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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of the U.S. Provisional Application No. 60/417,776 filed Oct. 11, 2002.
FIELD OF THE INVENTION
[0002] The present invention relates generally to skeletal plating systems and components thereof, which can be used to adjust, align and maintain the spatial relationship(s) of adjacent bones or bony fragments during healing and fusion after surgical reconstruction of a mammalian bone structure. Such systems can comprise skeletal plates, bone screws and/or distraction screws and plate-to-screw locking mechanisms.
BACKGROUND OF THE INVENTION
[0003] The surgical removal of a herniated disc, whether from degenerative disease or traumatic disruption, is a common procedure in current medical practice. In the cervical spine, the procedure involves placement of a large temporary bone screw, which is also known as the distraction screw, into each of the vertebral bones above and below the diseased disc space. These screws are used to realign the vertebral bones into the desired anatomical relationship and to temporarily distract them so as to permit work within the intervening disc space. The disc is removed and a bone graft or suitable graft substitute is placed into the evacuated space. The temporary distraction screws are then removed from the vertebrae and a metallic skeletal plate is used to maintain the position of the vertebral bones while bone healing occurs. The bones are fixed to the skeletal plate using implantable bone screws (usually two screws per vertebrae), which are separate and distinct from the distraction screws.
[0004] Removal of the distraction screws from the vertebral bodies usually produces robust bone bleeding and requires that the bone holes be filled with a hemostatic agent. The empty bone holes also act as stress concentration points within the vertebral bodies, as would any empty opening or crack within a rigid structural member, and predispose the vertebral bodies to bone fracture, screw/plate migration and construct failure. Further, the empty holes often interfere with proper placement of the implantable screws and the associated skeletal plate, making proper alignment of the plate along the anatomically desired plane more difficult. This is especially problematic since the plate is placed at the end of the operative procedure and the preceding surgical steps have distorted the anatomical landmarks required to ensure proper plate alignment.
[0005] Lastly, once placed, the plate will effectively cover the vertebral bodies of the reconstructed segment. Extension of the operation to an adjacent level at a future date will require placement of a distraction screw within a covered vertebrae and, thus, necessitate plate removal. The latter requires re-dissection through the scarred operative field of the initial procedure and significantly increases the operative risk of the second procedure for the patient.
[0006] In view of the above, it would be desirable to design an improved distraction screw. The new device should minimize blood loss, reduce the potential for stress concentration, maximize the likelihood of proper plate alignment, provide an additional point of fixation for the skeletal plate and provide a ready mechanism for distraction screw replacement at the time of surgical revision without obligatory plate removal.
SUMMARY OF THE INVENTION
[0007] The present invention is one of an improved distraction screw and a method for its use. The design substantially enhances the functional capability of distraction screws used in the surgical reconstruction of mammalian bones. In this invention, the multi-segmental distraction screw comprises an implantable distal segment and a detachably secured proximal segment. The distal segment includes a head portion and a threaded shank portion. The proximal segment is represented as an elongated body having an internal bore that extends through its length. A deployable member is disposed within the proximal segment, which is extendable beyond the distal end of the internal bore to engage and secure the distal segment, thus forming a unitary distraction screw. Once assembled, the screw is used to realign and distract the bones during surgical reconstruction of a degenerated skeletal segment. Upon completion of that work, the proximal and distal segments are disengaged leaving the latter attached to bone. Securely affixed, the distal segment provides an additional point of anchoring and/or fixation for the skeletal plate and facilitates its proper placement. It also provides a ready mechanism for distraction screw replacement at the time of surgical revision without obligatory plate removal.
[0008] In other embodiments of the present invention, different proximal and distal segment designs are provided as well as an optional rotational locking means to inhibit the rotational movement of the proximal and distal segments relative to each other. Further, where the distal segment is affixed to the underlying bone at an inclined angle, a poly-axial head adapter is provided to ensure proper aligment during placement of the skeletal plate.
[0009] The distraction screw design of the present invention provides significant advantages over the current and prior art. These and other features of the present invention will become more apparent from the following description of the embodiments and certain modifications thereof when taken with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0010] [0010]FIG. 1 is a partial side view of a distraction screw of the present invention, together with a tool driver to effect a rotational movement therefor;
[0011] [0011]FIG. 2 is a partial sectional side view of an assembled distraction screw of the present invention affixed onto a mammalian bone substrate;
[0012] [0012]FIG. 3 is a partial sectional side view of a distal segment of the distraction screw implanted onto a mammalian bone substrate;
[0013] [0013]FIG. 4 is a sectional side view of the distal segment affixing a skeletal plate onto the mammalian bone substrate;
[0014] [0014]FIG. 5 is a partial sectional side view of another embodiment of the present invention, which incorporates a rotational locking means as represented by a key-receptacle arrangement;
[0015] [0015]FIG. 6 a is a partial sectional side view of a further embodiment of the present invention, which incorporates another variation of a rotational locking means as represented by a hex insert-socket arrangement;
[0016] [0016]FIG. 6 b is a partial sectional side view of the assembled distraction screw shown in FIG. 6 a affixed onto a mammalian bone substrate;
[0017] [0017]FIG. 7 a is a sectional side view of another embodiment of the proximal segment;
[0018] [0018]FIG. 7 b is a sectional side view of the assembled proximal segment shown in FIG. 7 a;
[0019] [0019]FIG. 7 c is a sectional side view of the assembled proximal segment shown in FIG. 7 a, together with the distal segments and a tool driver to effect the rotational movement thereof;
[0020] [0020]FIG. 8 a is a partial sectional side view of another embodiment of the proximal segment, together with a tool driver used to effect its rotation;
[0021] [0021]FIG. 8 b is a sectional side view of one embodiment of the distal segment used with the proximal segment shown in FIG. 8 a;
[0022] [0022]FIG. 8 c is a sectional side view of another embodiment of the distal segment used with the proximal segment shown in FIG. 8 a;
[0023] [0023]FIG. 9 a is a partial sectional side view of another embodiment of the proximal and distal segments, together with a tool driver used to effect their rotation;
[0024] [0024]FIG. 9 b is a top view of the distal segment illustrated in FIG. 9 a;
[0025] [0025]FIG. 10 a is a partial sectional side view of another embodiment of the proximal and distal segments, together with a tool driver used to effect their rotation;
[0026] [0026]FIG. 10 b is a top view of the distal segment illustrated in FIG. 10 a;
[0027] [0027]FIG. 11 a is a partial sectional side view of another embodiment of the proximal and distal segments, together with a tool driver used to effect their rotation;
[0028] [0028]FIG. 11 b is a partial top view of the distal segment illustrated in FIG. 11 a;
[0029] [0029]FIG. 12 a is a partial sectional side view of the distal segment of the embodiment illustrated in FIG. 11 a;
[0030] [0030]FIG. 12 b is a partial top view of the distal segment of the embodiment illustrated in FIG. 11 a;
[0031] [0031]FIG. 13 is a partial sectional side view of another embodiment of the present invention, which incorporates a poly-axial feature;
[0032] [0032]FIG. 14 is a partial sectional side view of the embodiment of FIG. 13 shown as an assembly;
[0033] [0033]FIG. 15 is a partial sectional side view of a distal segment with a poly-axial feature implanted onto a mammalian bone substrate on which a skeletal plate is affixed;
[0034] [0034]FIG. 15 a is a partial top view of a mounting plate used to secure the skeletal plate onto the distal segment;
[0035] [0035]FIG. 15 b is a side view of the mounting plate of FIG. 15 a;
[0036] [0036]FIG. 16 a is a partial sectional side view of another embodiment of the present invention incorporating another variation of the poly-axial feature;
[0037] [0037]FIG. 16 b is a top view of the screw cap shown in FIG. 16 a;
[0038] [0038]FIG. 17 is a partial sectional side view of the assembled distraction screw of the embodiment shown in FIG. 16 a; and
[0039] [0039]FIG. 18 is a partial sectional side view of a distal segment with poly-axial feature implanted onto a mammalian bone substrate on which a skeletal plate is affixed.
DETAILED DESCRIPTION
[0040] The present invention provides an improved distraction screw and a method for its use. FIG. 1 shows an embodiment of the present invention, as represented by a distraction screw 10 , which comprises a distal segment 120 and a removable proximal 130 segment. The distal segment 120 is implantable on a vertebral bone as part of the surgical procedure. The distal segment 120 has a head portion 122 , and a threaded shank portion 124 which can be securely fastened unto the bone structure and which may be self-tapping and/or self-drilling.
[0041] As shown in FIGS. 1 and 2, the proximal segment 130 has an elongated body 132 with an internal bore 134 extending through its length from its proximal end portion 135 to its distal end portion 137 . The elongated body 132 houses a deployable member 136 , which is disposed within the internal bore 134 . The deployable member 136 is adapted to be retractably deployed beyond the opening 138 of the internal bore 134 at the distal end portion 137 of the elongated body 132 .
[0042] Along the wall 140 of the interior bore 134 of the elongated body 132 are cooperating threads 142 , which complement threads 144 of the deployable member 136 such that rotation of the deployable member 136 relative to the elongated body 132 in one direction extends it beyond the opening 138 of the internal bore 134 in a deployed position, as shown in FIGS. 1 and 2. Conversely, rotation of the deployable member 136 in the opposite direction effects its retraction from the deployed position. Thus the deployable member 136 can be rotated independently of the elongated member 130 .
[0043] For the embodiment shown in FIG. 1, the threads are made as right-hand thread, that is, viewing from the proximal end portion 135 of the elongated body 132 , a clockwise rotation of deployable member 136 causes it to extend beyond the opening 138 of the internal bore 134 . Conversely, a counter-clock wise rotation of the deployable member 136 effects its retraction into the internal bore 134 .
[0044] The proximal segment 130 is adapted to be attached to the distal segment 120 . As shown in FIGS. 1 and 2, the deployable member 136 has a threaded end portion 138 , with threads 150 , which are adaptably securable to interfit and interlock with complemental threads 162 of the threaded well 158 of the distal segment 120 . Threads 150 and 162 are oriented in the same turn direction and have the same pitch (number of threads per unit length) as those of threads 142 and 144 . This enables the threaded portion 138 to advance into the threaded well 158 when turned clockwise.
[0045] Construction of the threads 142 and 150 , and their respective counterpart complemental threads 144 and 162 can be accomplished by various means. For example, threads 142 and 144 can be constructed as a screw drive arrangement to facilitate the relative movement between the elongated body 132 and the deployable member 136 in deployment or retraction. Likewise, threads 150 and 162 can be constructed for effective mutual engagement. As a matter of design preference, threads 142 and 144 may be of any length and may be placed at any point throughout the internal bore of the elongated member. In addition, though not necessary, threads 150 of the deployable member 136 can be an extension of its threads 144 .
[0046] At its proximal end portion 152 , the deployable member 136 is adapted to be manipulated to effect its extension beyond the opening 138 of the internal bore 134 in a deployed position or retraction. For the embodiment as shown in FIGS. 1 and 2, the rotational movement of the deployable member 136 can be effected by tools such as a wrench, socket wrench, screwdriver, or the like. In one embodiment of the present invention as shown in FIG. 1, the proximal end portion 152 of the deployable member 136 has a hex-shaped configuration, which is engageable by a socket or a wrench to effect a rotational action. In alternative embodiments, proximal end portion 152 has an intersecting depression (not shown) adapted to accommodate the driving tip of a “Phillips” screwdriver to effect a rotational action. Any alternative means and arrangements for engaging and rotating the deployable member 136 can be employed including, but not limited to, a driver or “Allen” wrench configuration.
[0047] As referenced above, rotation of the deployable member 136 relative to the elongated body 130 extends the deployable member for its threads 150 to engage the threads 162 of the head portion 160 of the distal segment 120 . Once threads 150 are engaged with threads 162 , both the proximal and the distal segments are coupled as a unit.
[0048] The deployable member 136 can be removed from the elongated body 132 , allowing for different sizes, threads and/or shapes for the head portion and/or tool attachment portions. Thus, the attachment and/or arrangement of the elongated body 132 and the deployable member 136 can be a screw-fit, or snap-fit arrangement, which does not interfere with the rotation of the deployable member 136 .
[0049] The proximal segment 130 is provided with a tool attachment end portion 180 that is adaptable to receive a rotational torque to effect a rotational action of the elongated body 132 . As shown in FIG. 1, a “hex-head” end configuration is provided, on which a socket 187 can be fitted to effect the rotational action of the elongated body 132 . Optionally, the proximal end can incorporate a flange 154 to limit the extension of the deployable member 136 beyond the distal end of the proximal segment.
[0050] The coupled proximal and distal segments employing the above-described means of engagement provide a detachably coupled distraction screw, which functions as a unitary device. In a surgical application, a socket (coupled to a wrench, not shown) 187 is attached to the tool attachment portion 180 , and the distraction screw is positioned at a site of a bone structure 20 . By applying a rotational torque to the elongated body 132 in a clockwise direction, both the proximal and distal segments rotate in unison so that thread 110 of the distal segment 120 may engage opening 22 of the underlying bone. Shank 124 is advanced and secured onto the bone structure as shown in FIG. 2.
[0051] As shown in FIGS. 1 and 2, the distal segment 120 comprises a threaded shank portion 124 and a head portion 160 . As referenced above, threads 110 of the shank portion 124 would preferably, but not necessarily, be self-tapping and/or self-drilling. The threads 110 would also follow the same turn direction as those of threads 150 and 144 . Depending on the particular application, the shank portion 124 can be of variable lengths and threads 110 may be of any known configurations. One of ordinary skill in the art would understand that the threads can be of any design that is understood and well known to be applicable for screwing and inserting into mammalian bone. In the embodiment shown in FIGS. 1, 2 and 3 , the internal diameter of the threaded shank portion is progressively tapered from the head portion to the distal tip.
[0052] The shape of the head portion 160 may be of any geometric design, including but not limited to, rectangular, trapezoidal, cylindrical, circular, spherical, hybrid configurations and the like. Further, the head may be absent altogether, placing the engagement adapter directly into the body of the screw shank (FIG. 7 c ). In the embodiment as shown in FIGS. 1, 2 and 3 , the head portion 160 is mono-axial, remaining in a fixed plane relative to the threaded shank. As used herein, “mono-axial” refers to rotation of the head portion and shank along a common arbitrary axis. This is defined by the placement of the head portion in a fixed geometric relationship to the threaded shank such that when the shank is rotated, the head portion also rotates along the same axis. Thus, in the embodiment as shown in FIGS. 1, 2 and 3 , the head portion is arranged with its diameter perpendicular to the length of the shank, which defines a common mono-axial relationship.
[0053] The distal segment 120 can be made of any biologically adaptable or compatible materials. Materials considered acceptable for biological implantation are well known and include, but are not limited to, stainless steel, titanium, combination metallic alloys and the like, various plastics, ceramics, biologically absorbable materials and the like. It would be understood by one of ordinary skill in the art that the distal segment 120 can be made of any materials acceptable for biological implantation and capable of withstanding the torque required for insertion and the load encountered during use. Any components may be further coated/made with osteo-conductive (such as deminerized bone matrix, hydroxyapatite, and the like) and/or osteo-inductive (such as Transforming Growth Factor “TGF-B,” Platelet-Derived Growth Factor “PDGF,” Bone-Morphogenic Protein “BMP,” and the like) bio-active materials that promote bone formation. The proximal segment 130 may be made from any non-toxic material capable of withstanding the torque required for insertion and the load encountered during use. Materials used in the proximal segment 130 need not be limited to those acceptable for implantation, since it functions to deliver the implatable distal segment 120 but is not, itself, implanted.
[0054] As shown in FIG. 2, the distraction screw 10 is placed at a predefined location of the vertebral bone. As rotational torque is applied to the distal segment 120 by the tool attachment, both the segments rotate in unison, which inserts the threaded portion 110 of the distal segment into the bone opening 22 . The coupling of the proximal and distal segments provides the longitudinal stability and the structural integrity of the coupled segments as a distraction device. In another embodiment of the present invention as shown in FIGS. 5, 6 a and 6 b, in addition to coupling the deployable member 136 with the distal segment 120 , the elongated body 132 of the proximal segment 130 is also engageable to the distal segment 120 to prevent their relative rotational movement by a rotation locking means.
[0055] As shown in FIG. 5, at the distal end portion 137 of the proximal segment 130 , a key 170 is provided. The key 170 is fitted to be inserted into a receptacle 172 as defined by a depression located at the head portion 160 of the distal segment 120 . When the key 170 is inserted into receptacle 172 , the elongated body 132 of the proximal segment 130 is engaged with the distal segment 120 , which prevents the relative rotational movement between the two segments. FIGS. 6 a and 6 b show another embodiment of the present invention in which a variation in the design of the rotation locking means is presented. The distal end portion 137 of the proximal segment 130 incorporates a hex extension 190 , which can be fitted into the well 158 of the head portion 160 with a complemental hex socket receptacle 194 . When so fitted, rotation of the distal segment 120 proximal segment 130 relative to each other is inhibited. As shown in FIGS. 6 a and 6 b, hex extension 190 has an internal bore 192 through which the deployable member 150 passes for engagement with the distal segment by way of their cooperating threads 150 and 162 .
[0056] While the rotation locking means is illustrated in a key-receptacle arrangement and hex extension-socket configuration, it is not limited to these examples. It is understood that any engageable arrangement can be used as a rotational locking means. These include, but are not limited to, one or more extended protuberances of the elongated body 132 to seat within complemental bored depressions on the head portion of the distal segment 120 . Similarly, square-jaw or spinal jaw clutch arrangements, and serrated or saw tooth edges can be incorporated to mate or interlock with similar features on the head portion (not shown).
[0057] In embodiments that incorporate such rotation locking means, assembly of the proximal and distal segments can be easily accomplished. The deployable member 136 is fitted within the internal bore 134 of the elongated body 132 in a retracted configuration by effecting a relative rotational movement between elongated body and the deployable member along their cooperating threads. The proximal segment 130 is then held adjacent to the head portion 160 of the distal segment 120 to insert key 170 into the receptacle 172 . For the embodiment shown in FIGS. 6 a and 6 b, the hex extension 190 is seated within the socket 194 of the head portion 160 . A suitable tool such as a screw driver, wrench, pliers, or the like is used to engage the proximal end portion 152 of the deployable member 136 in a rotating action to extend the threaded end portion 152 beyond the end opening 138 of the bore 134 (or bore 192 of the hex extension) to engage the internal threads 162 of the head 160 of the distal segment 120 . Their actions secure the proximal and distal segments in a coupled relationship and inhibits any relative longitudinal and rotational movements between the segments.
[0058] As discussed above, the proximal segment 130 is securably coupled to the distal segment 120 as a distraction device while being anchored onto the bone structure. After the need for the distraction has been met, the proximal segment 130 is detached from the distal segment 120 . From the coupled configuration, the elongated body 132 is held stationary and, using segment 152 , the deployable member 136 is rotated in a direction opposite to that which was used to effect its coupling to the internal threads 162 of the head 160 . This rotation disengages threads 150 from threads 162 of the distal segment 120 . The rotation also releases the friction between the distal portion of the elongated body and the head portion of the distal segment. Detachment of the proximal and the distal segment is thus effected, leaving the latter securely implanted onto the vertebral structure, as shown in FIG. 3.
[0059] The deployable member can be retracted and stowed into the internal bore 134 of the proximal segment. For the embodiment as shown in FIG. 5, once the complemental threads 150 and 162 are disengaged, the proximal segment 130 can be dislodged with the key 170 disengaged from the receptacle 172 to separate from the distal segment 120 . In a similar manner, for the embodiment shown in FIGS. 6 a and 6 b, once threads 150 and 162 are de-coupled, the hex extension 190 can be withdrawn from hex socket 194 of the distal segment. In this way, the use of the rotation locking means further ensures that the distal segment 120 would not be inadvertently rotated and de-coupled from the skeletal bone while rotating the deployable member 136 during detachment of the proximal and distal segments.
[0060] [0060]FIGS. 7 a - 7 c, 8 a - 8 c, 9 a, 9 b, 10 a, 10 b, 11 , 12 a, 12 b illustrate other embodiments of the modular distraction screw. Since a thorough description of the device has been presented above, only the relevant design differences of the other embodiments will be described in detail.
[0061] [0061]FIG. 7 a demonstrates another embodiment of the proximal segment. This embodiment employs an elongated proximal segment 130 with a smooth internal bore 134 and no internal threads. A deployable member 133 has a threaded tip 150 on its distal end and proximal segment 152 which is adapted so as to be engaged by a screw driver, wrench or the like in order effect its rotation. A flange 154 is placed immediately distal to the engageable proximal end. FIG. 7 b demonstrates the assembled proximal segment wherein the outer elongated body and the deployable member are each independently rotatable from the other. FIG. 7 c shows the proximal segment 130 , distal segment 160 and the wrench 187 . As threads 150 of the proximal segment are engaged with threads 162 of the distal segment, flange 154 limits the extension of the deployable member and applies a compressive force across the elongated element 130 , thus forming a rigid distraction screw. As before, the screw is inserted into bone by application of a rotational force onto element 180 using wrench 187 . Rotation may be achieved by any engageable means and is in no way limited to the hex-wrench arrangement illustrated. After completion of the bone work, the distal segment is disengaged from the proximal segment by rotation of element 152 in the direction opposite to that used for engagement while segment 130 is held stationary using element 180 . Optionally, a rotation locking means can be incorporated as part of the distal tip of the proximal segment in order to ensure that the distal segment 120 does not inadvertently rotate and de-couple from the skeletal bone during distraction screw disassembly.
[0062] [0062]FIGS. 8 a - 8 c shows another embodiment of the present invention in which a proximal/distal interface is defined by a threaded extension 157 disposed on the head portion of the distal segment. The threaded extension 157 is fitted within the complmental threaded female receptacle 156 of the proximal segment. It is undersood that the head of the distal segment beneath extension member 157 may be of any geometric configuration. Further, in these or any of the other embodiments presented herein, the proximal/distal interface is not limited to the screw and screw receptacle arrangement depicted. Thus, for example, FIGS. 9 a and 9 b demonstrate a sprocket arrangement 159 (male member) and a complementary receptacle 143 (female member), and FIGS. 10 a and 10 b show a smooth male member 161 with a key which is used to engage the complementary receptacle 145 . These two design arrangements demonstrate the adaptation that any engageable means can be used.
[0063] [0063]FIGS. 11 a, 11 b, 12 a and 12 b demonstrate a sprocket arrangement which permits a locking engagement with the complementary receptacle. As illustrated in FIGS. 12 a and 12 b, the cylindrical head 163 , which is a smaller-diameter continuation of the screw shank 124 , is fitted with engageable teeth 167 in the parallel plane (along the long axis of shank 124 ) and engageable teeth 165 in the perpendicular plane. The distal end portion of the elongated body 132 is provided with a receptacle 147 which is complimentary to the cylindrical head 163 of the distal segment 120 . Receptacle 147 has a central bore and engageable teeth in both the parallel and perpendicular planes relative to the long axis of the proximal segment to accommodate and engage teeth 163 and 165 of the distal element 120 .
[0064] The elongated body 132 of the proximal segment 130 has an engageable proximal end portion 181 , which is adapted to be rotated, as for example, by means of a wrench 191 . Similarly, the proximal segment 130 is rotatable by means of a wrench 189 . With rotation, the proximal segment 130 advances along threads 119 to the receptacle 147 of the proximal segment around the cylindrical head 163 of the distal segment to produce a rigid distraction screw.
[0065] Wrench 191 is used to engage the end portion 181 of the proximal segment 132 to effect its rotation. The teeth within receptacle 147 of the proximal segment engage the complimentary teeth 165 and 167 of the distal segment, which rotates the distal segment and drive threads 111 into the underlying bone. Once the bone work has been completed, wrench 189 is used to rotate the proximal segment 130 in the direction opposite to that used during engagement causing it to retreat along threads 119 . In this way, the head portion 163 can be disengaged from the receptacle 147 thus leaving the distal segment 120 attached to the bone. One of ordinary skill in the art will understand that the engageable arrangements described herein are illustrative and not restrictive, and that any engageable means may be alternatively used at any of these points of contact.
[0066] The distal segment 120 of the distraction screw 10 , which remains securely affixed onto the vertebral bone, provides enhanced structural integrity of the bone by reducing the stress concentration generally expected of an empty opening in a structural member. Leaving the distal segment 120 in place further eliminates the robust bone bleeding encountered after removal of current, commercially-available distraction screws and obviates the need to fill the holes with a hemostatic agent.
[0067] The distal segment 120 can also provide a point of anchoring for a skeletal plate 30 or other prosthetic devices to adjust, align and maintain the spatial relationship(s) of adjacent bones or bony fragments during healing and fusion after surgical reconstruction, as shown in FIG. 4. Since placement of the distraction screws is performed as the first step in the surgical procedure, the anatomical landmarks required to ensure proper alignment of the plate or other prosthetic device in the desired anatomical plane are still intact.
[0068] Plate fixation using the affixed distal segment is largely similar for the many mono-axial embodiments illustrated. For simplicity, it will be described in detail for the first embodiment alone. As shown in FIG. 4, a skeletal plate 30 is mounted onto the distal segment, where head portion 160 is adapted with peripheral surface contour to fit an opening 32 of the skeletal plate. A mounting plate 212 having a tapered opening 214 centers the screw 210 in alignment and engagement with the threads 162 of the head portion. The mounting plate 212 also serves as a washer to assert the necessary force onto the skeletal plate 30 to be secured onto the bone substrate 20 . In this way, the distal segment guides the placement of the plate and maximize the likelihood of correct anatomical alignment. It will also provide an additional point of attachment for the plate or device and enhances the structural integrity of bone/plate interface.
[0069] It is accepted that fusion of a specific spinal level will increase the load on the disc space immediately above and below the fused segment. Over time, the increased load will promote degeneration of the adjacent discs and may ultimately require that they be removed and the fusion extended to the adjacent bony level. In that event, the mounting plate 212 can be removed, permitting access to the distal segment 120 . The proximal segment 130 and the elongated member 136 can be reattached to the distal segment 120 and, thus, reconstitute the distraction screw without removal.
[0070] A second distraction screw is placed into the bone of the new operative level and the surgical reconstruction is performed. After the necessary work, the proximal segments 130 are removed from each distraction screw, leaving distal segments 120 securely affixed to the vertebral bodies. A bone plate or device is affixed to maintain the spatial relationships of the new operative level while bone healing and fusion progress. Again, each distal segment 120 so affixed provides an additional point of attachment for the plate or device.
[0071] In other embodiments of the present invention, the distal segment incorporates a poly-axial design feature, which further facilitates the mounting of the skeletal plate 30 onto the vertebral bone. As used herein, “poly-axial” refers to the ability for the head portion of the distal segment to rotate about an axis that is other than that of the longitudinal axis of the threaded shank. This design provides a ready mechanism through which a skeletal plate maybe affixed onto an implantable distal segment that has been placed into the skeletal bone at an angle other than the perpendicular. This situation arises when the degenerated bony elements have suffered significant mal-alignment, requiring that the distraction screws be placed at an angle to the bone surface in order to achieve the trajectory needed to realign the bones.
