve or vice versa.
[0096] The following describes the use of a symmetric underlying function with an asymmetric superimposed function, but the use of an asymmetric underlying function will be obvious to one skilled in the art. The underlying function is defined in the XY plane and connects the leaflet attachment points to the scallop at a given height from the base of the valve. This underlying function shown in FIG. 5 , can be trigonometric, elliptical, hyperbolic, parabolic, circular, or other smooth analytic function or could be a table of values.
[0097] Using sine functions, one possible underlying wave is shown in FIG. 5 and is defined using the following equation.
[0000]
X
u
=
X
(
n
,
0
)
+
A
u
·
sin
[
(
0.5
π
Y
(
n
,
0
)
)
·
(
Y
-
Y
(
n
,
0
)
)
]
[0098] The superimposed wave is defined in the XY plane, and connects the attachment points of the leaflet to the scallop at a given height above the base of the valve. The superimposed wave is of higher frequency than the underlying wave, and can be trigonometric, elliptic, hyperbolic, parabolic, circular, or other smooth analytic function, or a table of values.
[0099] Using sine functions, one possible symmetric leaflet design is formed when the underlying wave is combined with a superimposed wave formed using the following equation.
[0000]
X
s
=
-
A
s
·
B
s
(
Y
)
·
sin
[
(
1.5
·
π
Y
(
n
,
0
)
)
·
(
Y
-
Y
(
n
,
0
)
)
]
[0100] A s can be varied across the leaflet to produce varying wave amplitude across the leaflet, for example lower amplitude at the commissures than in the leaflet centre. B s can be varied to adjust the length of the wave. The superimposed wave is shown in FIG. 6 . The composite wave formed by combining the underlying wave ( FIG. 5 ) with the superimposed wave ( FIG. 6 ) is shown in FIG. 7 .
[0101] Using sine functions, one possible asymmetric leaflet design is formed when the underlying wave ( FIG. 5 ) is combined with a superimposed wave formed using the following equation.
[0000]
X
s
=
-
A
s
·
B
s
(
Y
)
·
sin
[
(
π
Y
(
n
,
0
)
)
·
(
Y
-
Y
(
n
,
0
)
)
]
0
Y
(
n
,
0
)
X
s
=
0.5
·
A
s
·
B
s
(
Y
)
·
sin
[
(
2.0
π
Y
(
n
,
0
)
)
·
Y
]
(
-
Y
(
n
,
0
)
)
o
[0102] A s can be varied across the leaflet to produce varying wave amplitude across the leaflet, for example lower amplitude at the commissures than in the leaflet centre. B s (Y) can be varied to adjust the length of the wave. The superimposed wave is shown in FIG. 8 . The resulting asymmetric composite wave is shown in FIG. 9 . The composite wave W(X c , Y c ) n is created by offsetting the superimposed wave normal to the surface of the underlying wave ( FIGS. 7 , 9 ).
[0103] While the general shape of the leaflet in position P has been determined using the composite wave, at this stage it is not specified in any particular position. In order to specify the position of P, the shape of the partially open leaflet position can be defined as X open (Z). This is shown as reference numeral 7 in FIG. 10 .
[0104] One possible function determining this shape is given as follows:
[0000]
X
open
(
Z
)
=
-
[
E
oJ
·
(
1
-
(
Z
-
Z
oO
E
oN
)
2
)
]
0.5
+
E
oO
[0105] In order to manipulate the composite wave to produce the belly shape X open (Z) the respective amplitudes of the individual sine waves can be varied from the free edge to the leaflet base. For example, the degree of ‘openness’ of the leaflet in position P can be varied throughout the leaflet.
[0106] The composite wave is thus defined to produce the molded “buckle” in the leaflet, and X open (Z) is used to define the geometry of the leaflet at position P. At this stage it may bear no relation to the closed leaflet shape in position C. In order to match the area distribution of both leaflet positions, (thus producing essentially the same leaflet in different positions) the composite wave length is iterated to match the length of the relevant leaflet contour in position C. Thus the amplitude and frequency of the individual waves can be varied in such a manner as to balance between: (a) producing a resultant wave the length of which is equal to the relevant value in the length function L(Z) thus approximating the required closed shape when back pressure is applied, and (b) allowing efficient orifice washout and ready leaflet opening. Also the area contained between the contours in the open leaflet is measured using the same process of triangulation as in the closed position C, and is iterated until it matches with the area contained between relevant contours in position C (denoted K(Z)) (through tilting the contours in P relative to each other). Thus the composite waves (P(X,Y) n ) pertaining to the contour n and length L(Z) can be tilted at an angle to the XY plane about attachment points X (n,0). Y (n,0) and X (n,0). -Y (n,0) until the correct area is contained between P(X,Y) n and P(X,Y) n-1 (See FIGS. 10 & 11 ).
[0107] This process identifies the values of B S. A U and the contour tilt angle to be used in constructing the mold for the valve leaflet. As long as the constants such as B s and A u , and the tilt angle of the contours relative to the XY plane, are known, the surface of the leaflet in its molded position can be visualised, enclosed and machined in a conventional manner. As a result of this fitting process the composite wave retains the same basic form but changes in detail from the top of the leaflet to the bottom of the leaflet. A composite wave can be defined in the leaflet surface as the intersection of the leaflet surface with a plane normal to the Z axis. This composite wave will have the same general form as the composite wave used in the leaflet design but will differ from it in detail as a result of the tilting process described above.
[0108] In summary therefore one possible method of designing the leaflet of the first embodiment of the present invention is in the following way:
(1) Define a scallop shape; (2) Define a shape approximating the shape of the closed leaflet using elliptical, hyperbolic, parabolic or circular functions, smooth analytical functions or table of values; (3) Compute the functions L(Z) and K(Z), which define the length of the leaflet in the XY plane along the Z axis and the area distribution of the leaflet along the Z axis; (4) Use one or more associated sine waves to generate a geometry which is partially-open, which pertains to a leaflet position which is between the two extreme conditions of normal valve function, i.e., leaflet open and leaflet closed; (5) Vary the frequency and amplitude of the sinewaves to fit to the length function L(Z) and the angle at which the contour is tilted to the XY plane to fit to the area function K(Z); and (6) The respective amplitudes of the individual sine waves can be varied from the free edge to leaflet base, for example the degree of ‘openness’ of the leaflet can be varied throughout the leaflet.
[0115] Examples 1 and 2 set forth hereafter are examples of how the invention of the first embodiment can be put into practice. Using the scallop constants in Table 1, the constants required to produce an example of a symmetric leaflet valve (example 1, FIG. 12 ) and an example of an asymmetric leaflet valve (example 2, FIG. 13 ) are given in Table 2 and Table 3 respectively. These constants are used in conjunction with the aforementioned equations to define the leaflet geometry.
[0116] With one leaflet described using the aforementioned equations, the remaining two leaflets are generated by rotating the geometry about the Z axis through 120° and then through 240°. These leaflet shapes are inserted as the leaflet forming surfaces of the dipping mold (otherwise known as a dipping former), which then forms a 3-dimensional dipping mold. The composite wave described in the aforementioned equations, therefore substantially defines the former surface which produces the inner leaflet surface.