[0072] Examples of the poly-axial head design are illustrated in FIGS. 13, 14, 15 a - c, 16 a, 16 b, 17 and 18 . With such a feature, a poly-axial distal segment 220 incorporates a head portion 222 , which generally assumes the geometric shape of a spherical segment, or cup shape, and a neck portion 224 with a narrower cross-sectional profile that tapers to the shank portion 226 . A poly-axial head adapter 230 is swivelably fitted over the head portion 222 . The poly-axial head adapter 230 has a ring body 232 , which has an internal ring opening with a smaller internal diameter at its lower portion 234 than its upper portion thus forming a socket arrangement. The lower portion 234 also has a smooth concave external contour 236 .
[0073] Poly-axial head adapter 230 is installed over the head portion 222 by way of the opening at its lower ring portion. A rotational space between the poly-axial head adapter 230 and the head portion 222 is provided to allow the poly-axial head adapter to move. This type of connection can be considered a ball joint, or socket connection, though other means for providing a connecting relationship between the poly-axial head adapter and the head portion while permitting varying degrees of rotational flexibility (swivelability) can also be adapted.
[0074] A flange 228 is located between the neck portion 224 and the shank portion 226 , on which the poly-axial head adapter 230 can be rested. Flange 228 also provides as a stop when the shank 226 is inserted onto the bone structure, as well as a measure of the depth of the shank implant. A concave curvature in the lower portion of the flange 228 allows the maximum thread/bone contact and support when the distal segment 220 is affixed in an inclined angle relative to the surface of the bone 20 .
[0075] Coupling of the proximal segment 130 and the distal segment 220 in this embodiment can employ any of the coupling designs described in detail for the mono-axial distal segment. These methods include, but are not limited to, the design illustrated in FIGS. 13 and 14. Once coupled, the segments will function as a unitary device. By applying a rotational force to the proximal segment 130 , the threaded shank of the distal segment 226 can be advanced and secured into the underlying bone, as described for the mono-axial design.
[0076] Following the distraction work and detachment of the proximal segment from the implantable distal segment, the skeletal plate 30 can be mounted onto the implantable distal segment. As shown in FIG. 15, the adapter ring 230 is peripherally contoured for it to be fitted within an opening 32 of the skeletal plate 30 .
[0077] Poly-axial head adapter 230 has an open top with internal circumferential thread 238 for receiving a mounting plate 242 with complemental threads 244 . As shown in FIGS. 15, 15 a and 15 b, mounting plate 242 has a circular-shaped top flange 246 , which is seated on the rim 34 of the opening 32 of the skeletal plate 30 . After the skeletal plate 30 is mounted onto the adapter ring 230 , the mounting plate 242 is threaded onto its internal thread 238 , thus forming a unitary piece. Before the treads 242 and 238 are completely engaged, the skeletal plate can be tilted or rotated for it to be aligned in proper placement. Since the adapter ring 30 is swivelable in relation to the head portion 222 , skeletal plate 30 can be easily manipulated to assume the desired position in relation to the bone structure despite the other than normal or vertical entry of the distal segment onto the bone structure.
[0078] After placement of the bone plate 30 , the mounting plate 242 is tightened against the thread 238 . The force asserted by the thread engagement draws the head adapter close to the mounting plate, which in turn closes the space between the lower portion 234 of the adapter ring and the head portion 222 and to firmly secure the head adapter onto the distal segment as well as the skeletal plate. As shown in FIG. 15 a, the mounting plate has a central opening 250 into which a turning devise can be inserted to facilitate its turning. Although illustrated as a hexagonal opening into which an “Allen” wrench driver may be deployed, any engagement method consisting of a driver and complimentary receptacle can be employed.
[0079] [0079]FIGS. 16 a, 16 b, 17 and 18 show another variation in the poly-axial design feature. The poly-axial head adapter 310 is provided with a cap 312 , which is coupled to the head adapter by means of threads 318 . In assembly, screw 274 is fitted into the poly-axial head adapter 310 and cap 312 is used to engage threads 318 . The screw 274 has a head portion 276 and a flat top 278 . The cap 312 has a central opening 316 with internal threads 320 , which is adapted to receive the threaded, rounded distal end 402 of the deployable member 136 . Cap 312 may be further adapted to receive an optional rotation locking means. While the key design (opening 314 ) is illustrated for simplicity, it is understood that the rotation locking means may be of any engageable configuration.
[0080] After key 170 is fitted into the key opening 314 , the deployable member is extended to pass through the threaded opening 316 and to push against the top surface 278 of the screw 274 . As the threaded distal portion is rotated further in relation to threads 320 , the force exerted by the rounded end 402 on surface 278 causes the under surface of the screw head 276 to firmly engage portion 322 of head adapter 310 , forming a unitary distraction screw. With distraction screw assembly, its important that the long axis of the proximal segment 130 be the same as the long axis of screw 274 , permitting uniform rotation of both segments along a common axis. In use, a rotational torque is applied to the proximal segment 130 , which is translated by the key 170 to the head adapter 310 and, in turn, to screw 274 . The shank rotates and engages the underling bone.
[0081] Following distraction and bony realignment, the proximal portion is detached from the poly-axial head adapter, leaving the implantable distal segment affixed to bone. The skeletal plate 30 is mounted with its opening 32 to fit over the peripherally contour of the distal segment and is manipulated to assume the desired position. The swivel action of the poly-axial head adapter permits proper placement of the skeletal plate even with angled placement of bone screw 274 . A mounting plate 324 is seated on the stepped rim 34 of the opening 32 of the skeletal plate 30 . It has a central opening 326 though which a mounting screw 328 can be passed to engage threads 320 of screw cap 312 . As the threads are tightened, force is exerted onto surface 278 by the rounded end of screw 328 causing the under surface of the screw head 276 to firmly engage portion 322 of head adapter 310 , and locking the poly-axial head portion to screw 274 . The same action also effects a force on the mounting plate, bearing against the step rim 34 of the skeletal plate 30 for it to be securely anchored. For this embodiment, it is understood that a space is provided between the screw cap and the mounting plate to provide for the engagement of the poly-axial head adapter and the head portion.
[0082] From the above, it is apparent that the poly-axial design will produce a highly versatile distraction screw and can be used even with significantly mal-aligned bony structures. The ability of adapter ring 310 to rotate and swivel permit it to accommodate and orient the skeletal plate 30 , thus ensuring proper alignment and correct plate fixation.
[0083] As described above, the present invention is that of a distraction screw and its use. It provides a significant design advantage over existing art by decreasing the bone stress encountered at the empty bone holes and reducing the extent of operative bleeding. The present design also provides an additional point of fixation for the implantable plate/prosthesis, maximizes the likelihood of proper plate/prosthesis alignment, and provides a ready mechanism for modular extension of the surgical reconstruction to adjacent levels at a future date. While the different embodiments of the present invention have been illustrated as consisting of a proximal and distal segment, it is understood that a modular distraction screw may be constructed from more than two components. The preceding descriptions and accompanying drawings are to be considered as illustrative and not restrictive in character. Further understanding of the present invention, and other embodiments as described herein can be obtained through a review of the claims:
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An improved distraction bone screw and a method for its use are described. The distraction screw is comprised of an implantable distal segment and a detachably secured proximal segment. The distal segment includes a head portion and a threaded shank portion. The proximal segment is represented as an elongated body having an internal bore that extends through its length. A deployable member is disposed within the bore, which is extendible outside the internal bore to securely couple to the distal segment. As an assembly, the distraction screw is used to affix and realign bone during surgical reconstruction. Upon completion of the surgical work, the proximal segment is removed and the distal segment is left attached to the reconstructed bone. Securely affixed, the distal segment provides an additional point of fixation for the skeletal plates that are used to preserve the bony alignment while bone healing occurs. The affixed distal segment will also provide a ready mechanism for distraction screw replacement at the time of surgical revision without obligatory plate removal. Different embodiments of the proximal segment, distal segment and the rotational locking mechanisms which inhibit the rotation of one segment relative to the other during deployment were also described. In addition, in cases where the distraction screw must be placed into the bone at an inclined angle, poly-axial heads were provided so that proper skeletal plate placement can still be accomplished.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to systems for moving heavy equipment. More particularly, the present invention relates to systems for use in moving heavy telecommunications equipment, computers, and other electronics systems.
2. Description of the Prior Art and Related Information
Many businesses and institutions utilize computer systems and other electronic systems incorporating very heavy cabinets enclosing system components. The substantial weight of such systems results from a combination of the hardware components and the cabinet structure itself which must sufficiently protect the system. Shielding, cooling, earthquake reinforcement and other environmental or application factors can significantly increase the weight of the computer systems. When it is necessary to move the equipment, for certain machines and applications it is possible to simply utilize a system that is on wheels. Frequently, however, the size and/or weight of the equipment or applicable governmental agency regulations preclude a free-standing system permanently housed on wheels. Moreover, in certain circumstances, governmental regulations require that the equipment be secured to the floor surface. Because such equipment can not be housed on wheels or rollers, various methods and apparatus must be employed in order to both install the equipment, and to subsequently move the equipment when required.
Where the utilization of a permanent wheel housing is not permitted, the more common methods of moving heavy equipment employ cranes or forklifts. Both cranes and forklifts require large access areas and also involve the purchase or rental of large and expensive moving equipment that may have otherwise very limited use. Additionally, many current installations preclude the use of large moving machinery. Exemplary are the National Equipment Building (NEB) standards which require that in certain environments electrical lines and connections, temperature control apparatus and conduits, and other building wiring or connections be positioned overhead or in ceilings rather than in the facility floor. Where such NEBs are applicable, the use of cranes and similar devices is severely handicapped, or even eliminated, because of potential damage to the overhead connections and equipment.
In such areas where cranes or forklifts cannot be used, due to NEBs or other conditions, a dolly system that is attachable to the equipment has been used. A dolly system has the advantage of being able to lift the equipment up from the floor through the use of comparatively small and compact components. In one prior art dolly system, a number of brackets having wheels are affixed to the equipment to be moved, and the equipment is then raised by rotating the wheel. In such prior art device, however, the weight of the equipment often causes metal fatigue and failure due to the arrangement of the wheel and bracket. Additionally, in the existing device it is difficult to attach the bracket to the body of the equipment to be moved because access to mounting bolts or screws is limited. Still further, the raising of the equipment is often quite difficult due to the arrangement of the components through which vertical adjustment is accomplished.
Accordingly, a need presently exists for a lifting dolly which solves these problems.
SUMMARY OF THE INVENTION
The present invention provides a detachable dolly system for moving heavy electronic equipment such as computer cabinets in environments with limited space. The present invention further provides a dolly system which is easily attached to the electronic equipment when the equipment is moved. The dolly system of the present invention also minimizes metal fatigue and failure caused by the weight of the equipment on the dolly system during the attachment and load lifting and lowering steps of the moving operation.
The dolly system of the present invention employs a detachable wheel bracket system for use with heavy computer systems for initial installation and for moving the systems to new locations as required. The wheel bracket system of the present invention includes a mounting bracket and a separate detachable wheel assembly. After attachment of the mounting bracket to the equipment, the wheel assembly is engaged to the mounting bracket. An adjustment mechanism on the wheel assembly is then used to adjust the wheel bracket system in the vertical direction, and through this vertical adjustment the equipment may be raised off of the floor surface and rolled to the desired location.
In a preferred embodiment, the mounting bracket includes a mating flange and a support plate, which is secured to the equipment by at least one lifting/load bearing dowel and separate mounting bolts. The lifting dowel and mounting bolts are matingly received within the equipment to ensure secure attachment of the mounting bracket. The wheel assembly of the present invention includes a wheel mounted within a wheel bracket and a threaded stem which is secured to the wheel bracket and is integrally attached to a ball bearing assembly. The wheel assembly is detachably engaged with the mounting bracket by a mating member. The mating member is mounted upon and movable along the threaded stem and is receivable within the mating flange. The wheel is raised or lowered along the vertical axis by rotation of the threaded stem, which lifts the equipment through the mating member engaged with the mating flange. Once the equipment is raised off the floor, it may be guided to a new location and then lowered to the ground by rotating the threaded stem in the reverse direction.
It will thus be appreciated that the present invention is easily attached to, and detached from, electronic equipment for facilitating the initial installation and moving of the equipment. The utilization of a detachable wheel assembly in the present invention enables easy access to the mounting bolts and also lessens the stress imposed on the bracket during attachment. Potential fatigue and failure is also lessened by the use of strong lifting dowels and separate mounting bolts.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention will be described with reference to the accompanying drawings, wherein:
FIG. 1 is a perspective view of a portion of a computer system cabinet incorporating the wheel bracket system of the present invention.
FIG. 2 is an exploded perspective view of the wheel bracket system of the present invention.
FIG. 3 is a partial cross-sectional view of the wheel bracket system of the present invention taken along plane 3--3 of FIG. 2.
FIG. 4 is a perspective view of the wheel bracket system of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The following description is of the best presently contemplated mode of carrying out the invention. This description is made for the purpose of illustrating the general principles of the invention, and is not to be taken in a limiting sense. The scope of the invention is best determined by reference to the appended claims.
Referring to FIG. 1, a portion of a cabinet housing heavy electronic equipment, e.g., a computer system, is generally shown by reference numeral 10. Although the invention is described with reference to a computer system, the invention may be utilized in other applications where similar size and weight concerns affect the moving of equipment. A wheel bracket system 12 is secured to the cabinet 10 by a mounting bracket portion 14 and a wheel assembly 16 is slidably engagable with the mounting bracket portion 14. As illustrated in FIG. 1, a number of wheel bracket systems (shown as 12, 12', 12'', 12''') may be utilized for a single piece of equipment and the wheel bracket systems 12-12''' may be affixed to a corner portion 18 as well as to a side edge 20 of cabinet 10.
FIG. 2 depicts an exploded perspective view of wheel bracket system 12. Mounting bracket 14 includes a plate 22, lifting dowels 24 and 26 (best shown in FIG. 3) and mounting bolts 28 and 30. Mounting bracket 14 also includes a slotted mating flange 32 capable of slidably engaging with wheel assembly 16. As illustrated in FIG. 2, mating flange 32 is disposed perpendicularly to plate 22 and first and second support members 34 and 36 angularly extend therebetween. First and second support members 34 and 36 provide both additional structural support for mounting bracket 14, and also serve to protect portions of wheel assembly 16, as is discussed within.
Wheel assembly 16 includes a wheel 38 engaged with a wheel bracket 40. Wheel bracket 40 is positioned adjacent and integrally attached to an adjustment mechanism 42 which includes a threaded stem 44. It should be appreciated that wheel bracket 40 may take a number of forms (as exemplified by FIGS. 1 and 2), and is limited only in that rotation of wheel 38 and secure attachment with adjustment mechanism 42 must be obtained. Adjustment mechanism 42 provides for the precise adjustment of wheel 38 to allow equipment 10 to be moved. More specifically, adjustment mechanism 42 includes adjustable ball bearing assembly 48 which is affixed to a threaded stem 44. Adjustable ball bearing assembly 48 is rotatably affixed to wheel bracket 40 and rotation of ball bearing assembly 48 serves to rotate threaded stem 44.
A bracket mating member 46 is rotatably attached to threaded stem 44 and is capable of engagably mating with mating flange 32 of mounting bracket 14. The rotatable attachment is achieved by surfaces defining a threaded aperture 50 located on mating member 46 (shown in shadow lines in FIG. 2) and mating member 46 is rotatably moveable in the vertical direction along threaded stem 44. When mating member 46 is slidably engaged with mating flange 32, mating member 46 is fixed along threaded stem 44 such that rotation of threaded stem 44 serves to raise or lower wheel bracket 40 (relative to mating member 46 and mounting bracket 14) along the vertical axis (as shown by directional arrow 52) depending on the direction of rotation.
In order to best understand the present invention, the wheel bracket system 12 will be described in more detail with respect to the actual operation and use. FIG. 3, a cross-sectional view of the mounting bracket 14 of the present invention taken along plane 3--3 of FIG. 2, shows support plate 22 and first and second lifting dowels 24 and 26 and apertures for first and second mounting bolts 28 and 30 in greater detail. As illustrated in FIG. 3, first lifting dowel 24 is positioned at the bottom portion of plate 22 and is engagable with a corresponding opening in equipment 10 (not shown) in order to support the equipment load. Second lifting dowel 26 is positioned above first lifting dowel 24 and is also used to lift and support equipment 10 by engaging with a spatially positioned opening in equipment 10 (not shown).
After plate 22 is affixed to equipment 10 by first and second lifting dowels 24 and 26, first and second mounting bolts 28 and 30 (best shown in FIG. 2) are used to securely mount plate 22 to equipment 10. This attachment is obtained as mounting bolts 28 and 30 extend through bolt apertures 54 and 56, respectively. Because wheel assembly 16 may be disengaged from mounting bracket 14, uninterrupted access to mounting bolts 28 and 30 as they are positioned within apertures 54 and 56 is achieved. The utilization of both lifting dowels 24 and 26 and mounting bolts 28 and 30 enables the stresses of mounting/load bearing to which the wheel bracket system 12 is subject to be born predominantly by lifting dowels 24 and 26. Since the dowels are in turn not used for attachment, they may be of simple shape and strong construction. The result is that the likelihood of failure due to stress and fatigue on wheel assembly 16 and on the wheel bracket system 12 as a whole are minimized.
Referring finally to FIG. 4, upon securing mounting bracket 14 to equipment 10, wheel assembly 16 may be slidably engaged with mounting bracket 14. This engagement is obtained by slidably fitting mating member 46 within mating flange 32. Mating member 46 may then be locked within mating flange 32 by a locking pin 58 which is attached to mounting bracket 14 by lariat 60 and lariat holder 62. Locking pin 58 is positioned within a proportionally spaced opening 64 on mating member 46 (as best shown in FIG. 2).
Upon secure engagement of mating member 46 with mating flange 32, wheel bracket 40 may be lowered in order to raise equipment 10 above the floor surface. The vertical movement of wheel bracket 40 is controlled by adjustment mechanism 42. Because mating member 46 is locked into place when engaged with mating flange 32 and is also threadingly engaged with threaded stem 44, rotation of threaded stem 44 raises or lowers wheel bracket 40 relative to the position of mating member 46 and bracket portion 14.
The rotation of threaded stem 44 is achieved in two steps. First, initial adjustment of height may be easily controlled by rotation of adjustable ball bearing assembly 48. Ball bearing assembly 48 includes upper casing 66 which is integrally secured to threaded stem 44 and lower casing 68 which is affixed to wheel bracket 40. Ball bearing assembly 48 may be manually rotated by moving upper casing 66, (as shown by directional arrow 70) and this manual rotation serves to rotate threaded stem 44. As upper casing 66 is rotated in a counter-clockwise direction, wheel bracket 40 is lowered by the downward movement of threaded stem 44. Wheel 38 is moved downward and as contact with the floor surface initiated, torque increases due to the weight of equipment 10 and rotation becomes more difficult. Next, threaded stem 44 is further rotated by use of a tool, e.g., a wrench, on bolt 72 affixed to the top portion of threaded stem 44.
The aforementioned rotation functions to raise equipment 10 up from the floor surface, and equipment 10 may then be guided to the desired location. Once appropriately repositioned, wheel 38 may be raised by rotating threaded stem 44 and equipment 10 lowered to the floor surface. Wheel bracket system 12 may then be removed from equipment 10 by reversing the above-described attachment steps. It should be noted that in environments requiring equipment 10 to be secured to the floor surface by a bolting system or other method, it may be possible to use the same apertures on equipment 10 employed to secure the equipment to the floor surface for wheel bracket system 12.
The best presently contemplated mode of carrying out the present invention has been described. A dolly system is provided in which equipment may be raised and moved by a detachable mounting bracket and wheel bracket. While in the preferred embodiment the wheel bracket is slidably engagable with the mounting bracket, it should nevertheless be understood that various modifications may be made without departing from the scope and spirit of the invention which is limited only by the scope of the appended claims.
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A detachable dolly for moving heavy electronic equipment employs a mounting bracket and a wheel assembly, the mounting bracket having a support plate and a mating flange. The mounting bracket is secured to the equipment by the support plate, having at least one lifting dowel, and at least one mounting bolt. The wheel assembly has a wheel mounted within a wheel bracket and a rotation adjustment mechanism for raising and lowering the wheel and is detachably engaged with the mating flange on the mounting bracket by the use of a mating member. The mating member is movably coupled with the adjustment assembly such that when the mating member is engaged with the mating flange, rotation of the adjustment assembly serves to vertically raise or lower the equipment.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present device relates to disinfecting surfaces. More particularly, the device and method herein, relate to disinfecting electronic touch screens and the like which become home to a wide variety of pathogens in a short amount of time. More specifically, the device and method employ a carrier component such as a microfiber cloth which is populated with highly ionic metal oxide particles which when placed in contact with a touch screen such as on a smartphone or pad computer, will kill germs, bacteria, and other pathogens on the surface of the touchscreen and leave an ionic residue to continue disinfection of the surface subsequently.
[0003] 2. Prior Art
[0004] Surfaces which are frequently touched by humans have been found to serve as reservoirs for the spread of pathogens such as viruses, bacteria, germs, and fungi which both colonize and persist upon such surfaces. Many surfaces suffer from this problem such as buttons on ATM machines, handrails on escalators, door handles on public buildings, and other surfaces where humans frequently and sequentially touch.
[0005] Such pathogens especially thrive on surfaces such as the touch screens which are modernly employed on smartphones, laptops, and pad computers and ATM machines and the like.
[0006] Further, once occupying these surfaces, such pathogens can survive for surprisingly long periods of time, for example a month or more. Consequently, each subsequent user touching a surface has the potential to acquire pathogens deposited by others from minutes before to weeks prior to a touch of a surface such as a touch screen.
[0007] Still further, many bacteria have become resistant to conventional means for their removal. Scientists have observed recently that the cell membranes of many disease-causing bacteria develop resistance to existing antibiotics and the like, by changing their electrical charge from negative to positive. Modern antibiotics work to remove bacteria because they carry a positive charge which attracts the antibiotic component to negatively charged bacteria cells. Because of the opposite charges between the two, antibiotics can penetrate and kill bacteria.
[0008] However, according to an article by Ohio State University, these bacterial pathogens have learned to adapt by changing their naturally occurring negative charge to positive. This allows bacteria cells which have learned to establish such a protective “coat” to repel the antibiotic. Consequently, many of the bacterial pathogens deposited on touch interface surfaces are likely to be resistant to conventional antibiotic material formerly used to remove them.
[0009] Adding to the problem of charge and bacteria removal is the operation of touch screen interfaces. While there are a large number of touch screen designs, two of the most employed types of touch screens employed for interfacing with a computer using a graphic interface are resistive type screens and capacitive screens.
[0010] Resistive screens have a soft protective layer on which the physical pressure of a finger (or object) creates a change in the flow of electricity on the screen's grid. This finger contact accounts for a physical bending of the screen to position the two electrically conductive layers being deflected to touch one another. One of these two layers is resistive and the other layer of the two is conductive. When the two layers in communication with a finger or contact component are deflected and pressed together, at a point on the screen, an electrical current changes at the point of contact. Interface software running on such devices is written to discern a change in the current at the location of the pixels in the area of finger contact, or the x-y coordinates thereof. Once so recognized the software causes an order or command to be initiated to carry out the function or command which corresponds with that X-Y location discerned. Capacitive touch screens have a hard protective layer and unlike resistive touch screens, capacitive screens do not use the pressure of the user's finger to cause a change in the flow of electricity at the given point on the screen pixel grid. Instead, capacitive touch screens will cause a change in the flow of electricity when contacted with anything which holds an electrical charge, including human skin. Such charges can be either a positive charge or negative charge and cause a sensed change at a position on the screen which correlates to software monitoring the input, as a command.
[0011] Capacitive touch screens are constructed from materials such as copper or indium tin oxide which store electrical charges within an electrostatic grid of tiny wires in the screen, each smaller than a human hair. There are two main types of capacitive touch screens including “surface” and “projective” touch screens which are conventionally employed for user input based on contact with positions on the screen relating to commands or icons.
[0012] Surface capacitive screens employ a plurality of sensors at the corners and a thin evenly distributed film across the surface. Projective capacitive touch screens employ a grid formed of rows and columns of tiny wires and have a separate electronic circuit or chip for sensing a voltage or capacitive change at a position on the screen which will then correlate with a command or icon at the same position, and allow for user input based on their contact with the screen.
[0013] In both instances, when a finger hits the screen at any position, a very small electrical charge is transferred to the finger of the user to complete the circuit. This transfer creates a voltage drop at pixel points on the screen which also host command keys or icons which the user is contacting to issue a command. Based on the position of the touch, and the command key or icon occupying the same position, and the relation of the command key or icon to a table of commands or actions, the software running the input of the touch screen processes the location of this voltage drop and orders the ensuing correlating action. Thus, users operating computer devices which require touch input to operate, continually contact their screens with their fingers which have been in contact with unknown pathogens.
[0014] Adding to the problem of a continual requirement for the user to touch or place a finger proximate the screen to operate the graphic interface software is the fact that the user in doing so, is continually depositing new and varied pathogens during their use of the touch screen. For example, users traveling through airports and on planes, in touching surfaces in such places that abound with pathogenic occupants, acquire new pathogenic occupants who take up residence on their touch screens when the user subsequently touches the screen during use. Thus, the population of such pathogens not only survives on such touch screens for long periods, when the device is used by the user, new populations of pathogens are continually deposited on such computers, smart phones, tablets, and other devices operated by a user which employ a touch screen interface to operate. Screen cleaners currently exist, however, conventionally such devices generally employ liquid sprays or wipes or provide a moist towelette which is impregnated with a liquid disinfectant such as alcohol or other liquid disinfectant cleaners. These devices were originally marketed for removing smudges and dirt from the glass or plastic surface of touch screens for which rubbing alcohol worked well as it is a well-known cleaner for windows. More recently, such glass cleaners have been marketed for disinfection and some have even included antibiotic or bacterial components.
[0015] However, almost all electronic device manufacturers recommend against placing a liquid anywhere proximate to an electronic device. Consequently, the use of wet towelettes is not a recommended course of action for any type of contact with the delicate electronics of modern smartphones and pad computers. Further, while a wipe with an alcohol-soaked towelette may clean off the dirt and smudges and remove some of the pathogens, once the alcohol evaporates there remains no long term deterrent to populations of new pathogenic occupants. Still further, the use of alcohol and many disinfectant liquids which may contain it or peroxide or the like, will also strip the fingerprint and smudge-resistant oleophobic coating from the screen.
[0016] Additionally, as noted, bacteria have been employing charge shifts to fend off modern antibacterial removal and the addition of a charged surface of the touch screen could enhance that ability for bacteria and pathogens to attempt to form a protective charged cover.
[0017] As such, there is an unmet need for a simple and portable means for disinfecting computers, smartphones, and other touch surfaces which are placed in contact with a single user, or multiple users. Such a device should be configured to kill resident pathogens such as germs and bacteria and viruses which populate touch surfaces on contact. Such a device should additionally impart a long term pathogen deterrent to the touch surface which will remain active after the initial removal. Further, such a device and method should be simple to employ, compact, and provide users with continually renewable protection against a return of a pathogen population on a touch surface interface such as smartphone screens. Finally, such a device and method should immediately remove and continually deter bacteria and the like including those which have a charged cover, through the employment of charged particles which will destroy even charged skinned pathogens.