[0117] As seen in FIG. 14 the dipping mold 20 is slightly tapered so that the end 29 has a diameter which is greater than the end 22 , and has a first end 22 having an outside diameter slightly smaller than the inside diameter of the frame. The former includes at least two and preferably three leaflet forming surfaces 24 which are defined by scalloped edges 26 and flats 28 . Sharp edges in the manufacturing former and on the frame are radiused to help reduce stress concentrations in the finished valve. During the dip molding process the frame is inserted over end 22 of the former so that the scallops 5 and stent posts 8 of the frame align with the scalloped edges 26 and flats 28 of the former. The leaflet forming surfaces 24 are configured to form leaflets during the molding process which have the geometry described herein. This mold can be manufactured by various methods, such as, machining, electrical discharge machining, injection molding. In order that blood flow is not disturbed, a high surface finish on the dipping mold is essential.
[0118] For the frame there are preferably three posts with leaflets hung on the frame between the posts. A crown-like frame or stent, 1 , is manufactured with a scallop geometry, which matches the dipping mold scallop. The frame scallop is offset radially by 0.1 mm to allow for the entire frame to be coated with a thin layer of leaflet material to aid adhesion of the leaflets. Leaflets may be added to the frame by a dip-molding process, using a dipping former machined or molded to create the multiple sinewave form.
[0119] The material of preference should be a semi-rigid fatigue- and creep-resistant frame material such as polyetheretherketone (PEEK), high modulus polyurethane, titanium, reinforced polyurethane, or polyacetal (Delrin) produced by machining or injection-molding etc. Alternatively, a relatively low modulus polymer may be used, which may be fibre-reinforced, to more closely mimic the aortic wall. The frame can be machined or injection molded, and is manufactured preferably from PEEK or polyacetal (Delrin).
[0120] The frame is treated by exposure to a gas plasma or other methods to raise its surface energy above 64 mN/m (milliNewtons/meter). Then the frame is dipped in a polyurethane solution (preferably Elast-Eon™ manufactured by Aortech Biomaterials Pty, Sydney Australia) in order to apply a coating of approximately 0.1 mm thick. Having dried the frame with applied coating in an oven overnight, it is placed on the dipping former and aligned with the former scallops. The combination of frame and three dimensional dipping mold is then dipped into polyurethane solution, which forms a coating of solution on frame and mold. This coating flows slowly over the entire mold surface ensuring a smooth coating. The new coating on the frame and dipping mold solvates the initial frame coating thus ensuring a good bond between leaflet and frame. The dipping mold with polyurethane covering is dried in an oven until all the solvent has been removed. One or more dips may be used to achieve a leaflet with a mean thickness between 40 μm and 500 μm. The shape of the former, and the viscosity and solvent interactive properties of the polyurethane solution, control the leaflet thickness and the distribution of thickness over the leaflet. A dipping process does not allow precise control of leaflet thickness and its variation across a leaflet. In particular, surfaces that are convex on the dipping former result in reduced leaflet thickness when compared with surfaces that are concave. Additionally the region of the leaflet adjacent to the frame essentially provides a very small concave radius which traps further polymer solution and this results in thickening of these regions.
[0121] The shape of the former is substantially defined by the composite wave. Radiusing and polishing of the former can both contribute to some variation of the shape. The shape of the inner surface of the leaflets will closely replicate the shape of the former. The shape of the outer surface of the leaflets will be similar to the shape of the inner surface but variations will result from the processing properties of the polymer solution and details of the dipping process used to produce the valve. The leaflet may be formed from polyurethanes having a Young's modulus less than 100 MPa, preferably in the range 5 to 50 MPa.
[0122] The valve is next removed from the dipping mold. The stent posts, which had been deflected by the taper on the former, now recover their original position. The shape of the leaflets changes slightly as a result of the movement of the stent posts.
[0123] At this stage the dipping mold and frame is covered with an excess of polyurethane due to the drain-off of the polymer onto the region of the mold known as the drain-off area 30 . Leaflet free edges may be trimmed of excess material using a sharp blade rotated around the opened leaflets or using laser-cutting technology.
[0124] An alternate valve manufacturing method is injection molding. A mold is constructed with a cavity which allows the valve frame to be inserted in the mold. The cavity is also designed with the leaflet geometry, as defined above, as the inner leaflet surface. A desired thickness distribution is defined for the leaflet and the outer leaflet surface of the mold is constructed by adding the leaflet thickness normally to the inner leaflet surface. The leaflet may be of uniform thickness throughout, in the range 40 to 500 microns, preferably 50 to 200 microns, more preferably 80 to 150 microns. The leaflet may be thickened towards its attachment to the frame. Alternatively the thickness of the leaflet, along a cross-section defined by the intersection of a plane perpendicular to the blood flow axis and the leaflet, can change gradually and substantially continuously from a first end of the cross-section (i.e., first edge of the leaflet) to a second end of the cross-section (i.e., second edge of the leaflet) in such a way that the mean thickness of the first half of the leaflet is different from the mean thickness of the second half of the leaflet. This mold is inserted in a conventional injection molding machine, the frame is inserted in the mold and the machine injects molten polymer into the cavity to form the leaflets and bond them to the frame. The polymer solidifies on cooling and the mold is opened to allow the complete valve to be removed.
[0125] The leaflets may also be formed using a reaction-molding process (RIM) whereby the polymer is synthesized during the leaflet forming. A mold is constructed as described above. This mold is inserted in a reaction-injection molding machine, the frame is inserted in the mold and the machine injects a reactive mixture into the cavity. The polymer is produced by the reaction in the cavity to form the leaflets and bond them to the frame. When the reaction is complete, the mold is opened to allow the complete valve to be removed.
[0126] Yet a further option is to compression mold a valve initially dipped. This approach allows the leaflet thickness or thickness distribution to be adjusted from that initially produced. By varying the thickness of the leaflets the dynamics of the valve opening and closing can be modified. For example, the thickness of the leaflet along a cross-section defined by the intersection of a plane perpendicular to the blood flow axis and the leaflet can be varied so that the thickness changes gradually and substantially continuously from a first end of the cross-section (i.e., first edge of the leaflet) to a second end of the cross-section (i.e., second edge of the leaflet) in such a way that the mean thickness of the first half of the leaflet is different from the mean thickness of the second half of the leaflet. This will result in the thinner half of the leaflet opening first and creating a sail-like opening motion along the free edge of the leaflet.
[0127] Leaflet shape resulting from conventional injection molding, reaction injection molding or compression molding, is substantially defined by the composite wave described above. It will differ in detail for many of the same reasons identified for dip molding.
[0128] The valves of the present invention are manufactured in the neutral position or close to it and are therefore substantially free of bending stresses in this position. As a result when the leaflet is moved to its closed position the total bending energy at the leaflet center free edge and at the commissures is reduced compared to a valve made according to U.S. Pat. No. 5,376,113 (Jansen et al.).
[0129] The valves of the present invention may be used in any required position within the heart to control blood flow in one direction, or to control flow within any type of cardiac assist device.
[0130] The following examples 1 and 2 use the same scallop geometry described using the constants set forth in Table 1: While the examples described herein relate to one valve size, the same method can be used to produce valves from a wide range of sizes. This can be carried out by modifying the constants used in the equations, by rescaling the bounding curves such as X closed (Z) and computing and iterating in the normal fashion or by rescaling the leaflet.
[0000]
TABLE 1
values (mm)
R
11.0
E So
21.7
E sJ
21.5
E sN
13.8
H sO
0.18
f(Z)
(0.05.Z) + 1.0
Example 1
[0131] The parameters described in the preceding sections are assigned the values set forth in Table 2 and are used to manufacture a symmetric valve. The included angle between adjacent leaflet free edges at the valve commissure for this valve is approximately 50°.
[0000]
TABLE 2
Parameter
Value (mm)
Closed position
Z cO
0
Z cO
0.0
E cN (Z)
E cN = 3.0.Z + 50.3
E cO
22.0
E cJ
20.0
X T(Z)
0.0
Partially-open position
θ
12.7°
E oJ
50.0
Z oO
4.0
E oO
51.8
E oN
27.7
A u
Result from iteration procedure finds that
A u varies from 1e−5 at the leaflet base to
5.1 at 4 mm from the leaflet base to 3.8 at
the free edge.
A s (Y)
1.0
B s
Result from iteration procedure finds that
B s varies from 1e−3 at the leaflet base to
1.6 at 3 mm from the leaflet base to 0.6 at
the free edge.
[0132] FIG. 12 shows the symmetric valve which is manufactured, using the values outlined in Table 1 and Table 2.
Example 2
[0133] The parameters described in the preceding sections are assigned the values set forth in Table 3 and are used to manufacture an asymmetric valve. The included angle between adjacent leaflet free edges at the valve commissure for this valve is approximately 48°.
[0000]
TABLE 3
Parameter
Value (mm)
Closed position
Z cO
0.0
E cN (Z)
E cN = 3.0.Z + 48.9
E cO
18.4
E cJ
20.0
X T(Z)
X T(n−1) = 0.97.(X T(n) ) where X T(free edge) = 2.1
Partially-open position
θ
7.1°
E oJ
50.0
Z oO
5.0
E oO
51.5
E oN
29.0
A u
Result from iteration procedure finds that
A u varies from 1e−5 at the leaflet base to
3.1 at 3 mm from the leaflet base to 2.2 at
9 mm from the leaflet base to
3.8 at the free edge.
A s (Y)
B s (Y) = (Y − c)/m where B s = 1 at leaflet base
and m = 5.04 and c = −15.1 at leaflet free
edge.
B s
Result from iteration procedure finds that
B s varies from 1e−3 at the leaflet base to
1.1 at 6 mm from the leaflet base to 0.4 at
the free edge.
[0134] FIG. 13 shows the valve which is manufactured using the values outlined in Table 1 and Table 3.
[0000]
TABLE 4
Definition of parameters
R
Internal radius of valve
Scallop (FIG. 2)
X ell , H sJ , H sN , X hyp are used to define a surface
which, when intersected with a cylinder, scribe a function
which forms the scallop for one leaflet. This method
for creating a scallop is described in Mackay et
al., Biomaterials 17 1996, although an added variable
f(Z) is used for added versatility.
X ell
Scribes an ellipse in the radial direction.
X hyp
Scribes a hyperbola in the circumferential
direction.
E sO
Ellipse X-axis offset
E sJ
Major axis of the ellipse
E sN
Minor axis of the ellipse
H sJ
Major axis of the hyperbola
H sN
Minor axis of the hyperbola
H sO
Hyperbola x-axis offset
f(Z)
Creates a varying relationship between
H sN and H sJ
Closed Leaflet geometry C (FIGS. 3 & 4)
X closed (Z) is defined as an ellipse (with a minor axis
E cN (Z) which changes with Z) in the XZ axis in the
plane defined in FIG. 2 by cutting plane 3-3. It is
defined using the following constants and functions.
Z cO
Closed ellipse Z-axis offset
E cN (Z)
Closed ellipse minor axis which changes
with Z
E cO
Closed ellipse X-axis offset
E cJ
Closed ellipse major axis
X T(Z)
Offset function which serves to increase
the amount of material in the belly
Molded position P
P is enclosed by a number (n) of contours P(X, Y) n
which run from one side of the scallop to the other.
The underlying function X u is used in defining both
symmetric and asymmetric leaflets. X u is simply an
ellipse (or other such function) running in a plane from
one side of the scallop to the other. The points on the
scallop are designated X (n,0) , Y (n,0) where
n refers to the contour number (see FIGS. 5, 7, 9, 11B).
Y
Variable in plane from Y (n,0) to − Y (n,0)
A u
A u is the amplitude of the underlying
wave
A s (Y)
A s is a function which biases the wave
amplitude in a defined way, e.g. the
amplitude of the wave can be increased
near the commissure if so desired.
B s
B s is the amplitude of the superimposed
wave
Composite Curve (FIGS. 7 & 9)
X c
X coordinate for defining the composite
curve. This is derived using X u and X s
Y c
Y coordinate for defining the composite
curve. This is derived using X u and X s
Open Leaflet position (FIG. 10)
X open (Z) is defined as an ellipse in the XZ axis in
the plane defined in FIG. 2 by cutting plane 3-3. The
contours defined in Composite Curve are married to
the Open Leaflet position X open (Z) to produce
the molded leaflet P.
It is defined using the following constants.
E oJ
Open ellipse major axis
Z oO
Open ellipse Z-axis offset
E oO
Open ellipse X-axis offset
E oN
Open ellipse minor axis
θ
Former taper angle
2. Second Embodiment of Heart Valve Prosthesis
[0135] The following describes another particular way of designing a second embodiment of a valve of the present invention. Other different design methodology could be utilized to design a valve having the structural features of the valve disclosed herein. Five computational steps are involved in this particular method:
(1) Define the scallop geometry (the scallop, 5 , is the intersection of the leaflet, 2 , with the frame, 1 ); (2) Define a contour length function L(z) and use this function to define a valve leaflet in the closed position C and optimize the stress distribution on the valve. The stress distribution can be confirmed using Finite Element Analysis (FEA). Thus the resulting stress distribution results from the length function L(Z) and FEA is used to confirm the optimal L(Z); (3) Rebuild the leaflet in a partially open position P; and (4) Match, using contour lengths, the computed leaflet area distribution in the partially open or molded position P to the defined leaflet in the closed position C. This ensures that when an increasing closing pressure is applied to the leaflets, they eventually assume a shape which is equivalent to that defined in closed position C.
[0140] This approach allows the closed shape of the leaflets in position C to be optimised for durability while the leaflets shaped in the molded partially open shape P can be optimised for hemodynamics. This allows the use of stiffer leaflet materials for valves which have good hemodynamics. An XYZ co-ordinate system is defined as shown in FIG. 2 , with the Z axis in the flow direction of blood flowing through the valve.
[0141] The leaflets are mounted on the frame, the shape of which results from the intersection of the aforementioned leaflet shape and a 3-dimensional geometry that can be cylindrical, conical or spherical in nature.
[0142] The leaflets are mounted on the frame, the shape of which results from the intersection of the aforementioned leaflet shape and a 3-dimensional geometry that can be cylindrical, conical or spherical in nature. A scallop shape is defined through cutting a cylinder of radius R (where R is the internal radius of the valve) with a plane at an inclined angle. The angle of the cutting plane is dictated by the desired height of the leaflet and the desired distance between the leaflets at the commissures.
[0143] The closed leaflet geometry in closed position C is chosen to minimize stress concentrations in the leaflet particularly prone to occur at the valve commissures. The specifications for this shape include:
(1) inclusion of sufficient material to allow a large open-leaflet orifice; (2) arrangement of this material to minimize redundancy (excess material in the free edge, 3 ) and twisting in the centre of the free edge, 3 ; and (3) arrangement of this material to ensure the free edge, 3 , is under low stress i.e., compelling the frame and leaflet belly to sustain the back-pressure.