[0018] The forgoing examples of related art and limitations related therewith are intended to be illustrative and not exclusive, and they do not imply any limitations on the pathogen removal and prevention invention described and claimed herein. Various additional limitations of the related art will become apparent to those skilled in the art upon a reading and understanding of the specification below and the accompanying drawings.
Objects of the Invention
[0019] It is an object of the present invention to provide a device and method which allows users of portable computers, smartphones, and other electronic devices employing a touch screen interface for operation, to disinfect the touch screen of resident pathogens such as bacteria, viruses and germs.
[0020] It is an additional object of this invention to provide such a device and method which is compact, and employable on multiple successive occasions to provide a long term solution to hand and finger contact with touch screen interfaces having pathogen populations.
[0021] It is a further object of this invention, to provide such a pathogen deterrent and removal system and device, which on use not only removes current pathogen residents, but also imparts a residual deterrent to the screen or surface to deter pathogen populations until the next use of the device.
[0022] It is yet another object of this invention to provide a deposited pathogen deterrent and removal material to the touch screen which is configured to remove even pathogens which have formed a charged cover which renders other antibiotic materials useless.
[0023] Yet another object of this invention is the provision of such a pathogen deterrent and removal device and method, which employs dry material rather than a liquid to thereby prevent damage to electronic devices caused by liquid contact.
[0024] These and other objects, features, and advantages of the present invention, as well as the advantages thereof over existing prior art, which will become apparent from the description to follow, are accomplished by the novel improvements described in this specification and hereinafter of the touch screen interface pathogen removal and deterrent as described in the following detailed description which fully discloses the invention, which however in no manner should be considered as placing any limitations thereon.
SUMMARY OF THE INVENTION
[0025] In accordance with the purposes of the present invention, as embodied and broadly described herein, the present invention provides a method and apparatus for sanitizing a touch surface screen used for computer operation and interface, as well as imparting material to the screen which will kill pathogenic occupants immediately and for a subsequent period after a sanitizing.
[0026] In operation for sanitizing and disinfecting a touch screen interface, in a particularly preferred mode, a microfiber cloth is employed which is infused with highly ionic metal oxide particles. The microfiber cloth is placed in a sandwiched contact between the finger of the user on one side, and the touch screen being cleaned on the other. In use as the user presses and rubs the microfiber cloth in contact against the screen to clean it.
[0027] During this contact some of the nanoparticles of metal ions or metal are imparted to the microfiber cloth, and some are communicated against and transferred to the touch screen.
[0028] As noted, in using the touch screen, when a finger touches a touch screen of a display of a touch computer such as a smartphone for example, the electric field at the nearest intersecting wires in or adjacent the glass in the proximity to the touch, grows so more electrical charge is stored on the glass surface. This de-powers the wires in that X-Y sector touched, and a sensor monitoring current on the screen surface discerns that while all the other wires of the grid are producing the standard amount of current, the area of the screen where the wires that intersect near a touching finger, are communicating the presence of a different current level.
[0029] As the electrostatic field of the touch screen changes at the point of finger contact, and depending on the situation, the field will change to be slightly more negative or positive.
[0030] During the act of use of the device and the compression and rubbing of the microfiber cloth against the screen surface by the user's finger, the user's finger is placed sufficiently proximate to the screen, to cause such an electrical field change at the surface to negative or positive, depending on the situation. At this point, because the metal nanoparticles deposited to the cloth have both positive and negatively charged metal ion particles, depending on the electrical field produced on the screen surface at the contact point with the microfiber cloth, opposite the user's finger pressing the cloth, either a positively or negatively charged metal nanoparticle is attracted to the opposite charged area to thereby temporarily engaged a deposit metal material or metallic ions on the touch screen surface. These nanoparticles preferably in metal ions attracted by the respective opposite charge, remain on the screen surface being held there by the charge force.
[0031] In this action, a finger placed proximate to the screen and causing a positively charged area on the grid will cause the attraction from the microfiber cloth of a negatively charged nanoparticle of metal or ionized metal to the screen surface proximate to that positive charge. Conversely, a touch to the screen with the cloth by a pressing of a finger which forms a negatively charged area on the surface, will result in the attraction and deposit of ionized metal nanoparticles which have a positive charge to the screen.
[0032] With both negatively and positively charged particles positioned within the cloth, which are then deposited on the screen in this fashion by a biased rubbing of the microfiber cloth against the touch screen, the deposited negatively charged nanoparticles of metal or metal ions will seek and kill a positively charged germ which comes into contact. Conversely, the negatively charged area on the grid which attracts and holds the metal nanoparticles of metal or metal ions that carry a positive charge, will subsequently be attracted and attach to a negatively charged pathogen.
[0033] Thus, because nanoparticle metal or metal ions with both positive and negative charges are imparted to the cloth, contact of those metal particles with pathogens during the rubbing of the cloth will immediately kill contacted pathogens. Metal nanoparticles or ionic metal particles which do not make engagement with a pathogen, will remain held to the screen surface by the charge attracting them and will continue to kill subsequent pathogens calling the screen surface home, afterward.
[0034] The negatively charged and positively charged metal nanoparticles or ionic particles which are imparted to the microfiber cloth, during manufacture and during any resupply, are communicated to the cloth using a pressurized stream of ultra-fine or nanoparticle sized, highly ionic metal oxide nanoparticles, or by tumbling the cloth in a closed container housing a supply of such nanoparticles.
[0035] The metal nanoparticles herein employed as noted, are nanoparticle-sized metal preferably ionic metal, which as used herein, are microscopic particles with at least one dimension less than 150 nm. Thus, the nanoparticle sized metallic material or ionic metallic material herein employs nanoparticle material having at least one dimension between 1 and 150 nm. These nanoparticles employed are included from a group of metal particles and include one or a combination of ionic particle types, from a group of metallic nanoparticles including zinc oxide, silver, titanium oxide, brass, copper, aluminum, and other metal ions.
[0036] Once the powdered mixture of nanoparticle metal or ionic metal material is operatively engaged to the cloth, they will remain trapped in-between the small fibers forming the yarn or thread of which the cloth is woven or knitted. So positioned, the particles will remain frictionally engaged to the fibers until sufficient electrical attraction draws them to be deposited to the touch screen during a sanitizing as noted depending on the electric charge.
[0037] As noted, when these metal nanoparticles or ionic particles come in contact with a pathogen, such as bacteria or a germ, they cause the outer surface of the pathogen to oxidize and yields a resulting break down of the barrier properties of that surface. Once this cell surface is compromised, it becomes porous and the nanoparticles of metal or metal ions move to a contact with the interior of the pathogenic cell. This contact is equally harmful to the cell as it causes a cessation of the cell's ability to utilize energy and stops cell DNA from replicating, and can impair the enzymes used to make oxygen.
[0038] These actions by the particles deposited by electrical attraction from the saturated cloth, to the touch screen, not only kill the pathogens but additionally those pathogens of the same ilk are rendered unable to develop immunity to the nanoparticle metal or metal ionized material. This is because during the time they might be starting to develop such immunity, they are being attacked with such swiftness by the piercing of their outer layer, that they expire in short order and before they can start to adapt.
[0039] One preferred metallic ion nanoparticle for the device herein is the silver ionic nanoparticle. Such silver ions are configured in a manner that they have more exterior surface area than many other metallic particles. This larger surface area is employed to more quickly and better surround a pathogen such as a bacteria or germ, and additionally increases the area placed in contact with the pathogen which increases its effectiveness. Experimentation with silver ion particles imparted to the cloth of the device herein has shown significantly enhanced pathogen eradication and prevention. Silver nanoparticles or ion particles employed averaged between 8.5 nanometers to as small as 1.9 nm.
[0040] However, it was found that by imparting silver nanoparticles or silver ion particles between 4.5 nm and 5.7 nm to the microfiber cloth, that the pathogen eradication was enhanced as was the long term eradication to pathogens later encountering the touch screen. As such, imparting such nanoparticles of silver or ionic silver in a size range between 4.5 and 5.7 nm with both positive and negative charges in the mix, is a particularly preferred mode of populating the cloth with nanoparticle metal or ionic metal material.
[0041] Another particularly preferred metallic nanoparticle or ion metal material used is zinc oxide. In experimentation, as noted above, while the silver metal nanoparticles or metal ions noted above had an excellent eradication and protection ability on touch screens, a downside was discovered that ionic or nanoparticle metallic silver material can tend to turn surfaces and skin a bluish color. While this change of color is harmless, further experimentation has shown that nanoparticle zinc oxide imparted to the microfiber cloth, was equally adept at removing and preventing subsequent pathogens from occupying surfaces such as touch screens but did not suffer from a color change issue.
[0042] Consequently, zinc oxide or titanium oxide nanoparticles are another particular favorite of the invention herein when imparted to the microfiber cloth used to clean and disinfect a touch screen or surface. Alternatively, a mixture of primarily zinc oxide nanoparticles or titanium oxide particles along with a small amount of silver particles such as a 90 to 10 ratio of zinc oxide or titanium oxide nanoparticles to silver nanoparticles, has been shown to allow the silver particles to work in concert with the zinc oxide or titanium oxide, but minimizes or eliminates to bluish colorizing. By adding the silver nanoparticles in such a small amount, any pathogen which might be resistant to the nanoparticle zinc oxide is eradicated by the silver nanoparticles and vice versa and a preferred outcome. With respect to the above description, before explaining at least one preferred embodiment of the herein disclosed touch screen interface pathogen removal and deterrent in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangement of the components in the following description or illustrated in the drawings. The device herein described and disclosed in the various modes and combinations is also capable of other embodiments and of being practiced and carried out in various ways which will be obvious to those skilled in the art. Any such alternative configuration as would occur to those skilled in the art is considered within the scope of this patent. 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.
[0043] 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 pathogen removal and deterrent devices for sanitizing and disinfecting touch interfaces and for carrying out the several purposes of the present disclosed device. It is important, therefore, that the claims be regarded as including such equivalent construction and methodology insofar as they do not depart from the spirit and scope of the present invention.
BRIEF DESCRIPTION OF DRAWING FIGURES
[0044] The accompanying drawings, which are incorporated herein and form a part of the specification, illustrate some, but not the only nor exclusive examples of embodiments and/or components of the disclosed device. It is intended that the embodiments and figures disclosed herein are to be considered illustrative of the invention herein, rather than limiting in any fashion.
[0045] In the drawings:
[0046] FIG. 1 depicts a touch screen device having a grid of wires which provide signals for computer action when the screen is touched.
[0047] FIG. 2 depicts the device herein being employed to disinfect and to provide long term pathogen detergence to the screen of FIG. 1 .
[0048] FIG. 3 depicts a cotton or similar fiber cloth having a much lower area of space for occupancy of positive and negatively charged metal nanoparticles or ionic metal nano particles.
[0049] FIG. 4 shows the preferred mode of the device showing a strand of microfiber yarn with a very high area and affinity for negative and positive metal nanoparticles or metal ions for deposit on the opposite electric charge on a touch screen mixing with pathogens on the screen and in the passages of the yarn.
[0050] FIG. 5 depicts one mode of provision of the device housed in a foil or plastic package with a microfiber component imparted with a supply of metal nanoparticles.
[0051] FIG. 6 shows a sliced view through a resealable mode of the package of FIG. 5 showing the folded material with imparted metallic nanoparticles or metallic ion particles which are also positioned within the package for resupply.
DETAILED DESCRIPTION OF THE INVENTION
[0052] Now referring to drawings in FIGS. 1-6 , wherein similar components are identified by like reference numerals, there is seen in FIG. 1 a glass touch screen 12 having a grid of wires 14 which are operatively positioned to provide electronic signals recognized by software adapted to the task. The software acting on the determined location of the electronic signal generated on the grid of wires 14 , initiates a related action. As noted, the touch screen 12 tends to become soiled and smudged and also harbors pathogens such as bacteria, viruses, and other infectious life forms.
[0053] As shown in FIG. 2 , the device 10 and system herein employs preferably a microfiber cloth 16 to which nanoparticle metal or metal ion material has been imparted. A flexible applicator 15 , formed of cloth or preferably microfiber material 16 is formed in a woven or non woven fabric of very fine fibers compared to more conventional fabrics using larger denier yarn. As used herein, to provide a measure for comparison, microfibers employed in forming such cloth, are half the diameter of a fine silk fiber which averages 15 micrometers, and one-third the diameter of cotton which averages 21 micrometers in diameter. Thus, the denier of a filament of microfiber material 16 , is significantly smaller than that of conventional materials such as cotton or silk or man-made fibers.
[0054] Denier is the term used to define the diameter or fineness of a continuous or twisted filament fiber such as silk or man-made fibers. Denier is the weight in grams of a 9000-meter length of fiber or yarn and thus the higher the number, the thicker the fiber. In general, in order to be termed a “microfiber,” the fiber must be less than one denier. In comparison, fine silk, for example, is approximately 1.25 denier. Thus, a microfiber is conventionally to be 0.9 denier or finer. A large majority of microfibers manufactured are from 0.5 to 0.9 denier.
[0055] In another example, very fine nylon stockings are knit from 10 to 15 denier yarns, with each yarn consisting of 3 to 4 filaments which are twisted to form the yarns. A 15 denier yarn made of microfiber can have as many as 30 filaments which are twisted to form the yarn. It is this high number of filaments twisted to form the very fine yarn which also yields a much more extensive surface area determined by the surfaces of the many filaments and the spaces between these individual filaments.
[0056] Experimentation has found that as shown in FIG. 3 , conventional fibers of twisted filaments have much less area on the perimeter for charged metallic nanoparticles or ionic metal nanoparticles to occupy. However, it was found that the very small gaps descending into microfiber yarn forming the microfiber material 16 ( FIG. 1 ), which render it soft to the touch, also provide an exceptionably large surface area compared to yarns forming other fabric material such as cotton as shown in FIG. 3 .
[0057] It is in this narrow but plentiful surface area, between filaments or descending into the filaments forming the microfiber yarns formed to the microfiber material 16 ( FIG. 1 ), where metal nanoparticles 20 are imparted and stay frictionally engaged until dislodged or until they encounter a pathogen. Further, in these narrow passages depending into the yarn forming the microfiber material, pathogens are drawn and can mix and be dispatched in an encounter with the nanoparticles such as in FIG. 4 .
[0058] As can be discerned, the surface area and descending areas of each of 30 filaments forming a 15 denier yarn of microfiber such as in FIG. 4 , significantly exceeds the surface area of each of 3 to 4 filaments twisted to form nylon stocking yarn or cotton yarn such as in FIG. 3 . Further the spaces between the twisted filaments of the microfiber yarn form gaps descending therein which are particularly well sized and suited to frictionally engage metal nano particles therein. As such the employment of microfiber material 16 ( FIG. 1 ), formed of yarn 0.9 denier or less, is particularly preferred in that it significantly increases the amount of metal nanoparticles which may be imparted to the microfiber cloth used herein.
[0059] As shown in FIG. 4 , the imparted metal nano particles 20 may be sprayed, tumbled, dropped, or otherwise imparted to the microfiber material 16 ( FIG. 1 ), and will immediately engage to the filament surfaces in the very small spaces 21 , between the multiple filaments 17 formed to the microfiber yarn 19 strands.
[0060] The nanoparticle sized metal particles or metal ions shown as nanoparticles 20 herein is formed of metal nanoparticles which have at least one dimension between 1 and 150 nm. Preferably sized in this fashion, the nanoparticles 20 herein are metal nanoparticles or metal ions including one or a combination of metal nanoparticles, from a group of metal nanoparticles of similar or ionic configuration, including zinc oxide, titanium oxide, silver, brass, copper, aluminum.
[0061] A particular favorite being titanium oxide and/or zinc oxide nanoparticles 20 solely, or in a combination with silver nanoparticles 20 , in a ratio of between 80 to 99 percent zinc oxide or titanium oxide, to 1 to 20 percent silver particles, of the total mixture. One particular favorite is a mixture of 90 percent zinc oxide and/or titanium oxide nanoparticles and 10 percent silver in nanoparticles which as noted above worked exceptionally well to eliminate and prevent re-occupancy of pathogens on touch screens.
[0062] In operation for sanitizing and disinfecting a touch screen 12 as seen in FIGS. 2 and 4 , the microfiber material 16 which is infused with highly metal oxide nanoparticles 20 which are preferably ionic in that they have different nanoparticles with opposite charges, which occupy the significant amount of space depending into the formed yarn, is swiped or rubbed upon the touch screen 12 . As shown in FIG. 2 , the microfiber material 16 , is placed in a sandwiched contact between the finger 13 and the touch screen 12 being cleaned.
[0063] In this fashion, as the user presses and rubs the microfiber material 16 in contact against the touch screen 12 to clean it, some of the metal nanoparticles 20 imparted to the microfiber material 16 , are communicated against, and transferred to, the surface of the touch screen 12 such as in FIG. 4 .
[0064] The electrostatic field of the touch screen 12 changes at the point of finger and microfiber cloth 16 contact, and depending on conditions the field will change to be slightly more negative or positive. Consequently, nanoparticles 20 with the opposite charge as depicted in FIG. 3 will be attracted to and attach to touch screen 12 areas of the opposite charge as in FIG. 4 . Because of the high volume of surface area provided by the microfiber material 16 as noted above, there is an ample supply of nanoparticles 20 of both charge to occupy the touch screen 12 . So positioned, these nanoparticles 20 formed of one or mixture of metal nanoparticles preferably ionic in nature to provide both charges, will remove pathogens of both charges and inhibit their return to the touch screen 12 .
[0065] As shown in FIG. 5 , the device 10 can provide the nanoparticle infused microfiber material 16 housed in a sealed cavity 23 of a foil or plastic package 25 . In this mode of FIG. 5 , the microfiber material 16 infused with nanoparticles 20 can be removed from the torn package 25 , used once, and discarded.
[0066] In FIG. 6 is shown a resealable mode of the package 25 of FIG. 5 where a zip lock 27 or other resealable opening is provided. In this mode the microfiber material 16 imparted with metallic nanoparticles 20 preferably ionic in charge of the included particles, and may be replenished be placement back in the package 25 and shaking it to cause the supply of nanoparticles 20 to impart to the yarn forming the microfiber material 16 .
[0067] As noted, any of the different configurations and components can be employed with any other configuration or component shown and described herein to form the device or employ the method. Additionally, while the present invention has been described herein with reference to particular embodiments thereof and steps in the method of production, a latitude of modifications, various changes and substitutions are intended in the foregoing disclosures, it will be appreciated that in some instance some components, or configurations, or steps in formation and/or use of the invention could be employed without a corresponding use of other components without departing from the scope of the invention as set forth in the following claims. All such changes, alternations and modifications as would occur to those skilled in the art are considered to be within the scope of this invention as broadly defined in the appended claims.
[0068] Further, the purpose of any abstract of this specification is to enable the U.S. Patent and Trademark Office, 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. Any such 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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A pathogen removal and deterrent device and system is provided for touch screens used for user input on computing devices. Using a flexible applicator placed in a biased contact with the touch screen, metallic nanoparticles infused to the applicator eradicate pathogens and deter their return.
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CROSS-REFERENCES TO RELATED PATENT APPLICATIONS
[0001] This is a Continuation Application of application Ser. No. 11/548,681, filed Oct. 11, 2006 the disclosure of which is incorporated herein in its entirety by reference.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The subject invention relates to hard drives and, more particularly for controlling the heat generated by the hard disk drive heads preamp.
[0004] 2. Related Art
[0005] FIG. 1 a depicts a prior art hard drive 100 with the cover removed, while FIG. 1 b depicts an enlarged image of the preamp area. The hard disk 100 uses rotating platters (disks) 110 to store data. Each platter is rotated by a spindle (not shown) and has a smooth magnetic surface on which digital data is stored. Information is written to the disk by applying a magnetic field from a read-write head (not shown) that is attached to an actuator arm 120 . For reading, the read-write head detects the magnetic flux emanating from the magnetic bits that were written onto the platter. Since the signals from the read/write head is very faint, a preamp 130 is provided in close proximity to the head. The preamp 130 is a chip that is mounted on a substrate 140 . The substrate 140 is mounted onto a carrier plate 150 , that connects to the actuator arm assembly 120 . The flexible circuit loop 160 is connected to the substrate 140 , to transfer signals between the preamp 130 and the associated electronics (not shown). The associated electronics control the movement of the actuator and the rotation of the disk, and perform reads and writes on demand from the disk controller.
[0006] FIG. 2 depicts a prior art preamp sub-assembly, showing a carrier plate 250 , upon which the substrate 240 is mounted. The preamp 230 is attached to the substrate 240 and makes electrical connections to tap points on the substrate 240 . As shown in the cross-section inside the broken-line callout, the substrate is generally made of a stainless steel or aluminum backing, generally referred to as a stiffener, 215 , an insulating polyimide layer 225 , and copper conducting contacts and lines 235 . The “legs” of the preamp chip 230 (or bumps in case of a flip chip) are soldered to the copper contacts 235 . In the case depicted, substrate 240 , having its own stiffener 215 , folds back a top carrier plate 250 . Carrier plate 250 and stiffener 215 can be made from a common metal layer. Alternate designs integrate the function of the carrier plate into the stiffener, eliminating the need for the carrier plate. The substrate is generally made using a sheet of stiffener material, upon which several substrates are formed, as illustrated in FIG. 3 . As depicted in FIG. 3 , a sheet of stiffener material, such as stainless steel or aluminum, 315 , serves as a starting material for fabricating the substrate 345 . For each substrate 345 , a polyimide layer 325 is deposited on top of the stiffener 315 to serve as an electrical insulator. On top of the polyimide various conductive elements 335 are deposited to form contacts and transmission lines. The fabrication of these layers is done using conventional photolithography techniques. Both subtractive and additive flexible circuit fabrication processes are commonly employed in hard disk drives. To maximize the available real estate, the substrates 345 are fabricated so as to “nest” with each other, and after the fabrication is completed the substrates 345 are cut out of the stiffener sheet 315 .
[0007] As the physical size of the hard drive decrease, the heat generated by the preamp affects performance and reliability of the hard drive.
SUMMARY
[0008] The present invention has been made by observing a problem in the prior art, in that the heat generated by the preamp is not readily dissipated. While the carrier arm 250 can be used as a heat sink, the inventors of the subject application have discovered that little heat passes from the preamp 230 to the carrier arm 250 . The inventors have postulated that the reason for the low heat transfer is that the polyimide layer 225 of the substrate 240 acts as a heat barrier. Notably, polyimide has a thermal conductivity of 0.12 W/m-K, which is thermally insulative. Additionally, conductive pads 235 provide a very limited conductive heat release means, and suffer as well from the thermal isolation of the polyimide layer. Accordingly, the inventors have invented schemes to better remove heat from the preamp by providing a thermal conduit from the top of the preamp to the carrier arm.
[0009] According to an aspect of the invention, a substrate for mounting a preamp chip thereupon is provided, comprising a stiffener layer made of first conductive material; an insulating layer provided over circuitry area of the substrate; a circuitry of a second conductive material provided over the insulating layer; and a flap comprising an extension of the stiffener layer having no insulating layer provided thereupon, and wherein the flap is fabricated to fold over the preamp chip. According to one aspect, the first conductive material comprises stainless steel or aluminum. According to another aspect, the second conductive material comprises copper. The flap may comprise fins. The flap may also comprise cutout configured for injective adhesive thereupon.
[0010] According to another aspect of the invention, an actuator assembly for a hard disk drive is provided, comprising: an actuator arm; a circuitry substrate mounted onto the arm; a preamp chip mounted onto the circuitry substrate; and, wherein the substrate comprises a flap folded over top of the preamp ship. The substrate may comprises: a stiffener layer made of first conductive material; an insulating layer provided over circuitry area of the substrate; a circuitry of a second conductive material provided over the insulating layer; and, wherein the flap comprises an extension of the stiffener layer having no insulating layer provided thereupon. An adhesive may be provided between the preamp chip and the flap. The flap may comprise a cutout for an adhesive injected via the cutout. The adhesive may comprise a heat conducting epoxy. The flap may comprise fins.
[0011] According to yet another aspect of the invention, a method for manufacturing a substrate for supporting an integrated circuit chip thereupon is provided, comprising: providing a sheet of stiffener comprising a first conductive material; providing an insulating layer on defined sections of the stiffener, each section defining a circuitry area of one substrate; providing contacts on the insulating layer, the contacts made of a second conductive material; and, cutting each substrate out of the sheet according to a designed outline, the designed outlined comprising the circuitry area and a flap, the flap comprising a section of the sheet of stiffener having no insulating layer thereupon. The method may also comprise cutting a cutout in the flap.
[0012] According to a further aspect of the invention, a method for manufacturing a preamp assembly for a hard drive is provided, comprising: providing a substrate, the substrate comprising a stiffener conductive layer, an insulating layer provided on the stiffener and defining a circuitry area, and a plurality of contacts provided on the insulating layer, and a flap comprising a section of the stiffener having no insulating layer thereupon; mounting the preamp on the circuitry area of the substrate so as to form electrical connection to at least some of the contacts; and folding the flap over the preamp. The method may further comprise injective adhesive between the preamp and the flap. The flap may comprise a cutout and the method may further comprise injecting adhesive onto the cutout.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] Other aspects and features of the invention would be apparent from the detailed description, which is made with reference to the following drawings. It should be appreciated that the detailed description and the drawings provide various non-limiting examples of various embodiments of the invention, which is defined by the appended claims.
[0014] FIG. 1 a depicts a prior art hard drive 100 with the cover removed, while FIG. 1 b depicts an enlarged image of the preamp area.
[0015] FIG. 2 depicts a prior art preamp subassembly.
[0016] FIG. 3 depicts a sheet of stiffener having several substrates fabricated thereupon.
[0017] FIG. 4 depicts a preamp subassembly with a substrate according to an embodiment of the invention.
[0018] FIG. 5 depicts a preamp subassembly with a substrate according to another embodiment of the invention.
[0019] FIG. 6 illustrates a sheet of stiffener having several substrates fabricated thereupon according to an embodiment of the invention.
[0020] FIG. 7 a depicts the resulting temperature distribution in the preamp for the prior art assembly without the flap, while FIG. 7 b depicts the temperature distribution in the chip with the flap according to the embodiment of FIG. 5 .
[0021] FIG. 8 a depicts a finite element simulation run of the model with the flap, but without the epoxy, while FIG. 8 b depicts a run of the model with the flap and epoxy.
[0022] FIG. 9 depicts another embodiment of the invention.
[0023] FIG. 10 is a plot depicting simulated temperature reductions due to the flap design versus heat rise in the preamp chip.
DETAILED DESCRIPTION
[0024] FIG. 4 depicts a preamp subassembly showing carrier plate 450 with a substrate 440 according to an embodiment of the invention. Notably, a flap 465 of stiffener material has been added to the fabrication of the substrate 440 . The flap 465 is folded over the preamp 430 , so as to remove heat from the top of the preamp 430 . The heat removed is conducted by the flap 465 to stiffener 415 , then to carrier plate 450 and to the actuator arm assembly (not shown), which acts as the conduction heat sink.
[0025] That is, as can be understood from FIG. 2 , the stiffener layer 215 of the substrate 240 is in physical contact with the carrier plate 250 . However, as noted above in the prior art, the heat from the preamp 230 is not conducted to the carrier plate 250 because the polyimide layer 225 of the substrate 240 acts as a barrier for heat conduction. On the other hand, the flap 465 of the embodiment of FIG. 4 has no polyimide deposited thereupon. Consequently, heat from the top of the preamp 430 can be easily conducted to the flap 465 . Since the flap 465 is fabricated as an integral part of the substrate 440 , the heat from the flap 465 is easily conducted onto the carrier plate 450 . Convective heat transfer also takes place from the exposed surface area of the flap 465 to ambient air.
[0026] To further improve heat conductance to the flap, optionally a conductive adhesive 475 can be provided between the preamp 430 and the flap 465 , as is illustrated by the broken-line callout 475 . In practice, an air gap between flap 465 and 430 may exist due to geometric tolerances and forming uncertainties, so the conductive adhesive 475 is useful in filling that poor conductive path. On the other hand, to ease assembly of the preamp and substrate, in FIG. 5 a cut-out 585 has been made in the flap 565 . In this embodiment, once the preamp 530 is attached to the substrate 540 , the flap 565 is folded over the preamp, as shown in FIG. 5 . Then a conductive adhesive is injected into the cutout 585 , so as to spread under the flap 565 and onto the preamp 530 , as is illustrated by broken-line callout 575 .
[0027] FIG. 6 illustrates a sheet of stiffener having several substrates fabricated thereupon according to an embodiment of the invention. In FIG. 6 , the starting material is a sheet of stiffener material, such as stainless steel 615 . Several substrates 645 are fabricated on sheet 615 in a nested arrangement. Each substrate 645 has a “circuit” region, defined by the polyimide layer 625 and shown in solid line, and a flap 685 , which is a differently processed area of the stainless steel. That is, flap 685 is not covered with a polyimide, but is rather bare stiffener material. When the substrate is cut out of the sheet material, the cut is made so that the flap is an integral part of the substrate. This ensures that heat conducted onto the flap would be immediately conducted to the entire stiffener layer of the substrate. Since the stiffener contacts the carrier plate, the heat would be conducted to it and to the actuator arm assembly, which acts as a heat sink.
[0028] During assembly, preamp 530 is attached to the substrate 645 , substrate 645 is folded along dash-dotted line 696 so as to mate carrier plate 550 and stiffener 515 , as shown in FIG. 5 . Incidentally, as shown in FIG. 5 , in this embodiment at the area of fold 696 there is no stiffener material, but rather only a polyimide layer. The flap 685 is then folded along dotted line 698 over the preamp 530 . Then, when a cutout is used, conductive adhesive is injected into cutout 585 . When no cutout is provided, the adhesive may be injected from the sides, or injected prior to folding the flap over the preamp. One type of adhesive that is suitable for use with the embodiments described herein is TIGA HTR-815 epoxy, available from Resin Technology Group of South Easton, Mass. This epoxy has thermal conductivity of 1.15 W/m-K, which is an order of magnitude higher than the polyimide.
[0029] The embodiment depicted in FIG. 5 has been entered into a free convection thermal finite element simulation (hereon referred to as model) assuming a 25° C. ambient temperature and a fixed self heat generation magnitude in the preamp chip volume. The model was run assuming a fixed film coefficient for all exposed surfaces of the chip and surrounding sub-assembly bodies, allowing heat transfer to the ambient air by convection. For the first run, the exposed surfaces were set to have a film coefficient of 1 e −4 W/mm 2 -K and the preamp self heat generation magnitude assumed was 0.05 W/mm 3 , or 250 mW. FIG. 7 a depicts the resulting temperature distribution in the preamp for the prior art assembly without the flap, while FIG. 7 b depicts the temperature distribution in the chip with the flap according to the embodiment of FIG. 5 . For illustration purposes, the surrounding structures are hidden in FIGS. 7 a and 7 b . The maximum temperature observed in FIG. 7 a was 60.1° C., while for FIG. 7 b with the flap it was 54.7° C. Additionally, without the flap, a large area of high temperature was observed on the preamp with the gradient increasing towards the center of the preamp, while with the flap, the center of the preamp was cooler than the edges, tending to show that heat is conducted to the flap via the epoxy. Therefore, it is believed that large coverage of epoxy over the preamp would lead to improved results.
[0030] The model was also run with the exposed surfaces set to have film coefficient of 2.0 e −4 W/mm 2 -K and the same heat generation magnitude. For this case the maximum observed preamp temperature was 52.0° C. without the flap and 47.1° C. with the flap. This tends to show that even when improved convection to ambient air is present, the flap still provides the benefits of heat removal from the chip.
[0031] FIG. 8 a depicts a run of the model in FIG. 5 with the flap, but without the epoxy, while FIG. 8 b depicts a run of the model with the flap and epoxy. As can be seen from FIG. 8 a , there is poor thermal conductivity between the preamp and the flap due to an air gap placed intentionally between them, when no epoxy is present. This exemplifies the prior art configuration to an extent, because heat is not being removed from the top of the chip. On the other hand, the center of the preamp is cooler at the center when the epoxy is added. Both the maximum chip temperature and average temperature within the chip volume, are reduced. Consequently, it can be seen that if no epoxy is provided, physical contact between the flap and the preamp must be assured, which may increase manufacturing tolerances. The epoxy enables relaxing these tolerances and ease manufacturing.
[0032] Another embodiment is depicted in FIG. 9 . In FIG. 9 , heat removal from the preamp 930 is enhanced by adding fins 995 to the flap 965 . In this manner, heat is dissipated from the preamp to the flap, and from the flap to the carrier plate by conduction and to the ambient atmosphere via enhanced convection from the fins. Of course, other designs of fins can be made and those shown in FIG. 9 are provided only as one example.
[0033] FIG. 10 is a plot depicting expected temperature reduction due to the flap design versus heat rise in the preamp chip. To simulate this trend, the preamp heat generation is varied from 0.05 to 0.2 W/mm 3 . It is shown, as the observed heat differential rises in the chip, the benefit provided by the flap increases. For example, for a chip that operates at about 35 degrees above ambient, the flap should provide a reduction of 5 degrees, as opposed to a design without a flap. On the other hand, a more typical chip operating temperature is about 100 degrees above ambient, for which the flap is expected to provide over 15 degrees reduction in maximum temperature.
[0034] Thus, while only certain embodiments of the invention have been specifically described herein, it will be apparent that numerous modifications may be made thereto without departing from the spirit and scope of the invention. Further, certain terms have been used interchangeably merely to enhance the readability of the specification and claims. It should be noted that this is not intended to lessen the generality of the terms used and they should not be construed to restrict the scope of the claims to the embodiments described therein.
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A substrate for mounting a preamp chip thereupon, fabricated using a stiffener layer made of a conductive material; an insulating layer provided over the circuitry area of the substrate; a circuitry made of a conductive material provided over the insulating layer; and a flap which is an extension of the stiffener layer having no insulating layer provided thereupon. The flap is fabricated to fold over the preamp chip to remove heat therefrom.
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BACKGROUND OF THE INVENTION
This invention relates to plastic drums for storing or transporting liquid and solid products. More specifically, the invention is directed to plastic drums having bottom-to-lid interlocking surfaces, which enable the drums to be placed in stacks that are both safe and stable during shipping or storing operations.
Plastic drums are commonly used in industry, particularly in chemical plants, to transport hazardous liquid and solid materials to disposal points, such as incinerators. Many of these drums have removable flat lids that are fastened to the drum with a ring clamp. When the drums are packed together inside a truck trailer, or on a pallet, the ring clamps are frequently damaged or dislodged from a drum. It's also quite difficult to use fork lift or parrotbeak equipment to move plastic drums that are filled with material. Lifting the drums with this type of equipment frequently loosens the ring clamp enough so that the lid drops off of the drum.
Another problem with plastic drums is the difficulty in trying to stack them to save space. When the drums are stacked, the flat bottom of the drum on top tends to slide on the flat lid of the drum on the bottom, so that the stack itself is very unstable. The flat lid can also collect water, or other liquids, which can be mistaken for hazardous waste materials.
SUMMARY OF THE INVENTION
The invention is a plastic drum that is both stackable and nestable. In one embodiment of the drum, it consists of an elongate, circular drum wall that tapers downwardly from the top end to the bottom end of the drum wall. The top end of the drum wall defines a lip portion. A removable, circular lid closes the top end of the drum wall and, at the bottom, the drum wall is closed by a bottom member that is joined to the drum wall. The lid has a convex profile and a hook structure is defined at its outer edge.
Along the top surface of the lid are formed two circular rib portions. The larger diameter rib portion is located adjacent to the hook structure, such that it surrounds the smaller diameter rib portion. The bottom member has a concave profile, and along the bottom surface of this member is formed a spline portion and a slot portion. The spline portion is formed at the periphery of the bottom member and it surrounds the slot portion.
The drum also includes a support ring that can be either fitted snugly to the outside surface of the drum wall, or it can be integral with the drum wall. The ring which is integral with the drum wall has a lip portion that extends out beyond the top of the drum wall. The lower end of the ring forms a base portion, which is a flat surface that lies perpendicular to the drum wall. The lower end of the ring forms a base portion, which is a flat surface that lies perpendicular to the drum wall.
When the drum described herein is stacked on top of another drum of similar design, the spline portion on the bottom member seats down against the large diameter rib portion in the lid of the drum on which it is stacked (bottom drum); and the slot portion seats down over the small diameter rib portion in the lid of the bottom drum. Since the bottom of the drum on top interlocks with the lid of the drum on which it is stacked, the drums are capable of being arranged in a very stable stack.
The drums described herein are also capable of being nested, when empty, in a very convenient nesting arrangement. In the nesting arrangement, when one drum is placed inside of another, the base portion of the support ring of the uppermost drum seats down against the lip portion of the drum immediately underneath it. The lip portion thus provides a "stop" member that keeps the nested drums from becoming wedged together.
DESCRIPTION OF THE DRAWINGS
FIG. 1 is a plan view of one embodiment for the drum of this invention. This view illustrates particularly the surface configuration of the drum lid.
FIG. 2 is an elevation view of the drum shown in FIG. 1.
FIG. 3 is an elevation view, mostly in section, showing how the drums of this invention can be stacked, one on top of another.
FIG. 4 is a detail view, as indicated by the circular line in FIG. 3, illustrating how the bottom of the top drum interlocks with the lid of the drum beneath it, to form a stable drum stack.
FIG. 5 is a fragmentary view, partly in section, of the top of one of the drums of this invention. This view illustrates how a removable support ring is fitted onto the drum near the top.
FIG. 6 is an elevation view, in section, showing a two-drum stack, in which the top drum is smaller than the drum on the bottom of the stack.
FIG. 7 is an elevation view, in section, of a stack of three empty drums, in which the drums are positioned in a nesting arrangement.
FIG. 8 is a plan view of another drum lid of this invention. The surface configuration on this drum lid is an alternative design to the lid configuration shown in FIG. 1.
FIG. 9 is a cross-section view of the lid shown in FIG. 8, as taken along line 9--9.
FIG. 10 is a plan view of another drum lid of this invention. The surface configuration on this drum lid is an alternative design to the lid configurations shown in FIGS. 1 and 8.
FIG. 11 is a cross-section view of the lid shown in FIG. 10, as taken along line 11--11.
DESCRIPTION OF THE INVENTION
Referring to the drawings, particularly FIGS. 1-5, the numeral 10 indicates one embodiment of the plastic drum of this invention. The main component of the drum is an elongate circular drum wall 11. A removable circular lid 12 fits over the top end of the drum wall. The bottom end of the drum wall is closed by a bottom member 13, which is joined to the drum wall. The lid 12 is fastened to drum 10 by a conventional ring clamp 14. The drum wall 11 tapers downwardly from the top end to the bottom end (note particularly FIG. 3).
In the embodiment shown in FIGS. 5 and 6, a lip portion 15 is defined at the top end of the drum wall. The drum also includes a removable support ring 16, which is fitted snugly to the outside surface of the drum wall, just below the lip 15. The lid 12 has a convex profile, with a hook structure 17 being defined along the outer edge of the lid. When the lid is placed on a drum, the hook structure 17 fits down over the lip 15.
In the top surface of the lid 12 is formed a large diameter rib portion and a small diameter rib portion. The large diameter rib portion consists of spaced-apart rib segments 18, which are located adjacent to the hook structure 17. The small diameter rib portion is made up of spaced-apart rib segments 19, which are positioned near the center of lid 12, and which are surrounded by the larger rib portion 18.
The spaces between the rib segments 18 and 19 provide channels 20 that allow water or other liquids that may collect on the lid 12 to drain from the lid. The lid 12 also includes an inspection bung 21, which can be removed to inspect the contents of the drum, or to take a sample of the contents. As shown in FIG. 1, a second inspection bung, or a pressure relief device, could also be positioned in the lid 12 in the blank spot indicated by numeral 22.
Referring to FIG. 1, the bottom member 13 of the drum 10 has a flat profile. In the practice of this invention, the larger drums, i.e. from about 30 to 50 gallons capacity, are constructed with flat bottoms. The larger drums are always used as the bottom drum in a stack, and the flat bottoms prevent the stack from becoming unstable.
The drum of this invention is also constructed with a bottom member 13A, which has a concave profile, as shown in FIGS. 3, 4, 6 and 7. Looking particularly at FIG. 4, a spline portion 23 and a slot portion 24 are formed in the underside surface 25 of the member 13A. The spline portion is formed at the periphery of the underside surface, and it surrounds the slot portion, which is defined near the center of the member 13A.
When the drums of this invention are stacked, the bottom member 13A of each drum will interlock with the lid 12 of the drum immediately beneath it, as best illustrated in FIG. 4. In the interlocking sequence, the outside surface 23a of spline portion 23, of the "top" drum, seats down against the inside surface 18a of the rib segments 18 on the lid 12 of the "bottom" drum. At the same time, the slot portion 24 in member 13A seats down over the segments 19 of the small diameter rib portion in lid 12.
As described earlier, the drum shown in FIG. 5 includes a removable support ring 16, which is positioned on the outside surface of the drum wall 11 just below the lip 15. In another embodiment of the present drum, as shown in FIGS. 3 and 7, the drum is fabricated so that the support ring, indicated by numeral 16A, is integral with the drum wall 11. In this embodiment, the upper end of the support ring defines a lip portion 15a, that extends out beyond the top of the drum wall. The lower end of ring 16A forms a base portion defined by a flat surface 26 that lies perpendicular to the drum wall 11. The lower end of the removable support ring 16 has the same type of base, i.e. a flat surface 26.
In the practice of this invention, a stable stack can be formed using drums of several different sizes. For example, drums ranging in size from 4 gallons to 55 gallons can be safely placed in the same stack. As illustrated in FIG. 6, the smaller drums are always placed on top of the larger drums.
In addition to being stackable, the drums of this invention can be stored in a convenient nesting arrangement. For example, as shown in FIG. 7, one drum is placed inside of another to form the nesting column. In this arrangement, the flat surface 26 on the support ring 16A of the uppermost drum will seat down against the lip portion 15a of the drum immediately below it in the nesting column. This prevents the drums in the nesting column from becoming wedged (sticking) together.
In addition to preventing the nested drums from sticking together, the support rings 16 and 16A have other advantages. For example, the support rings add additional strength to each drum, which makes it possible to stack one drum on top of another. The support rings are also designed to be strong enough so that the forks of a fork lift truck can be slipped under the flat surface 26 of each ring (the base portion of the ring), to enable moving the drums from one place to another. The extra strength added by the support rings also makes it convenient to handle the drums with conventional parrotbeak equipment.
It will be noted also that the outside diameter of each support ring 16 or 16A is slightly larger than the outside diameter of the ring clamps 14, as best shown in FIG. 2. This feature keeps the ring clamps on each drum from banging against each other when the drums are handled, which can loosen or dislodge the clamps.
A second embodiment of a removable circular lid for the drum 10 of this invention is illustrated in FIGS. 8 and 9. This lid, indicated by numeral 27, has a convex profile which is similar to the profile of lid 12, as described earlier. A hook structure 17A is defined at the outer edge of lid 27, and in the top surface of the lid is formed a group of paddle-shaped members 28, which are raised from the lid's surface. The members 28 are also spaced apart, such that a number of channels 29 are defined between the members. These channels provide for water or other liquids to drain off of the lid. Between the wide end of the members 28 and the hook structure 17A is a flat portion of the lid 12 that defines a shelf portion 30. At the center of the lid 27 is an inspection bung 31. Between the narrow end of the members 28 and bung 31 is a slot portion 32.
In the practice of this invention, another drum could be stacked on top of a drum which included the lid 27. To provide the desired interlocking sequence, as described earlier, the bottom member of the drum being seated on lid 27 would be designed with a concave profile similar to the bottom member 13A, which is shown in FIGS. 3, 4, 6 and 7.
A drum having a bottom member designed for interlocking with lid 27 is not illustrated herein. But, the bottom member of such a drum would have an underside surface in which is formed a first spline portion and a second spline portion. The first spline portion would be formed at the periphery of the bottom member, and it would be designed to seat down onto the shelf portion 30 of lid 27. The first spline portion would surround the second spline portion, which would be located near the center of the bottom member. And the second spline portion would be designed to seat down into the slot portion of lid 27.
A third embodiment of a removable circular lid for the drum 10 of this invention is illustrated in FIGS. 10 and 11. This lid, as indicated by numeral 33, has a convex profile similar to the profile of the lids 12 and 27, as described above. A hook structure 17B is defined at the outer edge of lid 33, and in the top surface of the lid are formed two sets of crescent-shaped members, which are raised from the lid's surface. The smaller, or minor set of the crescent-shaped members, as indicated by numeral 34, is located near the center of the lid. Numeral 35 indicates the larger, or major set of the crescent-shaped members, which is located adjacent to the hook structure 17B.
As shown particularly in FIG. 10, there is a space between the members 34 and 35, which forms a wide slot portion 36. An inspection bung 37 is located at the center of lid 33. It will also be noted from FIG. 10 that there is a space between each of the members 34 in the minor set, and each of the members 35 in the major set. These spaces, indicated by numeral 38, provide channels for water or other liquids to drain off of the lid 38.
According to the practice of this invention, another drum could be stacked on top of a drum which included the lid 33. A drum suitable for stacking on top of lid 33 would have a bottom member with a concave profile similar to the bottom member 13A, so that it could interlock with the lid 33. A drum designed for stacking on top of lid 33 is not illustrated herein. But, the bottom member of such a drum would have an underside surface in which is formed a wide spline portion, and the spline portion would be designed to seat down into the wide slot portion 36.
The drums of this invention can be constructed of any of several polymer compositions that are rigid, strong, impermeable to chemical attack, and resistant to high temperature. The polymer compositions should also be capable of being blow molded or injection molded. High density polyethylene compositions are particularly suitable for this purpose.
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The invention refers to plastic drums designed such that the bottom of the drum will interlock with the lid of another drum. This feature enables the drums to be placed in stacks that are stable, so they can be safely handled during shipping, storing, or handling operations. The drums are also designed so they can be stored in a nesting column, when empty, without the drums becoming wedged together in the column.
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims priority to Taiwan Patent Application No. 104207215 filed May 12, 2015, the disclosure of which is hereby incorporated in its entirety by reference.
FIELD OF THE INVENTION
The present invention relates to a pressure detector, and more particularly to a pressure detector with high accuracy and long service life.
BACKGROUND OF THE INVENTION
A pressure detector is a device for detecting the pressure of gas, which is connected to a container with gas to be measured and performs pressure detection, by a sensing unit inside the pressure detector, that detects the pressure of the gas directly flowing from the container to the inside of the pressure detector. However, due to the problem that the gas to be measures dissipates easily through the intervals between the components of the pressure detector, the pressure detector often fails to obtain a correct pressure value. Moreover, the vapor or other corrosive material in the to-be-measured gas may corrode the circuit board inside the pressure detector easily, which leads to damage of the circuit board and less accurate detections, and also leads to a shortened lifetime of the pressure detector.
SUMMARY OF THE INVENTION
The present invention is for solving the disadvantages mentioned above and to provide a pressure detector with high accuracy and long service life.
To solve the problems in prior art, the present invention provides a pressure detector comprising a passage casing, a fixing body, a sensing member, a sealing member, and a power supply member. A chamber is provided within the passage casing, wherein a draining valve is disposed at a first end of the chamber for draining a fluid to be measured, and a draining aperture connected to the chamber is disposed on a side wall of the passage casing. The fixing body is disposed at an outer side of the passage casing by surrounding and covering the draining aperture to form an receiving space between the fixing body and the passage casing. The sensing member is disposed in the receiving space and includes a circuit board and a sensing module. The sensing module is provided on the circuit board and includes a sensing unit which has an opening connected to the draining aperture for sensing a pressure of the fluid to be measured. The sealing member is for filling the receiving space and separating the sensing member from the fixing body. The sealing member covers the sensor unit and the periphery of the draining aperture in such a manner that a sensing passage formed by the opening and the draining aperture is air-insulated from the circuit board and an outside space of the pressure detector by the sealing member. The power supply member is disposed on the fixing body and connected to the circuit board.
According to another aspect of the present invention, the fixing body includes a filling hole through which the outside space of the pressure detector is connected with the receiving space and through which the sealing member fills the receiving space. A fixing bolt is disposed in the filling hole by passing through the receiving space and being connected between the fixing body and the passage casing thereby fixing the fixing body on the passage casing.
According to another aspect of the present invention, the sensor member further includes a sleeve element which is sleeved and connected between the opening and the draining aperture.
According to another aspect of the present invention, an outer surface of a side wall of the passage casing has a groove in which the draining aperture in located.
According to another aspect of the present invention, the sensor member further includes a wireless member disposed on the circuit board, and the wireless member includes an antenna which extends downwardly along a direction substantially perpendicular to the plane of the circuit board.
According to another aspect of the present invention, the antenna includes a curve portion which extends along the rim of the fixing body.
According to another aspect of the present invention, a supplying valve is disposed at a second end of the chamber.
According to another aspect of the present invention, the pressure detector of the present invention further includes a cap member covering the fixing body, wherein the fixing body has an external screw thread, the cap member has an internal thread to which the external screw thread corresponds in such a manner that the cap member is screwed on the fixing body.
By the technical means of the present invention, the pressure detector provided by the present invention prevents fluid from dissipating through the intervals between the members of the pressure detector, and thus the accurate measurement of pressure is achieved. The demand for precise assembly is also decreased, which leads to production cost reduction. Furthermore, in the present invention, since the fluid to be measured only contacts the sensing member and will not flow to the circuit board, it can prevent the circuit board from corroding. Thus, the lifetime of the pressure detector is lengthened, and the circuit board can function without errors.
BRIEF DESCRIPTION OF THE DRAWINGS
The structure and the technical means adopted by the present invention to achieve the above and other objects can be best understood by referring to the following detailed description of the preferred embodiments and the accompanying drawings.
FIG. 1 is a perspective view diagram illustrating the pressure detector according to one embodiment of the present invention;
FIG. 2 is an exploded view diagram illustrating the pressure detector according to the embodiment of the present invention;
FIG. 3 is a schematic diagram illustrating the pressure detector according to the embodiment of the present invention, wherein the pressure detector is being assembled; and
FIG. 4 is a cross-sectional view diagram illustrating the pressure detector according to the embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
The embodiments of the present invention are described below with reference to FIG. 1 to FIG. 4 . The description is for describing the preferred embodiments of the present invention, and is not intended to limit the way of embodying the present invention.
Refer to FIG. 1 to FIG. 4 . FIG. 1 is a perspective view diagram illustrating the pressure detector according to an embodiment of the present invention. The pressure detector 100 comprises a passage casing 1 , a fixing body 2 , a sensing member 3 , a sealing member 4 , a power supply member 5 , and a cap member 6 .
The passage casing 1 is a hollow casing within which a chamber 13 is provided. The passage casing 1 is connected to a container (for example, a tire) with fluid to be measured and conducts the fluid to be measured from the container to the sensing member 3 . A draining valve 11 is disposed at a first end of the chamber 13 for draining the fluid to be measured, and a draining aperture 14 connected to the chamber 13 is disposed on a side wall of the passage casing 1 .
The fixing body 2 is disposed at an outer side of the passage casing 1 , and the sensing member 3 and the power supply member 5 are disposed and fixed on a side of the passage casing 1 by the fixing body 2 . The fixing body 2 surrounds and covers the draining aperture 14 to form an receiving space 23 between the fixing body 2 and the passage casing 1 . A trench is disposed on the outer edge of the fixing body 2 , and is surrounded by and combined with a rubber ring 24 for the receiving space 23 to be more closely insulated from the outer space.
The sensing member 3 is disposed in the receiving space 23 , and includes a circuit board 31 and a sensing module 32 . The sensing module 32 is provided on the circuit board 31 and includes a sensing unit 321 . The sensing unit 321 has an opening 321 a connected to the draining aperture 14 for forming a sensing passage P which is for the fluid to be measured to pass through. In other words, the fluid to be measured enters the chamber 13 from a passageway 111 , and enters the sensing unit 321 via the sensing passage P. Then, the sensing module 32 can sense a pressure of the fluid to be measured. The fluid to be measured is not limited to gas, it can also be liquid or the mix of gas and liquid.
In general, compared with the capacity of containers with fluid to be measured, the capacity of the pressure detector 100 is very small. Thus, the fluid pressure variation generated by the pressure detector 100 can be omitted. After the fluid to be measured becomes stable inside the pressure detector 100 , the sensing member 3 can measure an accurate pressure value.
As shown in FIG. 4 , which is a cross-sectional view diagram illustrating a completely assembled pressure detector according to one embodiment of the present invention. The sealing member 4 is for filling the receiving space 23 and separates the sensing member 3 from the fixing body 2 . The sealing member 4 covers the sensor unit 321 and the periphery of the draining aperture 14 in such a manner that a sensing passage formed by the opening 321 a and the draining aperture 14 is air-insulated from the circuit board 31 and an outside space of the pressure detector 100 by the sealing member 4 .
The power supply member 5 is disposed on the fixing body 2 and is connected to the circuit board 31 for supplying power to the sensing member 3 . The power supply member 5 includes a first conductive element 51 , a second conductive element 52 , and a battery 53 . An end of the first conductive element 51 and an end of the second conductive element 52 are inserted into the fixing body 2 individually, and extend to the circuit board 31 for electrically connecting to the circuit board 31 . Another end of the first conductive element 51 and another end of the second conductive element 52 are individually and electrically connected to two electrodes of the battery 53 .
The cap member 6 covers the fixing body 2 for capping inner members, such as the fixing body 2 and the power supply member 5 , and for protecting the members from directly contacting the space outside the pressure detector 100 . Furthermore, the fixing body 2 has an external screw thread, and the cap member 6 has an internal thread to which the external screw thread corresponds in such a manner that the cap member 6 is screwed on the fixing body 2 .