[0147] The closed leaflet geometry is formed using contours S(X, Y) n sweeping from attachment points on one side of the scallop to the congruent attachment point on the opposite side of the scallop, where n is an infinite number of contours, two of which are shown in FIG. 4B . The geometry of the contours S(X, Y) n can be simple circular arcs or a collection of circular arcs and tangential lines; the length of each contour is defined by L(Z). Hence the geometry is defined and modified using the length function L(Z).
[0148] Thus the scallop shape and the contours S(X, Y) n are used to form the prominent boundaries for the closed leaflet in the closed position C. This process can be shortened by reducing the number of contours used to represent the surface (5<n<200). For design iteration, the ease with which the leaflet shape can be changed can be improved by reducing the number of contours to a minimum (i.e., n=5), although the smoothness of the resulting leaflet could be compromised to some extent. Upon optimising the function L(Z) for stress distribution, the number of contours defining the leaflet can be increased to improve the smoothness of the resulting leaflet (100<n<200). The function L(Z) is used later in the definition of the geometry in the partially open position P.
[0149] The aforementioned processes essentially define the leaflet shape and can be manipulated to optimise for durability. In order to optimise for hemodynamics, the same leaflet is molded in a position P which is intermediate in terms of valve opening. This entails molding large radius curves into the leaflet which then serve to reduce the energy required to buckle the leaflet from the closed to the open position. The large radius curves can be arranged in many different ways. Some of these are outlined herein.
[0150] As previously described with respect to the first embodiment the leaflet may be molded on a dipping former as shown in FIG. 14 . However, in this embodiment to aid removal of the valve from the former and reduce manufacturing stresses in the leaflet the former is preferably not tapered.
[0151] The geometry of the leaflet shape can be defined as a circular and trigonometric arrangement (or other mathematical function) preferably circular and sinusoidal in nature in the XY plane, comprising one or more waves, and having anchoring points on the frame. Thus the valve leaflets are defined by combining at least two mathematical functions to produce composite waves, and by using these waves to enclose the leaflet surface with the aforementioned scallop.
[0152] One such possible manifestation is a composite curve consisting of an underlying circular arc or wave upon which a second higher frequency sinusoidal wave is superimposed. A third wave having a frequency different from the first and second waves could also be superimposed over the resulting composite wave. This ensures a wider angle between adjacent leaflets in the region of the commissures when the valve is fully open thus ensuring good wash-out of this region.
[0153] The composite curve, and the resulting leaflet, can be either symmetric or asymmetric about a plane parallel to the blood flow direction and bisecting a line drawn between two stent tips such as, for leaflet 2 a , the section along line 3 - 3 of FIG. 2 . The asymmetry can be effected either by combining a symmetric underlying curve with an asymmetric superimposed curve or vice versa, or by utilising a changing wave amplitude across the leaflet.
[0154] The following describes the use of a symmetric underlying function with an asymmetric superimposed function, but the use of an asymmetric underlying function will be obvious to one skilled in the art. The underlying function is defined in the XY plane and connects the leaflet attachment points to the scallop at a given height from the base of the valve. This underlying function shown in FIG. 15 , can be trigonometric, elliptical, hyperbolic, parabolic, circular, or other smooth analytic function or could be a table of values.
[0155] The superimposed wave is defined in the XY plane, and connects the attachment points of the leaflet to the scallop at a given height above the base of the valve. The superimposed wave is of higher frequency than the underlying wave, and can be trigonometric, elliptic, hyperbolic, parabolic, circular, or other smooth analytic function, or a table of values.
[0000] One possible asymmetric leaflet design is formed when the underlying wave formed using a circular arc is combined with a superimposed wave formed using the following equation.
[0000]
X
s
=
A
s
·
B
s
(
Y
)
·
sin
[
(
1.5
π
Y
(
n
,
0
)
)
·
(
Y
-
Y
(
n
,
0
)
)
]
[0156] A circular arc is defined by its cord length, 2Y (n,O) , and amplitude, A u , as shown in FIG. 15 . A s can be varied across the leaflet to produce varying wave amplitude across the leaflet, for example lower amplitude in one commissure than the opposite commissure. B s can be varied to adjust the length of the wave. The superimposed wave is shown in FIG. 16 . The composite wave formed by combining the underlying wave ( FIG. 15 ) with the superimposed wave ( FIG. 16 ) is shown in FIG. 17 . The composite wave W(X c , Y c ) n is created by offsetting the superimposed wave normal to the surface of the underlying wave ( FIG. 17 ). Positive γ is defined as the direction of the normal to the underlying wave relative to the x-axis. When Y is positive, the composite curve is created by offsetting in the direction positive γ and where Y is negative the composite curve is created by offsetting in the direction negative γ (the offset direction is shown by arrows for a positive Y point and a negative Y point in FIG. 17 .
[0157] While the general shape of the leaflet in position P has been determined using the composite wave, at this stage it is not specified in any particular position. In order to specify the position of P, the shape of the partially open leaflet position can be defined using the ratio of the amplitude of the circular arc A u to the amplitude of the sinusoidal wave B s .
[0158] A large ratio results in a leaflet which is substantially closed and vice versa. In this example the ratio changes from 10 at the base of the leaflet to 4 at the free edge of the leaflet. The result of this is a leaflet which effectively is more open at the free edge than at the base of the leaflet. In this way, the degree of ‘openness’ of the leaflet in position P can be varied throughout the leaflet.
[0159] The composite wave is thus defined to produce the molded “buckle” in the leaflet, and the amplitude ratio is used to define the geometry of the leaflet at position P. At this stage it may bear no relation to the closed leaflet shape in position C. In order to match the area distribution of both leaflet positions, (thus producing essentially the same leaflet in different positions) the composite wave length is iterated to match the length of the relevant leaflet contour in position C. Thus the amplitude and frequency of the individual waves can be varied in such a manner as to balance between: (a) producing a resultant wave the length of which is equal to the relevant value in the length function L(Z) thus approximating the required closed shape when back pressure is applied, and (b) allowing efficient orifice washout and ready leaflet opening.
[0160] This process identifies the values of A u and B S to be used in constructing the mold for the valve leaflet. As long as the constants such as A u and B s are known, the surface of the leaflet in its molded position can be visualised, enclosed and machined in a conventional manner. As a result of this fitting process the composite wave retains the same basic form but changes in detail from the top of the leaflet to the bottom of the leaflet. A composite wave can be defined in the leaflet surface as the intersection of the leaflet surface with a plane normal to the Z axis.
[0161] In summary therefore one possible method of designing the leaflet of the second embodiment of the present invention is in the following way:
(1) Define a scallop shape; (2) Define a shape representing the closed leaflet using a contour length function L(Z); (3) Use circular arcs and sine waves to generate a geometry which is partially-open, which pertains to a leaflet position which is between the two extreme conditions of normal valve function, i.e., leaflet open and leaflet closed; (5) Vary the amplitude of the arcs and the sinewaves to fit to the length function L(Z); and (6) The respective amplitudes of the circular arcs and sine waves can be varied from the free edge to leaflet base, for example the degree of ‘openness’ of the leaflet can be varied throughout the leaflet.
[0167] Example 3 set forth hereafter is an example of how the invention of the second embodiment can be put into practice. Using the scallop constants in Table 5, the constants required to produce an example of an asymmetric leaflet valve are given in Table 6. These constants are used in conjunction with the aforementioned equations to define the leaflet geometry.