Please refer to FIG. 3 , which is a schematic diagram illustrating the pressure detector according to the embodiment of the present invention, wherein the pressure detector is being assembled. The fixing body 2 further includes a filling hole 21 through which the outside space of the pressure detector 100 is connected with the receiving space 23 and through which the sealing member 4 fills the receiving space 23 . A fixing bolt 22 is disposed in the filling hole 21 by passing through the receiving space 23 and being connected between the fixing body 2 and the passage casing 1 , thereby fixing the fixing body 2 on the passage casing 1 . In this embodiment, the fixing bolt 22 is a screw, and the filling hole 21 is a screw hole. However, the present invention is not limited to this.
The detail regarding how the sealing member 4 fills the receiving space 23 is explained below. The fixing body 2 includes a plurality of filling holes 21 and a plurality of fixing bolts 22 corresponding to the filling holes 21 . First, the members shown in the FIG. 3 are assembled together. The plurality of fixing bolts 22 are disposed in the corresponding filling holes 21 , and only one filling hole 21 is kept without the corresponding fixing bolt 22 passing through. Then, the filling hole 21 without fixing bolt 22 is used as an inlet for a sealing glue to enter the receiving space 23 . Before the sealing glue solidifies completely, a fixing bolt 22 is disposed in the filling hole 21 which acted as an inlet of the sealing glue, and after the sealing glue solidifies, the injected sealing glue forms the sealing member 4 . Finally, dispose the power supply member 5 and the cap member 6 above the fixing body 2 , and then the pressure detector 100 is completely assembled.
Furthermore, the sensing member 3 includes a sleeve element 34 which is sleeved and connected between the opening 321 a and the draining aperture 14 . The sleeve element 34 surrounds the sensing passage P for the fluid to be measured to flow to the opening 321 a via the sensing passage P instead of diffusing into the receiving space 23 . To facilitate the sealing process of sealing the contacting surface between the sleeve element 34 and the passage casing 1 by the sealing member 4 , an outer surface of a side wall of the passage casing 1 has a groove 15 in which the draining aperture 14 in located. The inner edge of the groove 15 is slightly larger than the outer edge of the sleeve element 34 . When the sleeve element 34 is disposed in the groove 15 , the said sealing glue enters the receiving space 23 and tends to flow to the groove 15 which is low-lying. Therefore, the sealing glue clusters around the periphery of the contacting surface of the sleeve element 34 . After the sealing glue solidifies and forms the sealing member 4 , the sealing member 4 can seal the contacting surface between the sleeve element 34 and the passage casing 1 .
The sensing member 3 further includes a wireless member 35 disposed on the circuit board 31 , and the wireless member 35 includes an antenna 351 which extends downwardly along a direction substantially perpendicular to the plane of the circuit board 31 and thus forms a stick antenna. The wireless member 5 is for transmitting data obtained by the sensing member 3 wirelessly, thereby making the pressure detector 100 becomes a wireless pressure detector.
Furthermore, except for a stick portion 351 a, the antenna 351 also includes a curve portion 351 b which extends along the rim of the fixing body 2 . With the curve portion 351 b, the wireless signals transmitted by the wireless member 35 can be strengthened and thus is easy to be received.
Furthermore, a supplying valve 12 is disposed at a second end of the chamber 13 , and thus the pressure detector 100 in the present invention becomes a double-pass pressure detector. In detail, a supplied fluid can be provided by entering the second end of the chamber 13 , and flowing into the container to be measured connected to the first end of via pressure detector 100 . Besides, the pressure detector 100 can discharge the fluid to be measured from the container to the outside space via the second end of the chamber 13 . Thereby, the pressure detector 100 can adjust the pressure of the fluid to be measured container according to the measured pressure value, in which the supplying valve 12 is a controlling valve for supplying or discharging fluid.
In summary, the pressure detector provided in the present invention prevents fluid from dissipating through the intervals between the members of the pressure detector, thus achieving accurate pressure measurement. The demand for precision and tolerance when assembling the pressure detector is also decreased, which leads to reduction of production cost. Furthermore, the fluid to be measured entering the passage after leaving the draining aperture, the sleeve element surrounding the sensing passage, and the sealing member filling the receiving space all prevent fluid to be measured from flowing to the circuit board, and thus protect the circuit board from corroding and damage. Therefore, the pressure detector of the present invention can have longer lifetime and circuit boards functioning without errors. In conclusion, the present invention provides a pressure detector 100 with technical advantages over conventional pressure detectors.
The above description should be considered as only the discussion of the preferred embodiments of the present invention. A person skilled in the art may make various modifications to the present invention. However, those modifications still fall within the spirit of the present invention and the scope defined by the appended claims.
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A pressure detector includes a passage casing, a fixing body, a sensing member, a sealing member, and a power supply member. The passage casing and the fixing body form a receiving space where the sensing member is disposed in. The sealing member is filled into the rest of the receiving space and separates the sensing member from the fixing body, and prevents a fluid to be measured coming from the chamber from leaking to outside space. The circuit board of the sensing member is protected from contacting the fluid to be measured directly. Thus, the accuracy of measuring pressure is improved, and the lifetime of the pressure detector is lengthened.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser. No. 12/805,437, filed Jul. 30, 2010, which is a continuation of U.S. application Ser. No. 09/902,707, filed Jul. 12, 2001, which is a continuation of U.S. application Ser. No. 08/817,528, filed Aug. 5, 1997, which claims priority to International Application No. PCT/FR94/01185, filed Oct. 12, 1994, and French Application No. 95/08391, filed Jul. 11, 1996, the entire contents of each of which are incorporated herein in its entirety by reference.
[0002] This application is related to our copending commonly assigned applications:
[0000]
USSN 08/817,690
(Corres. to PCT/FR94/01185
filed Oct. 12, 1994);
USSN 08/817,689
(Corres. to PCT/FR95/01333
filed Oct. 12, 1995);
USSN 08/817,968
(Corres. to PCT/FR95/01335
filed Oct. 12, 1995);
USSN 08/817,437
(Corres. to PCT/FR95/01336
filed Oct. 12, 1995)
USSN 08/817,426
(Corres. to PCT/FR95/01337
filed Oct. 12, 1995); and
USSN 08/817,438
(Corres. to PCT/FR95/01338
filed Oct. 12, 1995).
BACKGROUND OF THE INVENTION
Field of the Invention
[0003] The invention relates to a communications process for a payment-triggered audiovisual reproduction system.
[0004] These audiovisual reproduction systems are generally found in cafes or pubs. This type of system is composed of a sound reproduction machine usually called a jukebox linked to a monitor which displays video images or video clips. To do this the jukebox is equipped with a compact video disk player and a compact video disk library and includes selection buttons which locate the titles of pieces of music which are available. Payment of a proper fee followed by one or more selections authorizes activation of the system with automatic loading in the player of the disk on which the selected piece is found, the desired audiovisual reproduction then being able to start.
[0005] These systems, although allowing faithful and good quality reproduction, nevertheless have major defects. Thus, a first defect relates to the space necessary for storing the library; this consequently entails that the system will have large dimensions and will be bulky. Likewise these systems which call on mostly mechanical hardware using sophisticated techniques have high fault rates; this is another defect. Finally, it is very unusual for all the pieces on a disk to be regularly heard; some are almost never played, but still cannot be eliminated. Besides this defect, the additional problems are caused by the companies which manage and distribute these systems. More particularly, placing in the circuit a limited number of identical disks and imposing a certain rotation on their customers sometimes results in an unpleasant wait for the customers when a disk is not available.
[0006] In addition, patent application PCT/WO 93 18465 discloses computerized jukeboxes which allow reception via a telecommunications network and a modem connecting the jukeboxes to the network, digital data comprising remotely loaded songs or musical pieces in a mass storage of the jukeboxes. The communications systems is likewise used for remote loading of representative files of digitized graphics information, the songs and graphics files being compressed before they are sent over the network. The jukebox processor then uses these files by decompressing them and sending the graphics data to the video circuit and the song data to the audio circuit.
[0007] However, the processor also manages the man/machine interface, and management of these different elements is done by sequentially displaying the graphics images representative of the song, then by responding to the touch action of the user, then checking that the user has paid the prescribed amounts, and finally when the required amount has been accounted, placing the selection in a queue for its subsequent performance. This system can only operate by first displaying the graphics images and then starting performance of the song because the processor cannot, according to the flowcharts, execute two tasks at one time. Finally, the graphics representations are uniquely data digitized by a scanner table of the album cover of the song. In no case does this jukebox allow display of moving images during the broadcast of the song or music. Likewise, since the processor is used for digital data decompression and processing for conversion into audio signals, it cannot consider the new actions of a user making a new selection. This is apparent, notably on page 12 of the PCT application, lines 25 to 27. Selection of new songs can only be done when the jukebox is in the attraction mode, i.e., the mode in which it displays graphics representations of different songs stored in the jukebox in succession.
[0008] U.S. Pat. No. 4,956,768 discloses a broadband server for transmitting music or images formed by a main processor communicating by a DMA channel with a hard disk and output cards, each controlled by a supplementary local processor which manages an alternative mode of access to two buffer memories A and B. Memory A is used to deliver, for example, musical data to a user, while the other is filled. Each of the output cards is connected to a consultation station, which can be local and situated in the same vicinity as the server or, alternatively, at a distance and connected by an audio or video communications network. The server receives data block-by-block and ensures that the sample parities are correct and rejects a block including more than two successive wrong samples. Each of these blocks is of course designated by a number. Once a block has been accepted, it can be stored on the local hard disk by recording its ordinal number which has no relation to its physical address on the hard disk. The consultation stations have audio and video outputs such as loudspeakers or headphones and a television monitor which makes it possible to listen to music or display images in response to requests received from terminals included in the consultation stations. In this system, the consultation stations where the first communications processor exists must have specific software for management of selection requests for musical pieces or video. It is only when the request has been made and addressed to the broadband server processor that it can transfer, under the authority of the local processor, the data in the buffer memories, such that this local processor ensures that the data are sent to the consultation stations. Moreover, it is specified that the output cards and buffer memories are filled only after having received the authorization of the local processor of the card.
[0009] Consequently, this system can only function within the framework of a multiprocessor device and does not in any way suggest use of this server for a jukebox controlled by a single processor operating in an multitask environment. This system proposed by this U.S. patent thus implements a complex process which allows delivery of a service to several consultation stations; this complex process is thus costly and incompatible with a system of jukeboxes, of which the cost and price should be as low as possible.
[0010] Moreover the process of downloading by a central site of digitized audio and video files to the local servers is accomplished via a specialized line communicating unidirectionally with the V35 interfaces of the local server, and allowing passage of 64 kilobit frames. Thus a second parallel communication must be established via the switched telephone network by a serial interface to allow exchange of service data. It is specified that it is preferable to transmit new musical pieces to the broadband server at night to leave the system free for users during the day, and that transmission can be done continuously and simultaneously for all local servers, provided that they can register continuously, i.e., at night.
[0011] This device can only work to the extent that the central server is the master and the local servers are slaved. This thus entails availability of local servers at the instant of establishing communications; this is enabled by the local servers having a double processor which relieves the communication processor for a sufficient interval. In a single-processor architecture it is thus difficult to establish communications according to this protocol determined with a variable number of jukebox stations to allow remote operations such as downloading of music or video following a selection by the jukebox manager or sending statistics to the center, or recovering data concerning billing or security management of the units, or recovery for analysis and survey distribution.
[0012] The object of the invention is to eliminate the various aforementioned defects of the systems of the prior art, and to provide a system of communications between jukebox units allowing reproduction and display of audiovisual digital information and a central server which supports, among various functions, downloading of data.
[0013] This object is achieved by the communications process operating in a conference mode and it includes the following stages:
sending a heading before any transaction which includes the identity of the destination, identity of the sender, and the size of the packets; sending a server response in the form of a packet of data, each packet sent by the server being encoded using the identification code of the jukebox software; receiving a data packet by the decoding jukebox, wherein the packet at the same time checks the data received using the CRC method and sending a reception acknowledgment to the server indicating the accuracy of the received data to allow it to prepare and send a new packet to the unit destination.
[0017] According to another operating mode the server can send the data by stream, the stream including several packets, and the receiver unit will then perform decoding and storage, and after receiving the indicator of the last packet, will signal the defective packets received at the server.
[0018] According to another feature, each packet contains a first field allowing identification of the seller, a second field allowing indication of the identification of an application, this 32 bit field making it possible to specify whether it is a digital song, digital video, stationary image, software update, statistics, billing, or update of the unit database, a third field indicating the identification of a single type of application such as the identification number of the product, the type of billing, the difference between a midi song and a digital song, last block indication, finally a fourth field indicating the sequence number of the block in the transmission, a fifth block indicating the length of this block in octets, a sixth field composed of variable length data, a seventh field composed of cyclic redundancy verification data.
[0019] An object of the invention is to eliminate the various defects of the systems of the prior art by providing an intelligent digital audiovisual reproduction system which is practical to implement, compact, reliable, authorizes storage at the title level as well as easy deletion or insertion of titles not listened to or wanted, all this while maintaining performance and a high level of reproduction quality.
[0020] Another object of the invention is to provide a standard protocol which moreover allows the features mentioned above for remote updating of software.
[0021] The objects are achieved by the fact that the jukebox units contain software for interpretation of the second field of the communications packets which detect the code corresponding to remote updating of the software and after having verified that the software version number is greater than the version installed on the unit, initiates a system status verification procedure to ensure than there is no activity underway on the jukebox. If yes, the unit displays a wait message, during reception of the new software version on the screen, copies the back-up of the software version installed on the unit, modifies the system startup file for startup with the backup version, then begins execution of the new version of the software, verifies the state of system status after execution of this new version, reinitializes the system startup files for startup with the new version. In the case in which the status is not OK, the software reinitializes the system with the old version and signals a reception error to the central server.
[0022] According to another feature, each audiovisual reproduction system contains a multitask operating system which manages, using a primary microprocessor, the video task, the audio task, the telecommunications task, the input task (keyboard, screen, touch) and a status buffer is linked to each of the tasks to represent the activity or inactivity of this task.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] Other advantages and features of the invention follow from the following description, with reference to the attached drawings, given by way of a non-limiting example only, in which:
[0024] FIG. 1 shows a circuit diagram of the hardware comprising the invention;
[0025] FIG. 2 shows an organizational chart of the service modules specific to a task and managed via a multitask operating system, the set of modules being included in a library stored in the storage means;
[0026] FIG. 3 shows the organization of the multitask system which manages the set of hardware and software;
[0027] FIG. 4 shows a flowchart describing the operation of the multitask management system;
[0028] FIG. 5 shows a flowchart for verifying task activity;
[0029] FIG. 6 schematically shows the database structure;
[0030] FIG. 7 shows the structure of the packets used in the communications protocol;
[0031] FIG. 8 shows a method of updating the software which can be done using the invention protocol.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0032] Preferably, but in a nonrestrictive manner, the audiovisual reproduction system uses the aforementioned listed components.
[0033] Microprocessor central unit 1 is a high performance PC-compatible system, the choice for the exemplary embodiment being an Intel 80486 DX/2 system which has storage means and the following characteristics:
compatibility with the local Vesa bus, processor cache memory: 256 kO, RAM of 32 MO high performance parallel and serial ports, SVGA microprocessor graphics adapter, type SCSI/2 bus type controller, battery backed-up static RAM
[0041] Any other central unit with similar, equivalent or superior performance can be used in accordance with the invention.
[0042] This central unit controls and manages audio control circuit ( 5 ), telecommunications control circuit ( 4 ), input control circuit ( 3 ), mass storage control circuit ( 2 ), and display means control circuit ( 6 ). The display means consist essentially of a 14 inch (35.56 cm) flat screen video monitor ( 62 ) without interleaving of the SVGA type, with high resolution and low radiation, which is used for video reproduction (for example, the covers of the albums of the musical selections), graphics or video clips.
[0043] Likewise comprising part of the storage means, storage modules ( 21 ) using hard disks of the high speed and high capacity SCSI type are connected to the storage means already present in the microprocessor device. These modules allow storage of audiovisual data.
[0044] High speed 28.8 k/bps telecommunications modem adapter ( 41 ) is integrated to authorize the connection to the audiovisual data distribution network controlled by a central server.
[0045] To reproduce the audio data of the musical selections, the system includes loudspeakers ( 54 ) which receive the signal from tuner amplifier ( 53 ) connected to electronic circuit ( 5 ) of the music synthesizer type provided to support a large number of input sources, while providing an output with CD (compact disk) type quality, such as for example a microprocessor multimedia audio adapter of the “Sound Blaster” card type SBP32AWE from Creative Labs Inc. on which two buffer memories ( 56 , 57 ) are added for a purpose to be explained below.
[0046] Likewise the control circuit of the display means includes two buffer memories ( 66 , 67 ) for a purpose to be explained below.
[0047] A thermally controlled 240 watt ventilated power supply provides power to the system. This power supply is protected against surges and harmonics.
[0048] The audiovisual reproduction system manages via its input controller circuit ( 3 ) a 14 inch (35.56 cm) touch screen “Intelli Touch” ( 33 ) from Elo Touch Systems Inc. which includes a glass coated board using “advanced surface wave technology” and an AT type bus controller. This touch screen allows, after having displayed on video monitor ( 62 ) or television screen ( 61 ) various selection data used by the customers, management command and control information used by the system manager or owner. It is likewise used for maintenance purposes in combination with external keyboard ( 34 ) which can be connected to the system which has a keyboard connector for this purpose, controlled by a key lock ( 32 ) via interface circuit ( 3 ).
[0049] Input circuit ( 3 ) likewise interfaces with the system a remote control set ( 31 ) composed for example of:
an infrared remote control from Mind Path Technologies Inc., an emitter which has 15 control keys for the microprocessor system and 8 control keys for the projection device. an infrared receiver with serial adapter from Mind Path Technologies Inc.
[0052] A fee payment device ( 35 ) from National Rejectors Inc. is likewise connected to input interface circuit ( 3 ). It is also possible to use any other device which allows receipt of any type of payment by coins, bills, tokens, magnetic chip cards or a combination of means of payment.
[0053] To house the system a chassis or frame of steel with external customizable fittings is also provided.
[0054] Besides these components, wireless microphone ( 55 ) is connected to audio controller ( 5 ); this allows transformation of the latter into a powerful public address system or possibly a karaoke machine. Likewise a wireless loudspeaker system can be used by the system.
[0055] Remote control set ( 31 ) allows the manager, for example from behind the bar, access to and control of various commands such as:
microphone start/stop command, loudspeaker muting command, audio volume control command; command to cancel the musical selection being played.
[0060] The system operating software has been developed around a library of tools and services largely oriented to the audiovisual domain in a multimedia environment. This library advantageously includes an efficient multitask operating system which efficiently authorizes simultaneous execution of multiple fragments of code. This operating software thus allows concurrent execution, in an orderly manner and avoiding any conflict, of operations performed on the display means, audio reproduction means as well as management of the telecommunications lines via the distribution network. In addition, the software has high flexibility.
[0061] The digitized and compressed audiovisual data are stored in storage means ( 21 ).
[0062] Each selection is available according to two digitized formats: hi-fi and CD quality.
[0063] Prior to describing and reading this organization chart in FIG. 2 , it must be noted that while all these modules described separately seem to be used sequentially, in reality the specific tasks of these modules are executed simultaneously in an environment using the multitask operating system. Consequently the organizational chart indicates the specific operations which the module must perform and not a branch toward this module which would invalidate all the operations performed by the other modules.
[0064] The first module, labeled SSM, is the system startup module. This module does only one thing, consequently it is loaded automatically when the system is powered up. If the system is started with a correct registration number it then directly enters the “in service” mode of the module labeled RRM.
[0065] The REG module is the registration mode module which, when it is activated for the first time or when approval for a new registration is necessary, indicates its software serial number and requests that the user enter his coordinates, such as the name of the establishment, address and telephone number.
[0066] The RMM module is the module of the “in service” mode which is the mode of operation which the system enters when its registration number has been validated. In this mode the system is ready to handle any request which can be triggered by various predefined events such as:
customers touching the screen: when a customer or user touches the screen, the system transfers control of the foreground session to the customer browsing and selection mode CBSM module, telecommunications network server call requests: when the system detects a loop on the phone line, it emits an asynchronous background procedure: the telecommunications services mode TSM module, requests concerning key switch ( 32 ): when the manager turns the key switch the system hands over control of its foreground session to the management mode SMM module, reception of a remote control signal: when a command is received, it is processed in a background session by the system command 5MM module while the foreground session remains available for other interventions, appearance of end of timing, showing inactivity of the system: when one of the various timers is activated, control is temporarily handed over to the inactivity routines IPM module for processing.
[0072] The system remains in the “in service” mode until one of the above described events takes place.
[0073] The IRM module is the inactivity routines module. It contains the routines which perform predetermined functions such as album cover display, broadcast of parts of musical pieces present in the system, reproduction of complete selections for internal promotional proposes, audio reproductions for external promotional purposes, spoken promotional announcements of new musical selections, withdrawal to an auxiliary source which can be called when the system is inactive and when a predefined but adjustable time interval corresponding to a timer has expired.
[0074] The SMM module is the system commands module. This module allows execution of functions which command the system to accept a required input by an infrared remote control device, these functions being handled instantaneously without the process underway being stopped. A very large number of these functions are possible, only some are listed below, in a nonrestrictive manner:
audio volume control of the played selections, audio volume control of the auxiliary played source, microphone start/stop command, microphone audio volume control, balance control, left channel, right channel, control of base frequency level, control of treble frequency level, command to cancel or skip a musical selection, panoramic effects command, zoom forward, zoom back, triggering of reset of the software program.
[0085] The MMM module is the management mode module. This module is triggered when the key switch is turned by the manager. The display of an ordinary screen is replaced by a display specific to system management. With this new display the manager can control all the settings which are possible with remote control. He can likewise take control of additional low level commands allowing for example definition of commands to be validated or invalidated on the remote control. He is also able to define a maximum of high and low levels for each system output source, these limits defining the range available on the remote control. Using this screen the manager can access the mode of new selection acquisitions by touching a button located on the touch screen. When the manager has succeeded in defining these commands as well as the system configuration, it is then enough to remove the key and the system returns automatically to the “in service” mode.
[0086] The NSAM module is the new selections acquisition mode module.
[0087] The CBSM module is the customer browsing and selection mode module. Access to this module is triggered from the “in service” when the customer touches the screen. The display allows the user to view a menu provided for powerful browsing assisted by digitized voice messages to guide the user in his choice of musical selections.
[0088] The TSM module is the telecommunications services mode module between the central server and the audiovisual reproduction system. This module allows management of all management services available on the distribution network. All the tasks specific to telecommunications are managed like the background tasks of the system. These tasks always use only the processing time remaining once the system has completed all its foreground tasks. Thus, when the system is busy with one of its higher priority tasks, the telecommunications tasks automatically will try to reduce the limitations on system resources and recover all the microprocessor processing time left available.
[0089] The SSC module is the system security control module. This module manages security, each system is linked to a local controller system according to a preestablished time pattern for acquisition of the approval signal in the form of the registration number authorizing it to operate. In addition, if cheating has been detected or the system cannot communicate via the network, said system automatically stops working.
[0090] The SPMM module allows management of musical selections, songs or video queued by the system for execution in the order of selection.
[0091] Finally, the SMM module allows remote management of system settings by the manager by remote control.
[0092] The multitask operating system comprises the essential component for allowing simultaneous execution of multiple code fragments and for managing priorities between the various tasks which arise.
[0093] This multitask operating system is organized as shown in FIG. 3 around a kernel comprising module ( 11 ) for resolving priorities between tasks, task supervisory module ( 12 ), module ( 13 ) for serialization of the hardware used, and process communications module ( 14 ). Each of the modules communicates with application programming interfaces ( 15 ) and database ( 16 ). There are as many programming interfaces as there are applications. Thus, module ( 15 ) includes first programming interface ( 151 ) for key switch ( 32 ), second programming interface ( 152 ) for remote control ( 31 ), third programming interface ( 153 ) for touch screen ( 33 ), fourth programming interface ( 154 ) for keyboard ( 34 ), fifth programming interface ( 155 ) for payment device ( 35 ), sixth programming interface ( 156 ) for audio control circuit ( 5 ), seventh programming interface ( 157 ) for video control circuit ( 6 ), and last interface ( 158 ) for telecommunications control circuit ( 4 ).
[0094] Five tasks with a decreasing order of priority are managed by the kernel of the operating system, the first ( 76 ) for the video inputs/outputs has the highest priority, the second ( 75 ) of level two relates to audio, the third ( 74 ) of level three to telecommunications, the fourth ( 73 ) of level four to interfaces and the fifth ( 70 ) of level five to management. These orders of priority will be considered by priority resolution module ( 11 ) as and when a task appears and disappears. Thus, as soon as a video task appears, the other tasks underway are suspended, priority is given to this task and all the system resources are assigned to the video task. At the output, video task ( 76 ) is designed to unload the video files of the mass memory ( 21 ) alternately to one of two buffers ( 66 , 67 ), while other buffer ( 67 or 66 ) is used by video controller circuit ( 6 ) to produce the display after data decompression. At the input, video task ( 76 ) is designed to transfer data received in telecommunications buffer ( 46 ) to mass storage ( 21 ). It is the same for audio task ( 75 ) on the one hand at the input between telecommunications buffer ( 46 ), and buffer ( 26 ) of mass memory ( 21 ), and on the other hand at the output between buffer ( 26 ) of mass memory ( 21 ) and one of two buffers ( 56 , 57 ) of audio controller circuit ( 5 ).
[0095] The task scheduler module will now be described in conjunction with FIG. 4 . In the order of priority this module performs first test ( 761 ) to determine if the video task is active. In the case of a negative response it passes to the following test which is second test ( 751 ) to determine if the audio task is still active. In the case of a negative response third test ( 741 ) determines if the communications task is active. After a positive response to one of the tests, at stage ( 131 ) it fills memory access request queue ( 13 ) and at stage ( 132 ) executes this storage request by reading or writing in the mass storage, then loops back to the first test. When the test on communications activity is affirmative, scheduler ( 12 ) performs a test to determine if it is a matter of reading or writing data in the memory. If yes, the read or write request is placed in a queue at stage ( 131 ). In the opposite case, the scheduler determines at stage ( 743 ) if it is transmission or reception and in the case of transmission sends by stage ( 744 ) a block of data to the central server. In the case of reception the scheduler verifies that the kernel buffers are free for access and in the affirmative sends a message to the central server to accept reception of a data block at stage ( 747 ). After receiving a block, error control ( 748 ) of the cyclic redundancy check type (CRC) is executed and the block is rejected at stage ( 740 ) in case of error, or accepted in the opposite case at stage ( 749 ) by sending a corresponding message to the central server indicating that the block bearing a specific number is rejected or accepted, then loops back to the start tests. When there is no higher level task active, at stage ( 731 or 701 ) the scheduler processes interface or management tasks.
[0096] Detection of an active task or ready task is done as shown in FIG. 5 by a test 721 to 761 respectively on each of the respective hardware or software buffers ( 26 ) of the hard disk, ( 36 ) of the interface, ( 46 ) of telecommunications, ( 56 and 57 ) of audio, ( 66 and 67 ) of video which are linked to each of respective controller circuits ( 2 , 3 , 4 , 5 , 6 ) of each of the hardware devices linked to central unit ( 1 ). Test ( 721 ) makes it possible to check if the data are present in the buffer of the disk input and output memory, test ( 731 ) makes it possible to check if the data are present in the buffers of the hardware or software memory buffers of the customer interface device, test ( 741 ) makes it possible to check if the data are present in the buffers of the hardware or software memory of the telecommunications device, test ( 751 ) makes it possible to check if the data are present in the buffer of the hardware or software memory for the direction, test ( 761 ) makes it possible to check if the data are present in the hardware or software memory buffers of the video device. If one or more of these buffers are filled with data, scheduler ( 12 ) positions the respective status buffer or buffers ( 821 ) for the hard disk, ( 831 ) for the interface, ( 841 ) for telecommunications, ( 851 ) for audio, ( 861 ) for video corresponding to the hardware at a logic state illustrative of the activity. In the opposite case the scheduler status buffers are returned at stage ( 800 ) to a value illustrative of inactivity.
[0097] Due, on the one hand, to the task management mode assigning highest priority to the video task, on the other hand, the presence of hardware or software buffers assigned to each of the tasks for temporary storage of data and the presence of status buffers relative to each task, it has been possible to have all these tasks managed by a single central unit with a multitask operating system which allows video display, i.e., moving images compared to a graphic representation in which the data to be processed are less complex. This use of video display can likewise be done without adversely affecting audio processing by the fact that audio controller circuit ( 5 ) includes buffers large enough to store a quantity of compressed data sufficient to allow transfer of video data to one of video buffers ( 66 , 67 ) during audio processing while waiting for the following transfer of audio data.
[0098] Moreover, the multitask operating system which includes a library containing a set of tools and services greatly facilitates operation by virtue of its integration in the storage means and the resulting high flexibility. In particular, for this reason it is possible to create a multimedia environment by simply and efficiently managing audio reproduction, video or graphics display and video animation. In addition, since the audiovisual data are digitized and stored in the storage means, much less space is used than for a traditional audiovisual reproduction system and consequently the congestion of the system according to the invention is clearly less.
[0099] Database ( 16 ) is composed, as shown in FIG. 6 , of several bases: first ( 161 ) with the titles of the audiovisual pieces, second ( 162 ) with the artists, third ( 163 ) with the labels, fourth ( 164 ) with albums, fifth ( 165 ) with royalties. First base ( 161 ) contains first item ( 1611 ) giving the title of the piece, second item ( 1612 ) giving the identification of the product, this identification being unique. Third item ( 1613 ) makes it possible to recognize the category, i.e., jazz, classical, popular, etc. Fourth item ( 1614 ) indicates the date of updating. Fifth item ( 1615 ) indicates the length in seconds for playing the piece.
[0100] Sixth item ( 1616 ) is a link to the royalties base. Seventh item ( 1617 ) is a link to the album. Eighth item ( 1618 ) is a link to the labels. Ninth item ( 1619 ) gives the purchase price for the jukebox manager;
[0101] Tenth item ( 1620 ) gives the cost of royalties for each performance of the piece;
[0102] Eleventh item ( 1610 ) is a link to the artist database, This link is composed of the identity of the artist. The artist database includes, besides the identity of the artist composed of item ( 1621 ), second item ( 1622 ) composed of the name of the artist or name of the group. The label database includes first item ( 1631 ) composed of the identity of the label, establishing the link to eighth item ( 1618 ) of the title database and second item ( 1632 ) composed of the name of the label. The album database contains first item which is the identity of the album ( 1641 ) which constitutes the link to seventh item ( 1617 ) of the title base. Second item ( 1642 ) comprises the title, third item ( 1643 ) is composed of the date of updating of the album, and fourth item ( 1644 ) composed of the label identity. The royalty base is composed of first item ( 1651 ) giving the identity of the royalty and corresponds to sixth item ( 1616 ) of the title base. Second item ( 1652 ) comprises the name of the individual receiving the royalties. Third item ( 1653 ) is composed of the destination address of the royalties. Fourth item ( 1654 ) is composed of the telephone and fifth item ( 1655 ) is composed of the number of a possible fax.
[0103] It is apparent that this database ( 16 ) thus makes it possible for the manager to keep up to date on costs, purchases of songs and royalties to be paid to each of the artists or groups of artists performing the songs or videos, this provided that a communications protocol allows loading of the songs and modification of the content of the database depending on the songs loaded and allows communications with the central server by uploading or downloading the corresponding information. This communication protocol is composed of a first stage during which the center requests communication with the unit to which the communication is addressed. The unit decodes the heading sent by the center and if it recognizes it, indicates to the center if it is available or not depending on the state of its system status determined as explained above. If it is not available the center will then send a new request. If it is available, the center begins to send a first data block and the following blocks in succession. Each of the blocks is composed of a plurality of fields as shown in FIG. 7 . First field ( 810 ) indicates the identification number of the seller; this allows multiple sellers to share a single communications link with the central site. Second field ( 811 ) indicates the application identity and makes it possible to distinguish between a digital song, a digital motion video, a stationary video or an stationary digital graphical image, allows updating of software, transmission of statistics, billing, updating of the database, transmission of surveys. Third field ( 812 ) makes it possible to identify a subtype of application such as the identity number of the product, type of billing, indication of a song in the MIDI standard or a digital song, or finally indication of whether it is the last block of a transmission. The following field ( 813 ) makes it possible to recognize the number of the block assigned sequentially to the block in this transmission. Fourth field ( 814 ) makes it possible to recognize the octet length of each transmission block. Fifth field ( 815 ) makes it possible to recognize variable length data of the transmission and sixth field ( 816 ) contains cyclic redundancy verification information which allows the jukebox to verify that there has not been any error in transmission by recomputing the values of this information from the received data. The data are coded with the identification number of the receiving station, i.e., the number of the jukebox; this prevents another station from receiving this information without having to pay royalties. This is another advantage of the invention because in the processes of the prior art it is not exactly known which stations have received messages and at the outside a cheat could indicate that the information has not been correctly received to avoid having to pay the royalties. Here this operation is impossible since the cheat does not have access to his identification number known solely by the computer and encoding done using this secret identification number makes it possible to prevent cheating and reception by other units not authorized to receive the information. Finally it can be understood that this protocol, by the information which the blocks contain, allows high flexibility of use, especially for transmitting video images or digitized songs, or again to allow updating of software as explained below according to the process in FIG. 8 . In the case of software updating, the central system sends at stage ( 821 ) a first start signal allowing the jukebox for which it is intended to be recognized by its identification number and to indicate to this jukebox the number of the software version. At this stage ( 821 ) the jukebox then performs an initial verification to ensure that the version number is higher than the number of the versions installed and then initiates the process of verification of the system status indicated by stage ( 801 ). This verification process has already been described with reference to FIG. 7 . In the case in which at stage ( 822 ) there is no system activity, at stage ( 823 ) the jukebox initiates display of a waiting message on the display device to prevent a user from interrupting the communication, and during this time receives the data composed of the new software to be installed. At stage ( 824 ) the unit backs up the current version and at stage ( 825 ) the unit modifies the startup file for startup with the backup version. After having completed this modification the unit at stage ( 826 ) applies the software received to the system software and restarts the system software at stage ( 827 ). After having restarted the system, the unit reverifies status ( 801 ) and at stage ( 828 ) determines if the system statuses are valid or not. In the case in which no errors are detected, at stage ( 829 ) the unit updates the startup files with the newly received version and returns to a waiting state. If an error is detected, the unit reinitializes the system at stage ( 830 ). Once installation is completed, the unit awaits occurrence of an event representative of a task in order to handle its tasks as illustrated above.
[0104] Due to the flexibility of the multitask system and its communications protocol, each unit of the jukebox can thus be selected independently of the units connected to the network and can update the databases or the version of the desired song or again the software version without disrupting the operation of the other units of the network and without having to wait specifically for all the units of a network to be available. This is independent of the modems used which can be of the high speed type for a standard telephone line or a specialized modem on a dedicated data link or a SDN modem for fiber optic transmission or again an IRD modem for satellite connection.
[0105] If one or more packets are not received correctly by the jukebox during transmission, it does not interrupt transmission since other jukeboxes can also be in communication. However when communication is stopped by the central server, each jukebox which has had a incident takes a line and signals the numbers of the packets not received to the center. This allows the center to resend them. If registration of one or more songs or videos or part of a song or video has not be done due to lack of enough space on the disk or storage means, the system of each jukebox signals to the manager by a display or audio message the packet number if it is part of a song or a video, or the numbers of the song or video which have not be registered for lack of space. This allows the manager, after having decided to erase certain songs or videos from the hard disk, to again request that the center send these songs or videos or the part not received.
[0106] Any modification by one skilled in the art is likewise part of the invention. Thus, regarding buffers, it should be remembered that they can be present either physically in the circuit to which they are assigned or implemented by software by reserving storage space in the system memory.
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Method for communication between a central server and a computerized juke-box which operates in a conference mode, including: sending a header before any transaction, which includes the identity of the destination together, the identity of the emitter, and the size of the packets; responding from the server in the form of a data packet, each packet sent by the server being encoded using the identification code of the juke-box software; and receiving a data packet by the juke-box, which decodes the packet, simultaneously performs a check on the data received by the CRC method and sends an acknowledgement of receipt to the server indicating the accuracy of the information received, to allow it to prepare and send another packet to the juke-box.
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BACKGROUND OF THE INVENTION
This invention relates to burner control systems and, more particularly, to fail safe burner control systems that provide a purge period prior to ignition.
Extensive efforts have been directed toward the improvement of control systems for fuel burners such as gas and oil burners and the like. Increased system safety and reliability have been primary objectives of such efforts. These objectives, however, generally conflict with an obvious desire to limit the cost and physical size of the systems. Thus system complexity is an important consideration.
Such systems often ignite the fuel with a spark igniter. Interest has recently been directed toward systems that extinguish the spark after ignition to eliminate ratio frequency interference. However, circuits to extinguish the spark have greatly added to the complexity of the control circuit. This is particularly true since it is required that if flame is lost for any reason, the system must respond in one of two ways. Either the valve must be closed to stop the flow of fuel, or, as is preferable if heat is still required, the ignition apparatus must be reactivated in an effort to re-establish flame.
In addition, most burner systems must employ fuel supply valves that are controlled by flame sensing mechanisms which automatically interrupt fuel flow in response to a predetermined loss of flame condition. In accordance with the above requirements, circuits have been designed wherein the spark apparatus is responsive to the flame sensor so that when flame is detected, the igniter is stopped and upon loss of flame the igniter is activated to re-establish flame. A difficulty encountered with these circuits is their complexity; for example, often a plurality of feedback loops, or the like, are used. A danger in having such a complex system is that failure of one or more circuit components can cause an unsafe condition as, for example, a situation in which the valve remains open but the ignition apparatus is not activated. An explosive amount of fuel may thereby enter the combustion chamber.
Many conventional circuits provide a capacitor flame sensor that is charged by flame rectified current and a valve that opens when the charge on the capacitor exceeds a predetermined minimum. To initiate operation of some circuits of this type, the capacitor is precharged to open the valve and is kept charged by the rectified current if flame is achieved. If no flame is achieved before the capacitor becomes discharged, the valve closes and the system shuts down. The unsafe condition can occur in this circuit, for example, if flame is lost or never established, but a malfunction in the precharging circuit keeps the capacitor charged and thus the valve open. Other problems in circuits of this type result from line powered amplification stages utilized before the low energy flame signal and the valve control circuit responsive thereto. In certain instances, the line power can introduce false signals not distinguishable from the flame signal and therefore effective to cause improper and sometimes dangerous operation.
Many of the above problems are eliminated in a burner control system disclosed in U.S. Pat. No. 3,853,455. That system automatically activates an igniter to re-establish flame in the event of a loss thereof, but closes a fuel supply valve if a failure to establish flame occurs, either initially or after loss of flame. In addition, the system described is fail-safe; that is not subject to unsafe operation as a result of malfunction of either any component or any group of components.
Despite these advantages, certain characteristics of the system described in the above noted patent could be improved. For example, desirable improvements would be a capability for more rapid switching between purge and ignition periods, lower cost, greater immunity to circuit noise, and improved operational stability.
The object of this invention, therefore, is to provide an improved fuel burner control system.
SUMMARY OF THE INVENTION
One feature of the present invention is the provision of a burner control system including a valve for controlling the flow of fuel to a burner, a flame sensor for producing a flame signal in response to the presence of flame at the burner, a start-up circuit for producing a start-up signal, a control circuit for opening the valve to establish fuel flow in response to either the flame or the start-up signal, and a timing capacitor for first delaying the generation of the start-up signal for a predetermined purge period after energization of the start-up circuit and then terminating the start-up signal after a predetermined ignition period. Employing a single capacitor to establish the length of both purge and ignition periods provides a highly efficient burner control system.
In a preferred embodiment of the above invention a monostable electronic switch is provided for producing the start-up signal in response to the charge level on the timing capacitor and a valve initiator for opening the valve is powered by energy discharged by the timing capacitor during the ignition period. The monostable switch establishes rapid transition times between the purge and ignition periods and powering the valve initiator with the discharging timing capacitor insures a determinable energy supply for operating the valve.
Another feature of the invention is the provision of a burner control apparatus including a valve for controlling the flow of fuel to a burner, a flame sensor for producing a flame signal in response to the presence of flame at the burner, a timer for producing a predetermined purge period followed by a predetermined ignition period, a start-up circuit for initiating a start-up signal at the end of the purge period and terminating the start-up signal at the end of the ignition period, the start-up circuit having a multiple state switch with positive feedback to establish rapid switching into a stable state wherein the start-up signal is terminated, and a control circuit for opening the valve to establish fuel flow in response to either the flame or start-up signal. In a preferred embodiment, the electronic switch is a multivibrator including a pair of three terminal semiconductors one of which is conductive in the stable state and the other of which is conductive in another state in response to which the start-up signal is produced. Also included is an energy storage capacitor connected to the one semiconductor and effective to maintain current flow therein and maintain the stable state that follows the predetermined purge period.
DESCRIPTION OF THE DRAWINGS
These and other objects and features of the invention will become more apparent upon a perusal of the following description taken in conjunction with the accompanying drawings wherein:
FIG. 1 is a schematic block diagram illustrating the burner control apparatus of the invention; and
FIG. 2 is a schematic circuit diagram of the start-up circuit shown in FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring now to FIG. 1, there is schematically shown a burner control system 10 with a conventional fuel burner 11 that is supplied with a suitable fuel, for example, gas, by a fuel line 12 that includes a supply valve 13. Opening and closing of the valve 13 is controlled by a valve control circuit 14 that receives the output of an oscillator after amplification by an amplifier 17. The oscillator 16 is provided on line 18 with operating power from a flame sensing circuit 19 having a flame electrode 21 mounted in a region 22 occupied by flame emanating from the burner 11. A temporary source of power for initiating operation of the system is provided to the oscillator 16 by a start-up timer 23 on line 24. Also receiving the oscillating signal on line 15 is an inverter 25 that supplies on line 26 an ac signal to the flame sensing circuit 19 and to a spark generation circuit 27 having a spark electrode 28 mounted in the region 22. Power from a positive dc power supply 32 of, for example, 12 volts, is supplied through a thermostatic switch 30 to a supply line 31 connected to the start-up timer 23, the amplifier 17, and the inverter 25. All of the circuit blocks are tied together by a grounded circuit common line 33.
An oscillating signal provided by the oscillator 16 drives the amplifier 17 alternately between cutoff and saturation producing an oscillating squarewave signal output. This squarewave signal on line 15 is applied to the valve control circuit 14 which responds by maintaining the valve 13 in an open position and thereby establishing the flow of fuel to the burner 11. A valve control circuit suitable for this purpose is described in U.S. Pat. No. 3,853,455. Also receiving the squarewave output of the amplifier is the inverter 25 that produces an output on line 26 that is an ac signal at the frequency of the oscillator 16. Circuit details of a suitable inverter for this purpose also are described in U.S. Pat. No. 3,853,455. The output of the inverter 25 is applied to the flame sensing circuit 19 that in response to the presence of flame at the burner 11 produces a negative output on line 18 that is required to power the oscillator 16. Also receiving the output of the inverter 25 on the line 26 is the spark generation circuit 27 that responds by generating ignition sparks between the electrode 28 and the burner 11. Again, suitable circuit details for the flame sensing circuit 19 and the spark generation circuit 27 are described in the abovenoted U.S. Pat. No. 3,853,455.
Referring now to FIG. 2, there are shown circuit details of the start-up timer 23 illustrated in FIG. 1. The timer 23 includes a supply bus 41 connected to the line 31 (FIG. 1) by a diode CR1 and a resistor R1 and a common bus 42 connected to the ground line 33 (FIG. 1). Connected between one end of the resistor R1 and the common 42 is a capacitor C1 while the other end of the resistor R1 is connected to the common 42 by the parallel combination of a zener diode CR2 and a resistor R2. Also connected between the supply 41 and the common 42 is a monostable multivibrator 43 that includes a pair of transistors Q1 and Q2. The collector of the transistor Q1 is connected to the supply 41 by a resistor R3 and the emitter of the transistor Q1 is connected directly to the common 42. Connected between the base of the transistor Q1 and the common 42 is an RC combination of a resistor R4 and a capacitor C2. The collector of the transistor Q2 is connected to the supply 41 by a resistor R5 while the emitter thereof is connected directly to the common 42. Connected between the base of the transistor Q2 and the common 42 is the combination of a resistor R6 and a diode CR3. The collector of the transistor Q1 is connected also to the base of the transistor Q2 by the combination of a capacitor C3, a diode CR4 and a resistor R7. A resistor R8 is connected between the collector of the transistor Q2 and the junction between the resistor R4 and the capacitor C2 while a resistor R9 is connected between the common 42 and the junction between the capacitor C3 and the diode CR4. Also connected to that junction by a resistor R10 is the output line 24 (FIG. 1) to the oscillator 16.
When power is first applied to the supply bus 41, the capacitor C3 begins charging through the resistor R3 and the base-emitter of the transistor Q2 which is thereby conductive. Consequently, a zero potential is maintained on the capacitor C2 insuring that the transistor Q1 is off. While charge is being accumulated in the capacitor C3, there is no base current in the transistor Q1 through the resistor R4 because of the conduction by the transistor Q2. This charging period of the capacitor C3 establishes a predetermined purge period of, for example, about ten seconds. At the completion of the purge period, the charge on the capacitor C3 reaches a level that reduces the current flow through the base of the transistor Q2 causing it to turn off. This in turn forces current to flow through the resistors R4 and R8 into the base of the transistor Q1, which switches on establishing a stable state for the multivibrator 43 and initiating a predetermined ignition period. At this time the collector of the transistor Q1 is virtually at ground and has the effect of grounding the plus side of the capacitor C3. Consequently, the capacitor C3 functions as a negative supply for supplying operating power to the oscillator 16 (FIG. 1) via the line 24. The predetermined ignition period is established by the discharge time of the capacitor C3 and can be modified by altering the values of the capacitor C3 or of the resistors R9 or R10. Similarly, the values of the resistors R3, R6, or R7 can be selected to establish a desired purge period. The diode CR3 and the resistor R6 function as a temperature compensation network while the resistors R1 and R2 and the capacitor C1 form a conventional RC filter.
Thus, it will be appreciated that the single capacitor C3 serves dual functions, establishing a purge period while being charged to a level that switches the multivibrator 43 into its stable state and establishing a predetermined ignition period while being discharged through the transistors R9 and R10. Furthermore, because of the positive feedback provided, the multivibrator 43 switches rapidly from its initial state in which the transistor Q2 is on into its stable state in which the transistor Q1 is on. Stability in the latter state is insured by the capacitor C2 that stores energy and establishes a time constant that will maintain base-emitter current flow through the transistor Q1 despite noise induced fluctuations on the supply line 41. A return to the initial state in which the transistor Q2 is on requires discharge of the capacitor C2, which can only be accomplished by power interruption.
OPERATION OF THE INVENTION
When heat is desired at the burner 11, the start-up timer 23 is activated by, for example, completing a circuit to the dc power supply 32 via the thermostatic switch 30. As previously described, activation of the timer 23 results in a purge period established by the time of the capacitor C3. During this period, the valve 13 remains closed allowing dissipation of any fuel vapor occupying the region adjacent to the burner 11 prior to a try for ignition. After completion of the purge period, the multivibrator 43 switches to its stable state to initiate the ignition period established by the discharge of the capacitor C3. The discharging capacitor C3 produces a momentary starting signal on the line 24 that powers the oscillator 16 resulting in an oscillating output that is converted by the amplifier 17 into a square wave signal applied to both the valve control circuit 14 and the inverter 25. That signal activates the valve control circuit to open the valve 13 and initiate the flow of fuel to the burner 11. Simultaneously, the inverter 25 provides an output to the spark generation circuit 27 resulting in the generation of sparks that ignite fuel in the region 22. The presence of flame in the region 22 is detected by the spark circuit 27 which in response thereto discontinues the generation of sparks. Also responding to flame is the flame sensing circuit 19 which furnishes operating power to the oscillator 16 on line 18. This maintains output from the oscillator 16 to the valve control circuit 14 and insures that the valve 13 is maintained in the open position.
Assume, however, that flame is not quickly established in the manner described above. In that case, no energy is stored in the flame sensing circuit 19 for use in powering the oscillator 16. Accordingly, after a short ignition period of, for example, 10 seconds, the energy available in the power supply capacitor C3 (FIG. 2) will be dissipated and signal output from the oscillator 16 will terminate. The resultant cessation of square wave output from the amplifier 17 deactivates the valve control circuit 14 resulting in closure of the fuel valve 13 and thereby preventing the dangerous emission of unignited fuel from the burner 11. A subsequent try for ignition can be initiated only by opening the circuit between the power supply 32 and the start-up timer 23 to allow discharge of the capacitor C2 (FIG. 2). Upon subsequent application of power to the start-up timer 23, the above described operation will be repeated to again produce sequential purge and ignition periods.
In addition to insuring a stable operating state for the multivibrator 43, the capacitor C2 establishes failsafe operation of the system 10. Since the capacitor C2 appears as a short circuit when power is first applied to the start-up timer 23, the transistor Q2 is always turned on first. If, however, the capacitor C2 fails so as to present an open circuit, the transistor Q1 will come on first and the timing capacitor C3 will not change. Thus, neither a purge nor an ignition period wll be initiated and the valve 13 will remain safely closed. If the capacitor C2 fails so as to present a short circuit, the transistor will never turn on. Thus, the capacitor C3 cannot function as a negative supply for the oscillator 16 and the valve 13 will remain closed. Furthermore, because of the C2-R4 and C2-R8 time constants, the energy stored by the capacitor C2 will prevent noise on the supply line 41 from falsely triggering the timer 23.
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 can be practised otherwise than as specifically described.
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A burner control system including a valve for controlling the flow of fuel to a burner, a flame sensor for producing a flame signal in response to the presence of flame at the burner, a start-up circuit for producing a start-up signal, a control circuit for opening the valve to establish fuel flow in response to either the flame or start-up signal, and a timing capacitor first delays the generation of the start-up signal while charging during a predetermined purge period after energization of the start-up circuit and then terminates the start-up signal while discharging during a predetermined ignition period. A monostable electronic switch produces the start-up signal in response to the charge level on the timing capacitor and a valve initiator for opening the valve is powered by energy discharged by the timing capacitor during the ignition period.
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FIELD OF THE INVENTION
The invention relates to source routing in which each hop of a route through a network is encoded at a source by port descriptors in a header of a packet.
BACKGROUND OF THE INVENTION
Interconnection networks are used to route packets between terminal nodes in multicomputers, network routers, and other digital systems. Such networks consist of a number of fabric routing nodes arranged in a particular network topology, for example a butterfly or a torus. For a packet to travel from one terminal node A to another terminal B the packet must be routed; that is, it must select an output port at each switch node along the route from the source terminal to the destination terminal. With source routing, these selections are encoded in a routing header which contains a field for each hop along the route.
FIG. 1 shows an example interconnection network, and 8×2×2 three-dimensional torus. This network contains 32 nodes, each of which is identified by a three-digit address, zyx, the digits represent its coordinates in the z, y, and x dimensions, respectively. For example, node A in the figure is at address 001 , and node B is at address 105 . Each node in the figure is connected to six fabric channels, one in the positive and one in the negative direction in each of the three dimensions. The nodes on the boundary of the network have one or more channels that wrap around to the other side of the network. For clarity, the end-around channels in the y and z dimensions are omitted from several nodes.
FIG. 1 also shows a route from node A ( 001 ) to node B ( 105 ), denoted by arrows in the figure. This route contains five steps or hops. The source routing header for this route is a string of six port selectors: (+x,+x,+z,+x,+x,e). The first five port selectors specify the output ports to be taken for the five steps of the route. The final port selector, e, directs the packet to exit the network after completing the fifth hop. At each node along the route, starting with node A, the routing header is interpreted by using the first port selector to select the output port at that node and then removing this port selector from the route. For example, at node 002 (just to the right of A), the packet arrives with routing header (+x,+z,+x,+x,e). The first selector (+x) is used to select the +x output port of this node and then removed from the header leaving a header of (+z,+x,+x,e) for node 003 .
In a three dimensional torus, such as shown in FIG. 1, there are seven possible output ports at each step (six directions and exit) and thus the port selector can be encoded in a three-bit field with one unused code. One possible encoding is shown in the following table.
Port
Code
+x
000
−x
001
+y
010
−y
011
+z
100
−z
101
e
111
With this encoding, the route shown in FIG. 1 would be encoded as the 18-bit string; 000 000 100 000 000 111. With the route encoded in this manner, the leftmost three bits are used at each step of the route to select the next output port, and then the encoded route is shifted three-bits left to expose the next port selector for the next step of the route.
The mechanism used to process source routes is illustrated in FIG. 2 . An input route register (IRR) 10 holds the source route from the header of an arriving packet. In the figure, the IRR consists of five three-bit port selectors, 11 - 15 , packed into 15 bits. This small number of fields is used to avoid cluttering the figures. In most routes, considerably longer route registers are used as four hops is insufficient for all but the smallest networks. The IRR is processed to generate the current port selector (CPS) which selects the output port to be used by the packet, and to generate an output route register (ORR) 20 which will be used as the routing header by the router at the next hop. These two functions take place by simple field selection. No logic is required. The leftmost port selector from the IRR is selected as the CPS, and the remaining port selectors are shifted to the left to fill the first four port selectors of the ORR, 21 - 24 . The fifth port selector 25 may be filled with an arbitrary value.
Routers that employ source routing in this manner are similar to those described in U.S. Pat. No. 6,370,145, which issued on Apr. 9, 2002, entitled “Internet Switch Router,” which is incorporated herein by reference in its entirety.
SUMMARY OF THE INVENTION
Encoding source routes using fixed-length port selector fields gives a simple routing descriptor, but one that consumes more space than necessary. In large interconnection networks, the space required by these descriptors can become prohibitive and may limit the scalability of the network. For example, if a routing header for a three-dimensional torus must fit into 32-bits, at most 9 hops can be encoded. Only 10 three-bit fields fit into 32 bits, and one field is required for the exit code at the end of the route.