[0168] With one leaflet described using the aforementioned equations, the remaining two leaflets are generated by rotating the geometry about the Z axis through 120° and then through 240°. These leaflet shapes are inserted as the areas of the dipping mold (otherwise known as a dipping former), which form the majority of the leaflet forming surfaces, and which then forms a 3-dimensional dipping mold. The composite wave described in the aforementioned equations, therefore substantially defines the former surface which produces the inner leaflet surface. A drain-off area 30 is also created on the former to encourage smooth run-off of polymer solution. The drain-off region 30 is defined by extruding the leaflet free edge away from the leaflet and parallel to the flow direction of the valve for a distance of approximately 10 mm. The transition from leaflet forming surface of the dipping mold 24 to the drain-off surface of the dipping mold 30 is radiused with a radius greater than 1 mm and preferably greater than 2 mm to eliminate discontinuities in the leaflet.
[0169] The details of the manufacture of the valve of the second embodiment are similar to those previously described with respect to the valve of the first embodiment until the valve is removed from the dipping mold. Since the former used in making the valve of the second embodiment is not tapered the stent posts are not deflected by the former and do not move or change the leaflet shape when the valve is removed from the mold. At this stage the dipping mold and frame is covered with an excess of polyurethane due to the drain-off of the polymer onto the region of the mold known as the drain-off area 30 . To maintain the integrity of the frame coating, the leaflet is trimmed above the stent tips at a distance of between 0.025 to 5 mm preferably 0.5 mm to 1.5 mm from the stent tip. Thus part of the surface of the leaflet is formed on the drain-off region 30 which is substantially defined using the composite wave W(X c , Y c ) 0 . Leaflet free edges may be trimmed of excess material using a sharp blade rotated around the opened leaflets or using laser-cutting technology or other similar technology.
[0170] The valve of the second embodiment may be used in any required position within the heart to control blood flow in one direction, or to control flow within any type of cardiac assist device.
[0171] The following example 3 uses the same scallop geometry described using the constants set forth in Table 5: While the example 3 described herein relates to one valve size, the same method can be used to produce valves from a wide range of sizes. This can be carried out by modifying the constants used in the equations, and computing and iterating in the normal fashion or by resealing the leaflet.
[0000]
TABLE 5
values (mm)
R
11.0
slope
−2.517
intersection
14.195
Example 3
[0172] The parameters described in the preceding sections are assigned the values set forth in Table 6 and are used to manufacture an asymmetric valve according to the second embodiment. The included angle between adjacent leaflet free edges at the valve commissure for this valve is approximately 30°.
[0000]
TABLE 6
Parameter
Value (mm)
Closed position
L(Z)
Varies from 0.025 mm at the leaflet base
to 21.3 mm at the free edge
Partially-open position
θ
0°
A u
Result from iteration procedure finds that
A u varies from 0.0006 at the leaflet base
to 3.8 at 10.7 mm from the leaflet base to
3.35 at the free edge.
A s
At the free edge of the leaflet, A s (Y)
varies from 1.5 mm at one side of the
scallop to 1.0 mm at the opposite side of
the scallop.
At the base of the leaflet, A s (Y) is 1.0 mm.
B s
Result from iteration procedure finds that
A s varies from 0.0006 at the leaflet base
to 0.839 mm at the free edge.
[0173] FIG. 18 shows the asymmetric valve which is manufactured, using the values outlined in Table 5 and Table 6.
[0000]
TABLE 7
Definition of parameters
R
Internal radius of valve
Scallop (FIG. 2)
The scallop is defined using a simple straight line,
defined using a slope and intersection, to cut with
a cylinder.
Closed Leaflet geometry C
L(Z) is used to modify the inherent geometry of the
leaflet. Circular arcs and straight lines can be used
to enclose the surface defined using L(Z).
Molded position P
P is enclosed by a number (n) of contours W(X, Y) n
which run from one side of the scallop to the
other. The underlying function is used in defining
both symmetric and asymmetric leaflets. running in
a plane from one side of the scallop to the other.
The points on the scallop are designated X (n,0) ,
Y (n,0) where n refers to the contour number (see FIGS.
15, 16, 17, 18).
Y
Variable in plane from Y (n,0) to − Y (n,0)
A u
A u is the amplitude of the underlying
wave
A s (Y)
A s is a function which biases the wave
amplitude in a defined way, e.g. the
amplitude of the wave can be varied
from commissure to commissure to
produce asymmetry in the leaflet.
B s
B s is the amplitude of the superimposed
wave
Composite Curve (FIGS. 17)
X c
X coordinate for defining the composite
curve.
Y c
Y coordinate for defining the composite
curve.
Open Leaflet position (FIG. 18)
The open leaflet position is defined using a ratio
which determines the degree of “openness” of
the leaflet.
θ
Former taper angle
|
A cardiac valve prosthesis having a frame and two or more leaflets (preferably three) attached to the frame. The leaflets are attached to the frame between posts, with a free edge which can seal the leaflets together when the valve is closed under back pressure. The leaflets are created in a mathematically defined shape allowing good wash-out of the whole leaflet orifice, including the area close to the frame posts, thereby relieving the problem of thrombus deposition under clinical implant conditions.
| 8
|
BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention relates generally to improvements in ironing systems provided by the hospitality industry to guests.
2. Prior Art
Most of the better hotels, motels, inns, resorts and other members of the hospitality industry provide guests with irons and ironing boards to enable the guests to press garments. Usually, the ironing board is located in a guest room closet supported by a bracket mounted on the closet wall. Nearby, the iron is stored, usually in vertical attitude, in some form of housing affixed to the closet wall.
In order to press wearing apparel, it is merely necessary to lift the ironing board from the bracket, carry it to a location in the room that is close to a wall outlet, unfold the board to a convenient height and plug in the iron brought from the housing.
While this amenity is a welcome addition to any accommodation, risk to the guest and damage to the property is an ever present possibility in the typical prior art installation just described. More specifically, guests are sometimes prone to remove the iron from the closet and, instead of using the ironing board provided, will connect the iron to an electrical outlet and press their garments on the bed spread, bed sheet, or on the carpet or on a towel placed on a desk, dresser or other handy article of furniture. Not only does this practice often result in scorching the spread, sheet, carpet, towel, or furniture, but it sometimes causes fires when the guest leaves the room and forgets to disconnect the iron.
Furthermore, it is not unknown for a guest to check out with the iron concealed in the guest's luggage.
Although not of paramount consideration in the overall operation, scorch damage to the property and theft of the iron itself are of on-going concern to management. These problems are unfortunately inherent in the ironing systems heretofore used.
Nine U.S. patents were made of record in a co-pending design patent application, Ser. No. 29/061,365, filed by applicants herein on Oct. 11, 1996, for the Iron Holder, one of the key components of the present invention.
The nine cited patents are identified as follows:
Echols Des. 211,124
Wilson et al. Des. 211,603
Larkins Des. 2,514,400
Sitnick et al. Des. 2,528,846
Wentz Des. 3,136,516
Inverso Des. 3,176,947
Agrusa Des. 3,477,672
Kocsak Des. 3,951,369
Lomagno Des. 3,967,802
It is believed that the present invention is neither anticipated by nor rendered obvious by the art cited above, copies of which accompany the Information Disclosure Statement.
SUMMARY OF THE INVENTION
The combined iron, iron holder and ironing board, as arranged pursuant to the present invention, provide an integrated structure which overcomes the objections to and shortcomings of the prior art.
The iron and the iron holder as well as the iron holder and the ironing board are joined together in the preferred embodiment. The iron cannot be used to press garments unless the ironing board and the iron holder are also present.
A safety/security tether resiliently connects the iron to the iron holder and the iron holder in turn, is attached to the ironing board. The fastenings are installed with custom wrenches not ordinarily carried by a guest. Theft and tampering are inhibited.