By using a variable-length routing port descriptor, where the more likely ports are encoded with fewer bits than the less likely ports, we can substantially reduce the required length of a route descriptor. This improves storage efficiency, reduces the overhead of packet headers, and allows us to encode a longer route in a fixed-size descriptor.
In different embodiments, several techniques for space-efficient coding may be used independently or combined:
1. The requirement for an exit descriptor can be eliminated by always shifting in an exit descriptor on the right side of the route when left shifting the route to discard a used port descriptor.
2. Coding for runs of identical port descriptors with run length coding optimizes the common case where a route travels several hops in one direction.
3. More likely ports may be encoded with fewer bits than less likely ports using a variable length code.
4. In variable length coding, a preferred direction can be encoded in the packet header that specifies a set of encoding rules in which the ports that carry a packet in the preferred direction can be encoded with short descriptors while longer descriptors are required to encode a non-preferred direction.
5. The port on which an arriving packet arrives may be used as an implied preferred direction in that dimension thus reducing the length of a preferred direction field by one bit.
BRIEF DESCRIPTION OF THE DRAWINGS
The foregoing and other objects, features and advantages of the invention will be apparent from the following more particular description of preferred embodiments of the invention, as illustrated in the accompanying drawings in which like reference characters refer to the same parts throughout the different views. The drawings are not necessarily to scale, emphasis instead being placed upon illustrating the principles of the invention.
FIG. 1 illustrates a conventional 8×2×2 three dimensional torus.
FIG. 2 illustrates an input route register and output route register used to process source routes in the prior art.
FIG. 3 illustrates an input route register and output route register embodying one aspect of the invention where implied exit codes are inserted.
FIG. 4 illustrates another embodiment of the invention which implements run length coding of selectors.
FIG. 5 illustrates another embodiment of the invention which implements variable-length coding of selectors.
FIG. 6 illustrates an embodiment of the invention which uses variable-length coding based on preferred direction.
FIG. 7 illustrates an embodiment of the invention which includes implied exit codes, preferred direction variable-length coding and run length encoding.
FIG. 8 illustrates a preferred direction decoder for use in the embodiment of FIG. 6 .
DETAILED DESCRIPTION OF THE INVENTION
Implied Exit Descriptor
FIG. 3 shows how the number of hops that can be encoded by a routing header of a given length may be increased by one by implicitly encoding the exit port descriptor. This is accomplished by filling the final (rightmost) port descriptor of the ORR with an exit code (all 1s). In effect, there is always an implied exit descriptor to the right of the rightmost port descriptor in a routing header. This allows us to encode a five-hop route in the five fields of the IRR since no field is required to explicitly encode the exit descriptor. For example, the route shown in FIG. 1 would be encoded in the IRR as 000 000 100 000 000. The logic of FIG. 3 selects the leftmost port descriptor, 000, as the CPS. The logic also shifts the remaining port descriptors left while filling in the right with the exit code giving a route descriptor in the ORR of 000 100 000 000 111. After the first hop of the route, the exit descriptor becomes explicit. For routes that are shorter than the maximum length, an explicit exit descriptor is always used to terminate the route.
Run-Length Descriptor Coding
In large interconnection networks, it is common to include multiple hops in a single direction before changing directions. We can exploit this regularity in routing by encoding runs of port selectors in a single port descriptor. FIG. 4 illustrates a simple implementation of this concept. Here the IRR 10 consists of three port descriptors each consisting of a three-bit port selector, 11 - 13 , and a two-bit count, 31 - 33 . One skilled in the art will understand that different width fields may be used for the selector and count and that the selector and count may be combined in a single field using symbols from an alphabet that jointly encodes the selector and count. With the representation of FIG. 4, the leftmost selector 11 is used as the CPS to select the output port to be taken by the packet. The leftmost count 31 is used to determine the number of hops the packet should take in this direction before moving on to the next port descriptor. The two-bit hop count can encode a number of hops between 1 and 4. For example, the offset- 1 code (00=1, 01=2, 10=3, 11=4) may be used.
When a packet arrives at a router that implements the run-length coding of FIG. 4, the ORR is generated by processing the leftmost count field 31 and multiplexing as shown in the figure. The count field is first examined by a comparator 53 to see if it encodes a single hop (code 00). If so, then line 71 is driven high causing the six multiplexers 81 - 86 to select their right input and thus shift the port descriptors to the left. In this case, the leftmost output selector 21 is determined from the input selector 12 , output count 41 is determined from input count 32 , and so on. If the leftmost input count field encodes more than a single hop, then line 71 is driven low and multiplexers 81 - 86 select their left input. In this case, the fields of the IRR are passed directly across to the ORR with the leftmost count field being decremented by decrementer 54 .
Consider, for example, the route shown in FIG. 1 . With the variable-length coding of FIG. 4, this route would be encoded as 000 01 100 00 000 01 which encodes two hops in +x, one hop in +z, and two hops in +x. After the first hop, the routing header would become 000 00 100 00 000 01 which encodes one hop in +x, one hop in +z, and two hops in +x. After the second hop, the leftmost field is shifted off and the header becomes 100 00 000 01 111 00 which encodes one hop in +z, two hops in +x, and exit.
Run-length coding is particularly advantageous in large networks. The 15-bit routing header of FIG. 4 can represent routes of up to 12 hops, enough to route between each pair of nodes in an 8×8×8 network of 512-nodes. More typically, a 32-bit routing header with 5 descriptors, each containing a 3-bit selector and a 3-bit count, can encode routes of up to 40 hops, enough to route between any pair of nodes in a 32×32×16 network of 16K nodes.
Run-length coding is inefficient at coding routes that change direction on every hop. For such routes, run-length coding takes more bits to encode each port descriptor with no reduction in the number of descriptors. To overcome this limitation in applications that require such routes, the routing header can be augmented by a bit that selects between run-length coding (FIG. 4) and conventional coding with an implied exit code (FIG. 3 ). By using this bit to always select the most efficient encoding, the coding density is never more than one bit worse than for conventional coding.
Variable-Length Port Descriptors
In a network that has dimensions of unequal size, such as the network of FIG. 1, a packet is more likely to travel in a long dimension than in a short dimension. To first approximation, in the 8×2×2 network of FIG. 1, a packet is four times as likely to travel in x than in y or z. Using the well known technique of maximum entropy coding (Huffman coding), one can take advantage of this uneven probability of routing in different dimensions by using the variable-length port selectors shown in the table below:
Code
Port
Length
+x
00
2
−x
10
2
+z
010
3
−z
011
3
+y
110
3
−y
1110
4
Exit
1111
4
With the probability of x selectors four times that of y or z selectors, this encoding gives an average selector length of 2.4 bits, saving 20% over a fixed-length encoding.
A circuit for decoding routing headers containing variable-length port selectors is shown in FIG. 5 . Because the length of the leftmost port selector is not known a-priori, a variable length decoder examines the leftmost M bits of the routing header, where M is the maximum length of a port selector. If the leftmost selector is shorter than maximum length, not all of these bits will belong to the selector. The decoder uses these bits to determine the matching code from the table above and outputs the corresponding fixed-length port selector and the length of the code, L. The determination can be made because none of the three and four bit codes share the first two bits with any two bit code, and no four bit code shares the first three bits with any three bit code. The selector is used to select the output port for the packet, while the length field is used to control a left-shifter that shifts the routing header L bits (between 1 and M) to the left, filling in 1s from the right. This shift discards the leftmost L-bit code and fills in at least part of the implied exit code. By choosing an all 1s representation for the exit code, the implied exit code described above is achieved even though it may take several shifts to complete the exit code. One skilled in the art of router design will understand that the variable length decoder may be implemented as a lookup table indexed by its M-bit input or using logic gates.
Preferred Directions Variable Length Coding
In a network that employs minimal routing, viz. in which packets follow a shortest path from source to destination, a packet will travel in only a single direction in each dimension. For example, a packet traveling from node 000 to node 333 in an 8×8×8 torus network along a shortest path will travel only in the +x, +y, and +z directions and never in the −x, −y, or −z directions. Thus, while the overall distribution of output ports may be uniform, a given packet has a very non-uniform distribution with three ports very likely and three ports very unlikely.
We can exploit the tendency of an individual packet to route only in certain directions by including a preferred direction field within each routing header. This field encodes the directions that a packet is most likely to travel. The port selectors in the routing header are then encoded using a variable-length code specific to the preferred direction. In effect, the preferred direction field in a packet's header selects the code book used to decode the port descriptors in that header.
A simple method of encoding the preferred direction in a three-dimensional torus network, such as the network of FIG. 1, is to use a three-bit field where each bit specifies the preferred direction in each of the three dimensions. The first bit encodes the preferred direction in x(0=+, 1=−), the next bit encodes y, and the final bit encodes z. The table below enumerates this code. One skilled in the art will understand that other encodings are possible and that more or fewer probability distributions may be specified by using a longer or shorter preferred direction field.
Code
Preferred Direction
000
+x.+y,+z
001
+x.+y,−z
010
+x,−y,+z
011
+x,−y,−z
100
−x,+y,+z
101
−x,+y,−z
110
−x,−y,+z
111
−x,−y,−z
The preferred direction code in the routing header can be compressed by one bit by using the channel on which a packet arrives to specify the preferred direction in one dimension. The routing header needs only to encode the preferred direction in the other two dimensions. For example, if a packet with a preferred direction of −x,+y,−z arrives in the −x direction, the x-bit of the preferred direction code may be dropped and the code shortened to 01.
The table below shows a possible encoding of the port selector fields in a routing header that includes a preferred direction field. With this encoding, the three preferred directions are represented by two-bit codes, the non-preferred or reverse directions are represented by four-bit codes, and the all 1s code is used to specify the exit port to facilitate use of an implied exit port selector as described above. This code is particularly convenient as it can easily be decoded to the current port selector by taking the two most-significant bits from the port selector code and the least significant bit from the preferred direction field. The most-significant bits are taken from the first two bits of the code unless the code is 11, in which case they are taken from the second two bits. For example, if the preferred direction is 101 from the above table and the port selector code is 1101 from the table below, the current port selector is 011. The first two bits are taken from 1101, and the final bit is the reverse of the y field of the direction code. One skilled in the art will understand that other encodings are possible.
Code
Port
Length
00
Preferred x
2
01
Preferred y
2
10
Preferred z
2
1100
Reverse x
4
1101
Reverse y
4
1110
Reverse z
4
1111
Exit
4
Once a packet reverses direction, it often continues in the new direction. To take advantage of this behavior in encoding routing headers, the routing logic complements the appropriate bit of the preferred direction field whenever a reversing port selector is encountered. For example, if a packet arrives with a preferred direction field of 010 (+x,−y,+z) and the leftmost port selector is 1110 (Reverse z), the packet is routed in the −z direction and the preferred direction field is set to 011 (+x,−y,−z). The port selector codes, other than being shifted, remain unchanged since they were initially defined with the recognition that the preferred direction field would change.
A circuit for decoding a routing header with a preferred direction field is shown in FIG. 6 . The arrangement is similar to the decoder of FIG. 5 except that the preferred direction field of the IRR 61 and the current direction 81 are input to the variable-length decoder 50 and are used to select the code book to be used in decoding the leftmost port selector. The variable-length decoder also generates a new preferred direction field as an output to toggle the preferred direction in a given dimension when a reverse code is encountered.
A circuit that implements the variable length decoder for the preferred-direction code described above is shown in FIG. 8 . The circuit accepts the current preferred direction (p x ,p y ,p z ) and the leftmost M=4 bits of the port selector fields (d 3 . . . d 0 ) at the top. The circuit generates a new preferred direction (n x ,n y ,n z ) a current port selector (CPS), and the length of the port selector. As there are only two possible lengths, 2 and 4 , a single bit suffices to specify the length. (0 implies a length of 2, and 1 implies a length of 4.) AND-gate 91 detects if the code is a four-bit or two-bit code by examining the upper two descriptor bits. The output of this gate, line 101 , is the length output of the decoder and is used to control multiplexer 92 and enable decoder 98 . Multiplexer 92 selects the selector bits that specify the dimension to be routed on. For a two-bit code, line 101 is low and bits d 3:2 are selected. For a four-bit code, 101 is high and bits d 1:0 are selected. The selected dimension bits, on bus 102 , are then used to select the preferred direction via multiplexer 93 . For a four-bit code, the preferred direction on line 104 is complemented by XOR-gate 94 to produce the selected direction 103 . The selected direction 103 and selected dimension 102 are combined to produce the current port selector output. To complement the preferred direction when a reverse code is encountered, decoder 98 decodes the selected dimension 102 when enabled by line 101 . The output of this decoder is used to complement the appropriate bit of the preferred direction via XOR-gates 95 - 97 .
One skilled in the art will understand that other possible implementations of the decoder are possible. For example, one could use a ROM or RAM lookup table to implement the decoder, or synthesize the logic for the decoder from a Verilog (RTL) description that specifies the tables above.
Combined Decoder
The techniques of implied exit descriptor, preferred direction variable-length encoding, and run-length encoding of port selectors may be combined. FIG. 7 shows a block diagram of a decoder that combines all three techniques. The decoder is similar to that of FIG. 6 except that merge unit 52 has been added and variable decoder 50″ has been augmented to add an M-bit new-symbol output and a log 2 (M) bit merge count. The decoder operates in a manner similar to the decoder of FIG. 6 . However, when the VLD detects a run-length encoded symbol where the run-length is greater than one, rather than shifting to strip the symbol off, it generates a new symbol, with the same direction but a run length of one less than the input symbol, and directs the merge unit to replace the leftmost port descriptor with the new symbol. When the run length equals one, the port descriptors are shifted to the left and 1s are filled in from the right. The thus shifted descriptors are then passed through to the ORR with the leftmost M bits simply passed through the merge unit 52 .
While this invention has been particularly shown and described with references to preferred embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit and scope of the invention as defined by the appended claims.
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The required length of a route descriptor in a source routing system is obtained by inserting an implied exit field, use of run-length encoding, and use of variable-length encoding. In the variable-length encoding, codes having lesser bits are reserved for preferred directions. Preferred direction may be encoded in the routing header, and it may be implied by the arrival port.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to an exposure apparatus for the manufacture of semiconductive integrated circuits, and in particular to an exposure apparatus provided with a levelling mechanism for bringing the surface of a wafer into exact coincidence with an exposure reference plane.
2. Related Background Art
In the lithography process in the manufacture of semiconductive integrated circuits, a reduction projection type exposure apparatus of the step and repeat type, i.e., a so-called stepper, bears the main role in the lithography process. In such stepper, it is necessary to enhance the resolution limit of a projection lens correspondingly to the minimum line width of circuits formed, in the order of a submicron. The minimum line width becomes more minute year after year. At the same time a very severe requirement for satisfying both a great numerical aperture (N.A.) and a wide exposure field is increasing. However, a projection lens of a great numerical aperture (N.A.) and of a wide exposure field necessarily has a small depth of focus and therefore, if in a portion of any shot area on a wafer, inclination should occur relative to the projection image plane, it will become difficult to always effect accurate focusing on the whole surface in the exposure field. So, by the use of a horizontal position detecting optical system as disclosed, for example, U.S. Pat. No. 4,558,949, the inclination relative to the projection image plane is detected in each shot area on the wafer, and likewise, by the use of a stage device (wafer stage) as disclosed in U.S. Pat. No. 4,770,531, a plurality of predetermined points (e.g. three operating points) on a levelling stage are driven, whereby the angle of inclination of the levelling stage is controlled so that the inclination of each shot area becomes zero. When the levelling stage is to be inclined in any direction relative to the projection image plane, use is made chiefly of a two-point driving system in which one operating point is fixed and the remaining two operating points are driven.
In the above-described wafer stage, the design is such that when the stage is in a predetermined neutral state (a state in which, for example, the operating points are at the center of the movement stroke in Z-direction), the plurality of points on the levelling stage are positioned in an exposure reference plane containing the measuring axis of a laser interferometer of the wafer stage (the center axis of a laser beam) and the exposure reference plane coincides with the surface of a reference wafer placed on the levelling stage and also coincides with the projection image plane (the imaging plane) of a mask pattern formed by a projection lens.
As a result, by the use of a levelling mechanism comprising the above-mentioned horizontal position detecting optical system and the wafer stage, the surface of the shot area is brought into exact coincidence with the exposure reference plane or the imaging plane, whereby the projected image of the circuit pattern of a mask or reticle (hereinafter simply referred to as the "reticle") is projected and exposed with a high resolution without causing any partial focus deviation in the exposure field.
However, when replacement of a wafer or a wafer holder is effected in the stepper having the levelling mechanism of this type, the thicknesses of the wafer and the wafer holder, i.e., the thickness of the portion above the levelling stage, may be varied by an increase in the total thickness variation (hereinafter referred to as "TTV") of the wafer itself resulting from the tolerance of manufacture, manufacturing error, etc. Therefore, a deviation in Z-direction (focus deviation) occurs between the imaging plane and the surface of the wafer and also, a deviation in Z-direction occurs between a surface which provides the reference of the inclining movement of the levelling stage (hereinafter referred to as the "levelling reference surface") and the surface of the wafer.
Of these two deviations in Z-direction, the focus deviation can be eliminated by moving a Z-stage, but the deviation between the levelling reference surface and the surface of the wafer remains. In a state in which this deviation remains, the levelling of any shot area on the wafer is effected with the levelling stage inclined, for example, by an angle 1/4, and there has been a problem of lateral deviation of the center of the shot area relative to the coordinates system XY, in which the distance δ between the center of this shot area and the apparent center of pivotal movement of the levelling stage is a factor, i.e., so-called cosine error ΔCe (ΔCe =δ· (1 - cosθ), and a problem of lateral deviation in which the amount of deviation ν in height between the center of the shot area and the center of pivotal movement of the levelling stage is as a factor, i.e., so-called sine error ΔSe (ΔSe=ν/2 · sinθ).
Usually, the angle of inclination θ of the wafer is 1' at greatest and the distance δ is of the order of 220 mm (in the case of 8 inches) at greatest and thus, cosine error ΔCe is of the order of 0.01 μm at greatest. Also, the tolerance of the thickness variation of the wafer and wafer holder is ±75 μm and TTV is of the order of 20 μm and therefore, sine error ΔSe is of the order of 0.028 μm at greatest. The amount of lateral deviation comprising the sum of these errors is nevertheless too great for the positioning accuracy (of the order of 0.03 μm) required for the wafer stage of the stepper of this type. To correct these errors, the alignment between the projected image of the pattern and the pattern already formed on the wafer must be effected again after levelling is effected in each shot area, and this has led to the problem that the throughput is reduced.
SUMMARY OF THE INVENTION
Accordingly, it is an object of the present invention to solve the above-noted problems peculiar to the apparatus of the prior art and to provide an exposure apparatus having a highly accurate levelling mechanism which, even if a deviation occurs between the levelling reference surface and the surface of a wafer, can suppress the amount of lateral deviation comprising the sum of the cosine error and the sine error to less than a predetermined tolerance value, or zero and can accomplish exposure without reducing the positioning accuracy, the throughput, etc. of a wafer stage.
To achieve the above object, the apparatus of the present invention, which has a horizontal position detecting system for detecting the inclination of a wafer relative to the imaging plane of a projection lens, and in which the surface of the wafer is brought into coincidence with the imaging plane in conformity with the detection signal of said horizontal position detecting system, whereby a circuit pattern formed on a reticle is projected and exposed onto the wafer through the projection lens, is characterized by the provision of an X-Y stage holding the wafer thereon and two-dimensionally movable in the imaging plane, a Z-stage provided on the X-Y stage and movable in a direction perpendicular to the imaging plane (Z-direction), a levelling stage provided on the Z-stage and capable of inclining the wafer in any direction relative to the imaging plane, position setting means for moving each of a plurality of points which provides a pivot fulcrum of the levelling stage in Z-direction to thereby accomplish the position setting of the surface of the wafer relative to the levelling reference surface of the levelling stage, deviation detecting means for detecting any positional deviation in Z-direction between the levelling reference surface and the surface of the wafer, and control means for controlling said position setting means on the basis of the detection signal of said deviation detecting means so that the levelling reference surface becomes substantially coincident with the surface of the wafer.
Further, according to a specific embodiment of the present invention, a driving device as the position setting means has three potentiometers for detecting the amounts of displacement of three pivots in Z-direction, and these three pivots are servo-controlled on the basis of the detection signals of these potentiometers and the detection signal of a focus detecting system as the deviation detecting means so as to make the levelling reference surface substantially coincident with the surface of the wafer.
As described above, according to the present invention, if any deviation occurs between the levelling reference surface and the surface of the wafer, the position setting means of the levelling stage, i.e., the three pivots, are driven by the same amount in Z-direction on the basis of the detection signal of the deviation detecting means, whereby the levelling reference surface is brought substantially into coincidence with the surface of the wafer, whereafter levelling is effected. Accordingly, the amount of lateral deviation comprising the sum of cosine error and sine error resulting from levelling can be suppressed to less than a predetermined tolerance value, i.e., less than the resolving power (0.02 μm) of a laser interferometer, or zero.
According to the present invention, the design is such that even if the thicknesses of a wafer and a wafer holder vary and any deviation occurs between the levelling reference surface and the surface of the wafer, such deviation is corrected and thereafter levelling is effected and therefore, the amount of lateral deviation comprising the sum of cosine error and sine error can be reduced to a practically negligibly small value (less than the resolving power of the laser interferometer), or zero, and it is not necessary to effect fine alignment again after levelling by the use of an alignment optical system (a so-called laser step alignment optical system) for observing only the wafer through a projection lens from between a reticle and the projection lens, for example, as an off-axis system. Also, since levelling is effected by a three-point driving system, the amount of resilient deformation of a leaf spring can be made small, and this is advantageous in controlling the inclination of the levelling stage, as viewed from the absolute value of the resilient deformation of the leaf spring and also the absolute amount of vertical movement of three pivots can be made small, and it becomes possible to shorten the control time of levelling. As a result, there can be realized an exposure apparatus having a highly accurate levelling mechanism which can accomplish exposure without reducing the throughput.
Further objects, features and effects of the present invention will become fully apparent from the following detailed description taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a diagram, partly in cross-section, schematically showing the construction of an embodiment of the present invention.
FIG. 2 is a plan view schematically showing the construction of the wafer stage portion in FIG. 1.
FIG. 3 is a diagram, partly in cross-section, for illustrating the correction of the positional deviation between the levelling reference surface in FIG. 1 and the reference surface of a wafer.
FIG. 3a is a cross-sectional view along the arrow III in FIG. 3 for illustrating the state of the leaf spring in FIG. 3.
FIG. 4 is a diagram, partly in cross-section, for illustrating the operation of the embodiment shown in FIG. 1, and particularly showing a state in which the surface of the wafer center is brought into coincidence with the imaging plane.
FIG. 5 also is a diagram, partly in cross-section, for illustrating the operation of the embodiment shown in FIG. 1, and particularly showing a state in which the surface of the wafer center is brought into coincidence with the levelling reference surface.
FIG. 5a is a cross-sectional view along the arrow V in FIG. 5 for illustrating the state of the leaf spring in FIG. 5.
FIG. 6 is a schematic illustration for illustrating cosine error and sine error.
DESCRIPTION OF THE PREFERRED EMBODIMENT
An embodiment of the present invention will hereinafter be described in detail with reference to the accompanying drawings. FIG. 1 is a diagram, partly in cross-section, schematically showing the construction of a stepper provided with a levelling mechanism according to an embodiment of the present invention, and FIG. 2 is a plan view schematically showing the construction of a wafer stage.
In FIG. 1, a one-side telecentric or both-side telecentric projection lens 1 having an optic axis AX perpendicular to the XY movement plane (the coordinates system XY) of a wafer W forms the projected image of a circuit pattern depicted on a reticle on a predetermined exposure reference plane, i.e., the imaging plane IM. The wafer W to be exposed is held on a levelling stage 3 inclinable in any direction relative to the imaging plane IM, with a wafer holder 2 interposed therebetween. The levelling stage 3 is provided on a Z-stage 4 which in turn is provided on an X-Y stage 6 movable in X- and Y-directions along the imaging plane IM.
Also, the Z-stage 4 is designed to be moved only in Z-direction (the direction of the optic axis AX) relative to the X-Y stage 6 by an actuating portion 5, and a plane mirror 8 for a laser interferometer 7 for detecting the position in X-direction and a plane mirror 10 for a laser interferometer 9 for detecting the position in Y-direction as shown in FIG. 2 are provided on the end portion of the Z-stage 4. The center lines of laser beams applied from the laser interferometers 7 and 9 are measuring axes Lx and Ly in X- and Y-directions, respectively, and the measuring axes Lx and Ly are orthogonal to each other at a point Q and are defined so that the optic axis AX of the projection lens 1 passes through this point Q. Both of FIGS. 1 and 2 show a state in which the center point (reference point) of the wafer W (hereinafter referred to as the "wafer center WC") is registered to the point Q, and it is to be understood that the wafer W has thickness irregularity of t due to TTV.
Now, as shown in FIG. 2, on the levelling stage 3, radially extending arm portions 21a, 21b and 21c are provided integrally with one another at an angular interval of about 120 degrees with respect to the center of placement of the wafer on the levelling stage 3. Disc-shaped leaf springs 22a, 22b and 22c which are resiliently deformable in Z-direction but are not deformable at all with respect to X- and Y-directions are provided on the upper surfaces of the arm portions 21a, 21b and 21c, respectively, and the leaf spring 22a (as well as the leaf springs 22b and 22c) is fixed (screw-set) to the arm portion 21a at two locations 23a and 23b spaced apart from each other by 180 degrees. Also, two locations 23c and 23d spaced apart from the fixed points 23a and 23b of the leaf spring 22a and spaced apart from each other by about 90 degrees are fixed (screw-set) to a fixing member 24 provided integrally with the Z-stage 4 with the arm portion 21a interposed therebetween. The other leaf springs 22b and 22c are of similar construction. Accordingly, the levelling stage 3 is supported on the Z-stage 4 through the three leaf springs 22a, 22b and 22c.
Also, as shown in FIG. 1, a radial bearing 26 (functioning as a roller) is rotatably supported in the lower portion of the arm portion 21a through a moving shaft having a spherical acting point (pivot) 25 at the upper end thereof. The radial bearing 26 bears against a tapered nut 27 which is threadably engaged with a feed screw 28 rotated by a motor 29 fixed to the Z-stage 4. Thus, the design is such that by the revolution of the motor 29, the nut 28 is axially moved and the position at which the radial bearing 26 bears against the tapered portion of the nut 27 is charged horizontally as viewed in FIG. 1, whereby the pivot 25 is moved in Z-direction. The pivot 25 in the lower portion of the arm portion 21a and the motor 29 will hereinafter be collectively referred to as the "actuator 20a".