The iron holder serves as a safe repository for the iron, whether hot or cold, and whether stored or in use; and the iron holder is especially constructed so as to dissipate any heat transferred from a plurality of unique support buttons which, themselves, are fabricated from materials having very high heat tolerance and very low thermal conductivity.
Guest convenience and safety are enhanced while management benefits from theft containment and reduced property damage and liability.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
The drawing figures illustrate the best mode presently contemplated of carrying out the invention.
FIG. 1 is a front elevation of the combined unit in folded condition and suspended in vertical attitude from a hanger bracket on a closet wall;
FIG. 2 elevation thereof,
FIG. 3 is a top, rear perspective view of the combined unit in unfolded condition, with a cold iron removed from the holder and positioned face down on the upper surface of the board, and with electrical conductor disconnected from an outlet;
FIG. 4 is a perspective view of the iron holder, per se, to an enlarged scale;
FIG. 5 is a side elevation, to an enlarged scale, of the iron connected to and immobilized in the iron holder and the iron holder secured to the ironing board, with portions of the components being shown in the section; and,
FIG. 6 is a sectional view, to an enlarged scale, taken on the line indicated by the numerals 6--6 in FIG. 5;
FIG. 7 is a perspective view to an enlarged scale, of the tamper-proof clamp-type fitting securing the tether cord to the iron, and showing a custom hex key wrench for use with the fitting; and,
FIG. 8 is a sectional view of the fitting, taken on the line 8--8 in FIG. 7. Introductory Portion
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
As most clearly appears in FIGS. 1, 2, and 3, the Combined Iron, Iron Holder, and Ironing Board of the invention is designated by the reference numeral 10.
The iron 11 is preferably of a conventional make and includes the customary body 12 and electrical conductor 13. The lower portion of the body 12 includes a sole plate 14, or foot plate, extending from a pointed toe end 15 to a blunt heel end 16.
A continuous loop handle 17 mounted on the body 12 serves the usual purpose of manipulating the iron; and, in the preferred embodiment also serves as a component of anti-theft tethering means 19. The tethering means 19 comprises an extensible coiled cord 20 secured at one end 21 to the handle 17 by a special tamper proof clamp-type fitting 18 and at the other end 22 to an anchor 23 (see FIG. 4) on an iron holder 24 mounted on an ironing board 25.
The ironing board 25 is also of conventional make, and, affords certain functions in addition to the ordinary one of providing an exposed planar surface 26, usually covered by a pad and some type of heat resistant fabric. The ironing board 25 extends from a first, tapered end 27 to a second, butt end 28. The customary pivoted legs 29 and 30, and respective transverse feet 31 and 32 on the bottoms of the legs 29 and 30, are arranged in a manner which enables the user either to fold the legs into the compact condition of the board illustrated in FIGS. 1 and 2 or to unfold and releasably lock the legs 29 and 30 so that the board 25 is horizontally disposed at a height convenient for the user, as illustrated in FIG. 3.
When in folded condition the ironing board 25 is conveniently stored in a closet with the tapered end 27 up and with the respective transverse foot 31 suspended by a mounting bracket 33 affixed to the closet wall 34 (see FIGS. 1 and 2). In the vertical folded attitude assumed by the board, the amount of closet space required by the board is negligible.
The key link in the combination is the iron holder 24 which is connected both to the iron 11 and the ironing board 25.
The iron holder 24, as most clearly appears in FIG. 4, comprises a base plate 36 having generally the same shape as, although slightly larger in size than, the sole plate 14 of the iron 11. Thus, the base plate 36 extends from a moderately pointed toe end 37 to a blunt heel end 38 and between opposite side edges 39 and 40.
Covering a plurality of holes 35 in the upper surface 41 of the base plate 36 is a plurality of raised buttons 42 (see FIGS. 4 and 6) of a special phenolic material capable of withstanding the high temperature of the iron sole plate 14, but of very low thermal conductivity so as to minimize the extent of heat transfer to the base plate 36. Axially aligned with the holes 35 is a plurality of stanchions 43 supporting the base plate 36 in spaced relation above the heat resistant cover 44 and pad 45 covering the ironing board 25.
The stanchions 43 are mounted on the board 25 by threaded fasteners 46, or screws, driven by an Allen, or hex key, wrench engageable with the walls of hexagonal recesses 47 in the heads 48 of the stanchion screws 46. Since the hexagonal wrenches suitable for installing the fasteners must be of a precise size, the likelihood of theft is decreased.
Upstanding from portions of the side edges 39 and 40 of the base plate are opposed side walls 49 and 50, or wings, arranged in mirror symmetry. The side walls 49 and 50 are inclined somewhat inwardly and, adjacent their upper edges, are curved inwardly toward each other in order to embrace the opposite sides 51 of the iron 11. Since irons of different make differ somewhat in size and shape, the material from which the iron holder 24 is fabricated is chosen to afford a degree of malleability enabling the wings 49 and 50 to be bent inwardly or outwardly in order to embrace the sides 51 of the iron in snug relation. The material is stiff enough, however, to hold the iron firmly in place. A suitable material is 18 gauge steel which, for aesthetics is powder coated in white or ivory color, the powder coating affording resistance to discoloration from heat.
The wings 49 and 50, furthermore, are generously provided with vents, in the form of openings 52, enhancing the dissipation of heat received from the sides 51 of the iron 11.
When the iron 11 is positioned in the iron holder 24, the blunt, or heel end 16, of the iron is abutted by an end wall 53 upstanding from the blunt end 38 of the base plate 36 of the iron holder. As in the wings 49 and 50, vent openings 54 assist in dissipating heat from the heel end of a hot iron 11 lodged in the iron holder 24.
The nether end portion of the end wall 53 is bent along a bend line 56 to afford a ledge 57 having an opening 58 formed therein to receive the end 22 of the tether cord 20 and thus serve as part of the tether cord anchor 23 on the iron holder 24. The anchor 23 is substantially tamper proof owing to the provision of a compressible metal collar 61 clamped on the end 22 of the tether cord 20. The collar 61 is larger than the opening 58 and thus secures the tether cord.
A pair of opposed recesses 59 in the opposite ends of the ledge 57 provide convenient areas in which to wrap the conductor 13 of the iron 11 when the iron is stored.
The iron 11 is secured to the cord 20 by threading the end 21 of the tether cord 20 through the loop-type handle 17 on the iron and recurving the cord end 21 back on itself, as appears most clearly in FIG. 5, for clamping in the special fitting 18.
The special, tamper-proof clamp-type fitting 18 (see FIGS. 7 and 8) is installed on the parallel portions of the tether cord 20 by clamping together the two halves 64 and 65 of a block 63 with the two cord portions interposed in half tracks 66 and 67 formed in the respective halves 64 and 65. Special machine screws 68 are then tightened by a custom, modified Allen wrench 69 so as to clamp together the two halves 64 and 65 of the fitting 63.
As can be seen most clearly in FIG. 7, the wrench 69 essentially comprises a hollow hex key wrench, with a central axial opening 71 deep enough to receive an axial pin 72 disposed within the axial, hexagonal recess 73 in the head 74 of the machine screws 68. Once the especially modified screws 68 are driven into clamping position, even the customary "Allen-head" wrench will not be able to unscrew, and thereby release, the tether cord from the fitting 18.
Thus, the iron 11 is secured to the iron holder 24 in a substantially tamper-proof manner.
Similar comments apply to the structure serving to mount the iron holder 24 to the ironing board 25.
With particular reference to the enlarged sectional view, FIG. 6, the procedure for mounting the iron holder 24 on the ironing board 25 (and accompanying pad and cover) preferably includes the use of a template (not shown) in order to establish the location of the four stanchions 43 on the large, or butt end of the ironing board 25. The template carries indicia corresponding to the holes 35 in the base plate 36. The template indicia holes 35, are centered on the longitudinal centerline of the ironing board 25 with the two end holes 35 (i.e. the two holes 35 adjacent the end wall 53) about three to four inches from the broad end of the board 25.
Once the position of the four holes is established on the ironing board cover 44, four small pilot holes are gently pierced through the cover 44 and the pad 45. These small pilot holes will often align with the perforated holes found in many sheet metal ironing boards and will usually align with the openings in any wire mesh top board. If the four holes do not align with any openings or with openings of proper diameter in the board top, the necessary openings 75 in the board top can be drilled in the board.
Once the four openings 75 in the ironing board, cover and pad are in place, one top washer 76 is placed axially in register with each of the openings 75, the top washers 76 being located on the top surface of the heat resistant, fabric cover 44.
The iron holder 24, (with the threaded necks 77 of the four buttons 42 inserted through their respective holes 35 in the base plate 36 and threadably engaged with tapped registering sockets 78 in the stanchions 43) is thereupon positioned so that each of the stanchions 43 is axially aligned with and supported on the respective top washer 76.
It is to be noted that the top portion of each of the necks 77 of the buttons 42 is encompassed by a ring 79 integrally formed on top of the stanchion. It is often convenient to pre-assemble the button-stanchion fittings on the iron holder. In this case, the upstanding ring 79 on the top of the stanchion 43 is inserted through the hole 35 so that the top of the ring 79 is flush with the top surface of the base plate 36 and abuts the shoulder on the bottom of the mushroom-shaped button cap 82. It is preferable that there be an interference fit between the ring 79 and the hole 35 requiring swaging and thereby giving rigidity to the pre-assembly.
In axial alignment with the threaded socket 78 is a drilled and tapped opening 86 in the stanchion. Thus, when the base plate 36, with the four pre-fitted buttons 42 and stanchions 43, is placed in register with the top washers 76, four bottom washers 88 are properly positioned and the respective stanchion screws 46 are inserted from below and hand-tightened in the tapped openings 86.
When all four hand-tightened screws 46 are in place in the threaded openings 86 in the stanchions, a hex key wrench is inserted in each of the hexagonal recesses 47 in the heads 48 of the screws 46 and driven to assure a tight fit of all components, including the base plate 36 of the iron holder 24 and the ironing board 25, as well as the buttons 42 and the stanchions 43.
The ironing board 25 and the tightly secured iron holder can then be rested on the ironing board hanger, or mounting, bracket 33 which is attached to the wall with a pair of drywall anchor screws 94 of conventional type, as appears in FIG. 2.
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An ironing system for guests of the hospitality industry that is not only compact in size, for storage in a guest room closet, but is also convenient and safe to use when the guest needs to press garments or other articles of wearing apparel. By combining the customary iron and the usual ironing board with a specially constructed iron holder and tethering arrangement, property damage and loss is contained, all to the benefit of management and guest alike.
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BACKGROUND OF THE INVENTION
[0001] The present invention is directed to a system and appertaining method for manipulating identification data of medical images and data sets for quality assurance.
[0002] Digital medical data sets (for example, x-ray images, ultrasound images, fundus images, EKG, etc.) are provided with identifying data of a patient and examination data (designated as “ident data” in the following) in order to prevent confusions of the data sets.
[0003] A method is needed with which the ident data can be manipulated, while at the same time the legal security requirements with regard to the identification requirements are fulfilled. Such a manipulation can be necessary for quality assurance purposes, or for the anonymization or pseudonymization of images when, for example, data previously found by an examiner must be provided to him a second time without him being able to identify the case via its identifying data. At the same time, it must be ensured that the data sets do not differ from those used in routine operation.
[0004] The following explanation describes known procedures to identify medical data sets, and references FIGS. 1A and 1B . According to a known process, desired ident data 20 is written into a medical image 18 in an area of the image (data set) in which no relevant medical information is present 12 . Two different methods are currently used to accomplish this:
[0005] a) ( FIG. 1A ) the ident data 20 are written into the original image—the original data 16 is thereby lost and replaced by this writing. The advantage to this approach is that the ident data 20 become a part of the image and can no longer be manipulated in an easy manner or be lost in transmission.
[0006] b) ( FIG. 1B ) the ident data 20 are maintained separately, but are placed over the unaltered image 18 (overlay technique) upon the display of the data set. The advantage to this approach is that the original data 16 remain unaltered, and the image 18 can optionally be output with or without identifying data 20 . The disadvantage of this method is that the identifying 20 information can be lost.
[0007] U.S. Pat. No. 6,301,360 discloses a method of encoding information according to a position-based encoding scheme. In this method, data sequences are encoded into another data entity, such as a pixel-based image or medical record. The position for values to be changed are determined by a reversible function.
SUMMARY OF THE INVENTION
[0008] It is the object of the present invention to provide a system and appertaining method for providing ident data to a medical record that does not destroy a part of the original data while at the same time reduces or eliminates the possibility that the ident information becomes lost or disassociated with the examination/medical data.
[0009] This object is achieved by a method for providing ident data with medical image or examination data, comprising: collecting ident data regarding a subject; collecting an original medical image or examination data (original image data) regarding the subject; defining a region in the image data into which the ident data will be written; copying the image data from the defined region as original data in a storage location remote from the image data; generating associative information identifying the storage location of the original data; and writing the ident data into the defined region of the original image data, thereby producing overwritten image data.
[0010] This object is also achieved by a system for providing ident data with medical image or examination data (image data), comprising: an imaging or recording device configured to collect image data from a subject; a local processor connected to the imaging or recording device and having an input for receiving the image data; a network connected to the local processor; a server that is also connected to the network, the server having a storage device connected to it that has a memory for storing original data taken from a defined region of the image data obtained from the local processor; an ident data generator configured to generate ident data related to the subject and put the ident data into the defined region of the image data from which the original data was taken; and an associative data generator configured to generate data associating the original data with a memory location of the server storage device.
DESCRIPTION OF THE DRAWINGS
[0011] Embodiments of the invention are described below with reference to the following drawing figures.
[0012] FIG. 1A is a block diagram of a known medical data set identification scheme in which examination data is overwritten with ident data;
[0013] FIG. 1B is a block diagram of a known medical data set identification scheme in which identification data is provided as an overlay;
[0014] FIG. 2 is a pictorial diagram illustrating the major components of the inventive medical data set identification system; and
[0015] FIG. 3 is a block diagram illustrating an embodiment of the inventive medical data set identification system.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0016] Various embodiments of the invention are described below. FIG. 2 illustrates the major components of the system. A subject 2 undergoes a medical procedure using an imaging or recording device 4 , such as an x-ray, ultrasound, EKG, etc. A medical image (or examination data, collectively hereinafter “medical image”) 18 is retrieved from the recording device 4 and stored on a local processor 6 (either directly or indirectly by, e.g., scanning from a non-digital medium such as paper or film). Ident information 20 is collected regarding the user that may include name, age, gender, medical condition, test procedure, or any other relevant information related to the subject or the procedure being performed. This information may be collected by the local processor 6 or other system.
[0017] The local processor is connected through a network 8 , which may be a local area network or a wide area network, such as the Internet, to a server 30 that has storage device 32 associated with it.
[0018] According to the inventive method, and as illustrated in FIG. 3 , ident data 20 for a subject 2 is gathered by any type of medical procedure in a manual and/or automated process either before, concurrently with, or after medical image or examination data 18 is gathered for the subject 2 .
[0019] A region 24 of the medical image 18 is defined in which the ident data 20 and any additional associative (surjective) data 22 will be placed. This region 24 may be defined by coordinate boundaries, or it may be fixed, depending on a type or class of medical image 18 , or it may even be defined by a bitmap. What is important is that this region be large enough to hold any ident data 20 and associative or surjective data 22 that will later be applied to the medical image.
[0020] The original data 16 from this defined region 24 is copied or moved from the medical image 18 and stored electronically in a location remote (i.e., remote from a contact proximity) from the medical image data 18 , such as on the storage device 32 of the server 30 . The original data 16 that has been saved can be made available via, e.g., the server 30 via the network 8 . When a new image 18 is generated, the original data 16 of the area in which the ident data 20 are written are sent to the server 30 . The server 30 stores the original data 16 , generates a associative information (e.g., surjective identification) 22 identifying the location of the stored original data 16 , and delivers the associative information 22 back to a device, e.g., the local processor 6 , in the image-generating location. The local processor 6 may be used to write the ident data 20 together with the associative information 22 into the original image 18 . The original data 16 are thus stored in a remote location such that the original image can be produced again as needed.
[0021] The storage of the original data 16 can ensue in image formats that support the storage of supplementary information, such as DICOM, via utilization of the image format. DICOM is a standard for Digital Imaging and Communications in Medicine developed by the American College of Radiology (ACR) and the National Electrical Manufacturers Association (NEMA). This Standard is developed in liaison with other Standardization Organizations including CEN TC251 in Europe and JIRA in Japan, with review also by other organizations including IEEE, HL7 and ANSI in the USA. In the event that a particular image format does not support the storage of the original data 16 , this data can be stored in an additional or alternative databank according to some form of identification of the image. The medical image data 18 can originate from all medical modalities (e.g., x-ray (Rö), magnetic resonance (MR), computed tomography (CT), ultrasound (US), fundus exposures, electrocardiogram (EKG), etc) and medical data collection devices.
[0022] After the ident data 20 is collected, this data 20 is written to the defined region 24 of the medical image data 18 , along with the additional data 22 that may be used to identify the location of storage of the original data 16 . This additional/surjective identification 22 can be part of the ident data 20 inserted into the original medical image data 18 in the defined region 24 . The original data 16 can then be retrieved or recovered using the surjective identification data 22 of the original data 16 . This surjective identification data 22 can thus be part of the meta-information of an image 18 .
[0023] In order to restore the overwritten medical image 18 to its original form, the ident data 20 region and the surjective data region 22 must be exchanged with the original data 16 . The original data 16 is first retrieved using the surjective identification 22 of the original data 16 and used again in the image 18 . New ident information 22 can then be generated and inserted into the image 18 .
[0024] The same original image 18 can be manipulated multiple times; the surjective identification 22 can be written over in a consistent area in which the ident data 20 are written; the association with an original image remains. In this case, it is reasonable to also store the true ident data 20 separately, in addition to the original image data 16 .
[0025] The algorithm which sends the original data 16 to the server 30 can supply not only one image region (for example, a rectangular region) for storage, but rather it can send precisely the amount and location of the pixels manipulated by the ident data 20 . Exactly one original data set 16 belongs to a surjective identification 22 (surjective with regard to the true ident data); in other words, there is a one-to-one correspondence between the original data set 16 and its identification 22 .
[0026] Although not an ideal alternative, the surjective identification data 22 may be associated solely with the original data 16 on the storage area 32 of the server 30 and not with the overwritten medical image data 18 . This approach, while workable, has the danger that if the mapping on the server 30 is ever destroyed, it would be impossible (for any significant number of medical image data sets 18 ) to match the original data 16 with the associated medical image data 18 .
[0027] Alternately, the ident data 20 and/or the associative/surjective identification data 22 may be stored redundantly on the server storage area 32 along with the original data 16 .
[0028] Furthermore, although there should be a one-to-one correspondence of original data sets 16 with the corresponding surjective identification 22 , there is no reason that a single medical image data set 18 cannot utilize more than one ident data set 20 . Advantageously, such an inventive embodiment may be used in a quality control context. For quality control purposes, a particular image may be provided to multiple viewers or finders (an interperson test); these viewers are often working together in a common room or institution. If a plurality of viewers get a simultaneously distributed medical data set 10 having the same ident data 20 on it, they might then be able to identify the image as a quality control image by comparison, and thus might respond differently to it. Inventive embodiments permit providing multiple copies of a particular original image with different ident data 20 so that the viewers cannot make such an association.
[0029] Similarly, for quality control testing of intragrader/intraperson reliability (i.e., repeatability/reproducibility within a particular viewer), using different ident data 20 when giving the same file to a viewer multiple times in a temporally spaced manner will reduce the likelihood that the viewer would recognize the image as a quality control image based on a repeated viewing of the same ident data 20 .
[0030] For the purposes of promoting an understanding of the principles of the invention, reference has been made to the preferred embodiments illustrated in the drawings, and specific language has been used to describe these embodiments. However, no limitation of the scope of the invention is intended by this specific language, and the invention should be construed to encompass all embodiments that would normally occur to one of ordinary skill in the art.
[0031] The present invention may be described in terms of functional block components and various processing steps. Such functional blocks may be realized by any number of hardware and/or software components configured to perform the specified functions. For example, the present invention may employ various integrated circuit components, e.g., memory elements, processing elements, logic elements, look-up tables, and the like, which may carry out a variety of functions under the control of one or more microprocessors or other control devices. Similarly, where the elements of the present invention are implemented using software programming or software elements the invention may be implemented with any programming or scripting language such as C, C++, Java, assembler, or the like, with the various algorithms being implemented with any combination of data structures, objects, processes, routines or other programming elements. Furthermore, the present invention could employ any number of conventional techniques for electronics configuration, signal processing and/or control, data processing and the like.
[0032] The particular implementations shown and described herein are illustrative examples of the invention and are not intended to otherwise limit the scope of the invention in any way. For the sake of brevity, conventional electronics, control systems, software development and other functional aspects of the systems (and components of the individual operating components of the systems) may not be described in detail. Furthermore, the connecting lines, or connectors shown in the various figures presented are intended to represent exemplary functional relationships and/or physical or logical couplings between the various elements. It should be noted that many alternative or additional functional relationships, physical connections or logical connections may be present in a practical device. Moreover, no item or component is essential to the practice of the invention unless the element is specifically described as “essential” or “critical”. Numerous modifications and adaptations will be readily apparent to those skilled in this art without departing from the spirit and scope of the present invention.
REFERENCE CHARACTERS
[0000]
2 subject
4 imaging or recording device
6 local processor
8 network
10 medical data set
12 non-relevant medical data region
14 relevant medical data region
16 original data
18 medical image/examination data
20 surjective identification data
22 associative/surjective data
24 region into which ident and surjective data is added
30 server
32 server storage device
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Identification information is overwritten onto a defined region of a medical image or examination data. Original data formerly occupying the overwritten region is saved and stored on a server, and associative information identifying the storage location of the original data is determined and optionally written into the defined region. The original medical image can be reconstructed by locating the stored original data from the associative information and placing the original data back into the defined region.
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