Further, this actuator 20a has a potentiometer 30, and the amount of displacement of the pivot 25 in Z-direction is detected by this potentiometer 30 provided on the Z-stage 4. Likewise, actuators 20b and 20c each including a potentiometer of entirely the same construction are incorporated in the lower portions of the other two leaf springs 22b and 22c. By driving the actuators 20a, 20b and 20c thus provided at three locations independently of one another, the levelling stage 3 can be inclined in any direction relative to the imaging plane IM, and further, if the respective pivots 25 are driven by the same amount in Z-direction, the wafer supporting surface on the wafer holder 2 (or the wafer holder holding surface on the levelling stage 3) can be parallel-moved in Z-direction while keeping parallelism to the imaging plane IM.
During the initial adjustment of the stepper, as shown in FIG. 3, by the use of a reference wafer Wa and a reference wafer holder 2a having very good parallelism between the upper and lower surfaces thereof and having the mean value of the thickness tolerance as the thickness thereof, the levelling reference surface 3P determined by three points, i.e., the deformation reference point OA of the leaf spring 22a and the deformation reference points OB and OC of advance so as to coincide with the imaging plane IM and the surface of the reference wafer Wa.
FIG. 3a is a cross-sectional view of the leaf spring 22a taken along the arrow III in FIG. 3. As shown in FIG. 3a, no tension is applied to the leaf spring 22a (this also holds true of the leaf springs 22b and 22c), and in that state, the detection value of the potentiometer 30 for detecting the amount of displacement of the pivot 25 is reset to zero (or this detection value is memorized as the initial value), and likewise, the detection values of the other two potentiometer are reset to zero (or are memorized as the initial values).
As shown in FIG. 1, there is provided a focus detecting optical system of the oblique incidence type comprising an irradiating optical system 11a having a pin-hole or a slit therein and projecting an imaging light beam for forming the image of the pin-hole or slit toward the imaging plane IM of the projection lens 1 from an oblique direction relative to the optic axis AX through a beam splitter 13, and a light receiving optical system 11b for receiving the reflected light beam of the imaging light beam on the surface of the wafer W through a beam splitter 14. The construction of this focus detecting optical system 11 is disclosed, for example, in U.S. Pat. No. 4,650,983, and this focus detecting optical system detects the vertical (Z-direction) position of the wafer surface relative to the imaging plane IM, and detects the in-focus state of the wafer W and the projection lens 1. In the present embodiment, it is to be understood that along with the position setting operation for the levelling reference surface as the inclination reference plane shown in FIG. 3, the angle of parallel flat glass, not shown, provided in the light receiving optical system 11b is adjusted in advance so that the imaging plane IM becomes the zero point reference, whereby the calibration of the focus detecting optical system 11 is accomplished.
There is further provided a horizontal position detecting optical system 12 comprising an irradiating optical system 12a for projecting a parallel light beam from an oblique direction relative to the optic axis AX through the beam splitter 13, and a light receiving optical system 12b for receiving the reflected light beam of that parallel light beam on the surface of the wafer W through the beam splitter 14. The construction of this horizontal position detecting optical system 12 is disclosed, for example, in the aforementioned U.S. Pat. No. 4,558,949, and this horizontal position detecting optical system 12 detects the inclination of a predetermined area on the wafer W relative to the imaging plane IM. In the present embodiment, the calibration of the horizontal position detecting optical system 12 is effected so that when the surface of the reference wafer Wa and the imaging plane IM become coincident with each other as shown in FIG. 3, the light beam from the irradiating optical system 12a is condensed at the central position of a four-division light receiving element (not shown) in the light receiving optical system 12b.
Also, in FIG. 1, a main controller 15 servocontrols (closed-loop-controls) the actuating portion 5 and the actuators 20a, 20b and 20c on the basis of the detection signals of the focus detecting optical system 11, the horizontal position detecting optical system 12 and the three potentiometers including the potentiometer 30, and further generally controls the operation of the entire apparatus.
A description will now be given of the operation of the apparatus of the embodiment of the present invention constructed as described above. It is to be understood that the main controller 15 memorizes in advance as a reference value ZO the position of the Z-stage 4 when all of the levelling reference surface 3P, the imaging plane IM and the surface of the reference wafer Wa as shown in FIG. 3 are made coincident with one another.
Now, the main controller 15 first makes the wafer W to be exposed be vacuum-absorbed to the wafer holder 2. However, due to variations in the thicknesses of the wafer W and the wafer holder 2, some deviation may occur between the levelling reference surface 3P and the surface of the wafer W, as shown in FIG. 1. So, the main controller 15 uses the focus detecting optical system 11 to drive the Z-stage 4 through the actuating portion 5 so that the detection value of the focus detecting optical system 11 becomes zero, and brings the surface of the wafer center WC into coincidence with the imaging plane IM, as shown in FIG. 4. Further, the main controller 15 detects the then level Zc of the Z-stage 4, and calculates the amount of deviation λ(λ=ZO - Zc) between the levelling reference surface 3P and the surface of the wafer center WC on the basis of the level Zc and the reference value ZO. When the Z-stage 4 is positioned at a predetermined level (the reference value ZO), the deviation of the surface of the wafer center WC relative to the imaging plane IM may be detected by the use of the focus detecting optical system 11 and the amount of deviation λ may be calculated on the basis of the detection value and the reference value ZO.
Now, as shown in FIG. 4, the wafer center WC is coincident with the imaging plane IM, but deviates from the levelling reference surface 3P by λ. So, the main controller 15 calculates the amount of movement f(λ) of the three pivots including the pivot 25 for bringing the levelling reference surface 3P and the surface of the wafer center WC into coincidence with each other, on the basis of the amount of deviation λ. The main controller 15 servo-controls the actuators 20a, 20b and 20c on the basis of the detection signal of the amount of displacement of the pivot 25 from the potentiometer 30 so that the three pivots are moved in Z-direction (upwardly) by the same amount f(λ). As a result, as shown in FIG. 5, the levelling reference surface 3P and the surface of the wafer center WC exactly coincide with each other. FIG. 5a is a cross-sectional view taken along the arrow V in FIG. 5 and showing the then deformed state of the leaf spring 22a.
As shown in FIG. 5a, with the movement of the pivot 25, the leaf spring 22a is bent and the deformation reference point OA thereof moves in Z-direction by a predetermined amount f(λ). At that time, the deformation reference point OA and the other two deformation reference points OB and OC and the surface of the wafer center WC are moved in Z-direction (upwardly) relative to one another to thereby bring the levelling reference surface 3P and the surface of the wafer center WC into coincidence with each other. Therefore, the deviation between the surface of the wafer center WC and the imaging plane IM, i.e., focus deviation, occurs as shown in FIG. 5. So, the main controller 15 servo-controls the actuating portion 5 for the Z-stage 4 on the basis of the amount of deviation f(λ) of the wafer center WC relative to the imaging plane IM. That is, the main controller servo-controls the actuating portion 5 by the use of the focus detecting optical system 11 so that the surface of the wafer center WC coincides with the imaging plane IM, and moves the Z-stage 4 in Z-direction (downwardly) by f(λ). Thus, the levelling reference surface 3P, the imaging plane IM and the surface of the wafer center WC have all become coincident with one another.
Subsequently, the main controller 15 drives the X-Y stage 6 and sets the wafer W at a predetermined exposure starting position, whereafter it detects the angle of inclination of the shot area relative to the imaging plane IM by the use of the horizontal position detecting optical system 12. Then, the amounts of movement of the three pivots 25 with the wafer center WC as the apparent center of rotation of the levelling stage 3 are calculated from the angle of inclination of the aforementioned shot area so that the inclination of the shot area becomes zero without the surface of the wafer center WC and the levelling reference surface 3P deviating from each other.
Subsequently, by the use of the three potentiometers 30 and the horizontal position detecting optical system 12, the main controller servo-controls the actuators 20a, 20b and 20c on the basis of the amounts of movement of the above-described three pivots 25 and also servo-controls the actuating portion 5 by the use of the focus detecting optical system 11 so that no focus deviation may occur. Thereby, the shot area and the imaging plane IM become exactly coincident with each other and exposure is effected without focus deviation or the like occurring. Thereafter, by repetitively effecting the above-described operation for each shot area on the wafer W, the amount of lateral deviation comprising the sum of cosine error and sine error can be suppressed to less than a predetermined tolerance value (the resolving power of the laser interferometer) and exposure can be accomplished without reducing the throughput, etc.
In the present embodiment, the surface of the wafer center WC and the levelling reference surface 3P are brought into coincidence with each other and levelling is effected with the wafer center WC as the apparent center of rotation of the levelling stage 3 and therefore, the cosine error ΔCe occurring with levelling can be minimized on the whole surface of the / wafer W. For example, the distance δ between the center of rotation of the levelling stage 3, i.e., the wafer center WC, and the central point P of the shot area located near the outer periphery of the wafer W as shown in FIG. 6 is of the order of 100 mm at greatest (in the case of an 8-inch wafer), but even in the worst case, the cosine error ΔCe can be suppressed to the order of ΔCe=0.004 μm.
Also, as regards the sine error, the amount of deviation λ between the levels of the levelling reference surface 3P and the wafer center WC is zero and therefore, the factors for the variations in the thicknesses of the wafer W and the wafer holder 2 can be eliminated. Therefore, if there is not the thickness irregularity t due to TTV, the sine error will become zero, but as shown in FIG. 6, there may occur a sine error ΔSe with only the thickness irregularity t, i.e., the amount of deviation ν between the levels of the wafer center C and the central point P of the shot area as a factor. However, since TTV is of the order of t=20 μm as previously described, the sine error ΔSe can be suppressed to the order of ΔSe=0.006 μm for the angle of inclination θ=1' of the wafer even in the worst case. Accordingly, even if the above-mentioned two errors are added together, the amount of lateral deviation occurring with levelling is of the order of 0.01 μm, and the positioning accuracy of the wafer stage can be satisfied sufficiently.
Thus, when any deviation occurs between the levelling reference surface 3P and the surface of the wafer W, an operation similar to what has been described above is suitably repeated to thereby bring the levelling reference surface 3P and the surface of the wafer center WC into coincidence with each other, whereafter levelling is effected, whereby it becomes possible to accomplish exposure without reducing the positioning accuracy of the wafer stage, the throughput, etc.
As described above, in the present embodiment, the cosine error ΔCe can be suppressed to the order of 0.004 μm, but cannot always be made zero. However, as described above, levelling is effected without any deviation occurring between the levelling reference surface 3P and the surface of the wafer center WC and therefore, the wafer center WC can be specified as the center of rotation of the levelling stage 3. So, if the cosine error ΔCe is calculated from the distance δ between the wafer center WC and the central point P of any shot area on the wafer W and after levelling, the X-Y stage 6 is finely moved in conformity with this amount of lateral deviation, the cosine error ΔCe can be made zero.
Also, in the present embodiment, levelling has been effected with the surface of the wafer center WC and the levelling reference surface 3P always kept coincident with each other, but the levels (the positions in Z-direction) at the center WC of the wafer W and a plurality of positions around it may be detected in advance by the use of the focus detecting optical system 11 and weighting may be effected on these detection values to thereby find the imaginary reference surface of the wafer W. It is apparent that if levelling is effected by an operation similar to that described above with the center of said imaginary reference surface as the center of rotation of the levelling stage 3 while said imaginary reference surface and the levelling reference surface 3P are always kept coincident with each other at the center of the imaginary reference surface, the amounts of movement of the three pivots 25 can be made small and it becomes possible to shorten the time required for levelling.
Further in the present embodiment, levelling has been effected for each shot area with the levelling reference surface 3P and the surface of the wafer center WC made coincident with each other in advance, but the levelling method by the apparatus of the present invention is not restricted to the above-described embodiment. A similar effect can also be obtained, for example, by so-called global levelling in which before exposure is effected, the angles of inclination of the shot areas at a plurality of locations on the wafer W are detected in advance by the use of the horizontal position detecting optical system 12 and the average angle of inclination on the whole surface of the wafer W is found from these angles of inclination and with the wafer center WC as the center of rotation, the levelling stage 3 is once inclined before exposure on the basis of the average angle of inclination. Alternatively, an effect similar to that of the above-described embodiment can also be obtained when effecting so-called block levelling in which the shot area on the wafer W is divided into several blocks and on the basis of the average angle of inclination found for each block, the levelling stage 3 is once inclined for each block with the central point of each block as the center of rotation.
Also, if instead of levelling being effected for each shot area after the levelling reference surface 3P and the surface of the wafer center WC are brought into coincidence with each other, the central point P of each shot area and the levelling reference surface 3P are brought into coincidence with each other by an operation similar to that of the present embodiment and thereafter levelling is effected without any deviation occurring between the central point P of the shot areas and the levelling reference surface 3P, the sine error ΔSe due to TTV can be made zero. At this time, the central point P of the shot areas becomes the center of rotation of the levelling stage 3 and therefore, the cosine error ACe also becomes zero. Accordingly, it becomes possible to effect exposure with the projected image of the circuit pattern of the reticle and the circuit pattern already formed on the wafer W being superposed one upon the other with higher accuracy.
The amounts of movement of the pivots 25 for making the levelling reference surface 3P and the central point P of the shot areas coincident with each other for each shot area and the amounts of movement of the pivots 25 for making the surface of the shot areas and the imaging plane IM coincident with each other (levelling) are found together in a software fashion by the use of the focus detecting optical system 11 and the horizontal position detecting optical system 12. It is apparent that if the design is made such that the three pivots 25 are once drivingly controlled in conformity with the amounts of movement to thereby effect levelling, superposition exposure can be accomplished with higher accuracy without reducing the throughput.
While the present embodiment has been described with respect to a projection type exposure apparatus (stepper), a similar effect can also be obtained in a proximity type exposure apparatus or the like. Also, in the present embodiment, levelling has been effected in the three-point drive system, but the levelling system according to the present invention is not restricted thereto. However, when viewed from the viewpoints of levelling and control time, the three-point drive system is more desirable.
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An exposure apparatus for forming a pattern of a mask on a photo-sensitive substrate comprises an X-Y stage, a Z-stage supported on the X-Y stage, and a levelling stage that supports the photo-sensitive substrate. The levelling stage is supported on the Z-stage by a plurality of levelling devices that define a levelling reference plane, and that are operated in unison to change the level of the levelling stage relative to the Z-stage and relative to an exposure reference plane that is parallel to the levelling reference plane. The levelling devices are also operated individually to change the inclination of the photo-sensitive substrate relative to the levelling reference plane and relative to the exposure reference plane. A focus detector controls the movement of the Z-stage and the in-unison movement of the levelling devices. An inclination detector controls the individual operation of the levelling devices. The net result is that the surface of the photo-sensitive substrate is made coincident with the exposure reference plane and the levelling reference plane, and the center point of the surface of the photo-sensitive substrate becomes the pivotal center for changes in inclination of the photo-sensitive substrate.
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FIELD OF THE INVENTION
[0001] The present invention relates to an apparatus and method of deploying a desuperheater with a Seat-Ring designed to provide coolant injection at high temperature differential. The present invention's robust design provides for a high level of flexibility that allows operating at high temperature differentials between the coolant and the superheated fluid. The desuperheater Seat-Ring is made as a split hollow ring with a perpendicular slit traversing the ring's circumference. The opened slit design provides a high level of flexibility, which allows the seat ring to sustain severe temperature extremes by reducing thermal stress. The coolant is supplied to the seat ring through a specially designed coolant nipple liner connected to the seat-ring.
BACKGROUND OF THE INVENTION
[0002] In the operation of steam and boiler systems, it is often the case that steam which is available for use will be at a temperature much greater than is necessary or desired for a particular end use. In such cases, it is customary to utilize a desuperheater, by which a fluid, usually water is injected into the flowing stream of high temperature steam and subsequently mixed. Ideally, the injected fluid itself almost immediately turns to steam, serving to convert the incoming, high temperature steam to a somewhat larger volume of steam at a lower temperature, that is, the steam will have less superheat.
[0003] An earlier patent granted to Sanford S. Bowlus, U.S. Pat. No. 2,945,685, discloses an advantageous form of automatic desuperheater device, known as a variable orifice desuperheater. In the device of the Bowlus patent, incoming steam, traveling vertically upward through a desuperheater housing inlet, was arranged to lift against gravity a weighted valve element. The extent to which the valve element opened is automatically a function of the volume and velocity of the incoming steam.
[0004] Surrounding the weighted valve element is a small orifice communicating with a source of desuperheating water. When steam is flowing through the system the weighted valve element is lifted, resulting in a high velocity flow of the steam around the valve and an atomizing action of the steam on the surrounding water. The arrangement is such that, relatively independently of the volume of steam flow within reasonable limits, there will be an effective atomizing action of the steam upon the water. The amount of water injected into the desuperheater and combined with the incoming steam is controlled independently, as a function of steam temperature.
[0005] In basic principle, the variable orifice desuperheater of the Bowlus U.S. Pat. No. 2,945,685 is highly effective in operation. Thus, the present invention seeks to utilize the significant operative principles of the earlier Bowlus patent, while at the same time incorporating such principles into a substantially improved physical embodiment, which is more resistant to thermal fatigue than prior devices and at the same time less costly to produce and maintain. These advantages are achieved without sacrifice of performance and, indeed, with improvement in performance in certain respects.
[0006] For a more complete understanding of the above and other features and advantages of the invention, reference should be made to the following detailed description of a preferred embodiment and to the accompanying drawings.
SUMMARY OF THE INVENTION
[0007] Embodiments of the present invention advantageously provide for a variable orifice desuperheater device for in-line operation in conjunction with upstream and downstream piping, comprising A desuperheating device for in-line operation in conjunction with superheated fluid piping upstream and downstream therefrom and of type comprising an upper housing section and a lower housing section joined with a middle housing chamber of enlarged diameter relative to the upstream and downstream piping to form a mixing chamber of enlarged diameter relative to the upstream and downstream piping, wherein said joined housing sections being adapted for connection to said upstream and downstream piping. It also includes a desuperheater seat ring support fixed in said middle housing and supporting therewith an annular seat injection ring with a slot and said annular seat injection ring being adapted for connection to a cooling fluid inlet piping to supply a cooling fluid to said annular seat injection ring and an axially disposed valve cage base structure mounted on said desuperheater seat ring support and a valve plug slideably received in the axially disposed valve cage base structure to cooperate with said slot of said annular seat injection.
[0008] Another embodiment is for a method for cooling a superheated fluid with a desuperheater device, which comprises receiving at a lower section of a desuperheater device, said superheated fluid and flowing said superheated fluid though a variable orifice in a middle section of said desuperheater device and flowing a cooling liquid into said middle section. The method also include mixing said superheated fluid and said cooling liquid in said middle section to produce a less superheated fluid and flowing said less superheated fluid out of said desuperheater device through an upper section.
[0009] An alternative embodiment is for the means for cooling a superheated fluid with a desuperheater device, including the means for receiving at a lower section of said desuperheater device said superheated fluid and the means for flowing said superheated fluid though a variable orifice in a middle section of said desuperheater device and the means for flowing a cooling liquid into said middle section. It further includes the means for mixing said superheated fluid and said cooling liquid in said middle section to produce a less superheated fluid and the means for flowing said less superheated fluid out of said desuperheater device through an upper section
[0010] There has thus been outlined, rather broadly, certain embodiments of the invention in order that the detailed description thereof herein may be better understood, and in order that the present contribution to the art may be better appreciated. There are, of course, additional embodiments of the invention that will be described below and which will form the subject matter of the claims appended hereto.
[0011] In this respect, before explaining at least one embodiment of the invention in detail, it is to be understood that the invention is not limited in its application to the details of construction and to the arrangements of the components set forth in the following description or illustrated in the drawings. The invention is capable of embodiments in addition to those described and of being practiced and carried out in various ways. Also, it is to be understood that the phraseology and terminology employed herein, as well as the abstract, are for the purpose of description and should not be regarded as limiting.
[0012] As such, those skilled in the art will appreciate that the conception upon which this disclosure is based may readily be utilized as a basis for the designing of other structures, methods and systems for carrying out the several purposes of the present invention. It is important, therefore, that the claims be regarded as including such equivalent constructions insofar as they do not depart from the spirit and scope of the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] The above-mentioned and other features and advantages of this disclosure, and the manner of attaining them, will become more apparent and the disclosure itself will be better understood by reference to the following description of various embodiments of the disclosure taken in conjunction with the accompanying figures.
[0014] FIG. 1 is a cross sectional view of the desupheater valve of an embodiment of the present invention.
[0015] FIG. 1 a is a close up cross sectional view of the desupheater valve of an embodiment of the present invention.
[0016] FIG. 2 is a plan view of the seat ring deployed in an embodiment of the present invention.
[0017] FIG. 3 is a sectional slice view of the seat ring.
[0018] FIG. 4 is a view of the seat ring ends of the seat ring.
[0019] FIG. 5 illustrates a cutaway view of a desuperheater valve with flange connection.
[0020] FIG. 6 is a plan view of the seat ring deployed in another embodiment of the present invention.
[0021] FIG. 7 is a slide view of the seat ring showing the cooling fluid inlet which is deployed inside the seat ring.
[0022] FIG. 8 is a side view orientation of the seat ring and its location in conjunction with seat ring support of the embodiment show in FIG. 6 .
DETAILED DESCRIPTION OF THE INVENTION
[0023] In the following detailed description, reference is made to the accompanying drawings, which form a part hereof and show by way of illustration specific embodiments in which the invention may be practiced. These embodiments are described in sufficient detail to enable those skilled in the art to practice them, and it is to be understood that other embodiments may be utilized, and that structural, logical and processing changes may be made. It should be appreciated that any list of materials or arrangements of elements is for example purposes only and is by no means intended to be exhaustive. The progression of processing steps described is an example; however, the sequence of steps is not limited to that set forth herein and may be changed as is known in the art, with the exception of steps necessarily occurring in a certain order.
[0024] The Desuperheater consists of a body which houses the desuperheater internals. The body incorporates a seat over which a cage is located in such a manner that a coolant annulus is created around the seat. The coolant enters this annulus by means of a branch on the desuperheater body. The plug is free floating, but incorporates a spring-loaded stability button which provides stability to the plug under light load conditions. Incorporated in the top of the cage is a plug stop to limit the amount of travel of the plug.
[0025] In service, incoming vapor acts on the underside of the plug, which is weighted in such a manner that a certain amount of the energy in the vapor is used to lift the plug. As more vapor flows through the desuperheater, the higher the plug is lifted, thus creating a variable orifice for the vapor flow. The energy used in lifting the plug creates a pressure drop across the seat which is quite constant regardless of the vapor flow. This pressure drop creates a relatively high velocity across the seat area, and it is at this point of low pressure constant velocity that the coolant is admitted into the vapor flow.
[0026] Coolant enters the annulus under the dictates of a control valve responsive to a temperature controller sensing the downstream vapor temperature. The coolant is admitted into the vapor flow through a peripheral gap between the underside of the cage and the top of the seat. Coolant is admitted via slot located around the circumference of the seat to ensure that unequal cooling does not occur.
[0027] The coolant is picked up by the vapor flow as it discharges from the seat, and the low pressure zone that exists at this point is instrumental in atomizing the coolant into fine particles. In the turbulence which ensues as a result of the change in direction and velocity of the vapor, intimate mixing of the vapor and coolant takes place. Above the plug, as the vapor attempts to return to laminar flow, a vortex is created and any particles of coolant not completely absorbed by the vapor are drawn into this vortex where they suffer a further pressure reduction which again speeds up the atomizing process.
[0028] As virtually all of the desuperheating occurs within the desuperheater body itself, and as no coolant impinges on either the desuperheater or associated piping, no protective thermal liners for downstream piping are required.
[0029] FIGS. 1 and 1 a are a cross sectional views of an embodiment of the present invention. The desuperheater valve assembly 10 has three sections, a desuperheated fluid outlet or upper housing section 22 , a middle housing section 26 and a superheated fluid inlet or lower housing section 20 . They are joined together by welds 2 . Although the welds are shown as a single welded butt joint, the joining of the upper housing section 22 , the middle housing section 26 and the lower housing section 20 can be accomplished by any coupling method or casting method.
[0030] Inside the housing 26 , the segment rings 18 can be found adjacent to the seat support ring 42 . The seat support ring 42 holds and supports the annular seat injection ring 16 . A spacer ring 44 is located above the seat injection ring 16 . The valve cage base structure 38 is axially disposed inside the valve assembly and is on the downstream side of the spacer ring 44 . In this embodiment, the cage base structure 38 is welded to the housing 26 . A thermal liner 24 is attached to the cage base structure 38 and is positioned between the housing 26 and the internal cage 46 . Cage ribs 36 are located positioned above the cage base 38 . The plug stop 28 is located at the top of the internal cage 46 to limit travel of the plug assembly 40 . The plug assembly 40 includes a locking pin 30 , a loading spring 32 and a stability button 34 to provide stability to the plug under light load conditions. The thermal liner 24 is attached to the cage base structure 38 and is free to expand and contract reliving thermal stresses and protecting the housing 26 from thermal stress cracking. It may be attached, for example, by a welding process.
[0031] In operation, the cooling fluid enters the desuperheater valve through the cooling manifold fluid inlet 12 and flows through a first end of the coolant thermal sleeve 14 . The coolant thermal sleeve protects the weld joints and also reduces thermal stresses, extending design live of the unit. The coolant thermal sleeve 14 has piston rings 48 positioned about the coolant thermal sleeve 14 to permit movement of the thermal sleeve 14 within the cooling manifold 12 . The other end of the thermal sleeve 14 is positioned inside the annular seat injection ring 16 .
[0032] Now, referring to FIGS. 1-4 , the seat injection ring 16 is hollow and is shaped like a torus and includes a coolant nipple 17 attached to receive a cooling fluid. For example, the cooling fluid could be water, which is injected into the superheated fluid flowing through the desuperheater valve assembly 10 . As discussed above, the superheated fluid is moving through the desuperheater device, the plug assembly 40 will move away from the seat injection ring 16 creating an atomizing orifice area and the cooling fluid is then dispersed into the superheated fluid via slot 21 . The slot 21 travels around the circumference of the annular seat injection ring 16 . The cooling fluid is pulled into the superheated vapor flow and the low pressure zone that exists at this point is aids in atomizing the cooling fluid into fine particles.
[0033] In this embodiment, the seat injection ring 16 is interrupted by two seat ring ends 19 and are attached by welds 2 a . The interruption permits the seat injection ring 16 to expand and contract without causing damage to the device. For example, when the ring becomes heated and expands, the gap between the two seat ring ends 19 will narrow. However, depending on the temperatures involved in the operation of the desuperheater valve and the materials making up the desuperheater valve itself, other configurations of the seat injection ring 16 can be deployed. For example, the seat ring could be continuous, without the interruption and would not need the seat ring ends 19 . The seat injection ring 16 many also employ only one seat ring end 19 to distribute the cooling liquid in a particular manner.
[0034] When the desuperheater valve operation is closed, the plug assembly 40 meets up with the seat injection ring 16 covering the slot 21 . As the superheated fluid enters the desuperheater valve and the pressure builds, the generally cylindrical valve plug assembly 40 lifts, permitting the cooling fluid to with the superheated fluid, and thus lowering the temperature of the superheated fluid. FIG. 5 illustrates a cutaway view of the desuperheater valve of the present invention showing parts placement.
[0035] Now referring to FIGS. 6-8 , the coolant nipple 17 is placed inside the seat injection ring 16 . This configuration provides valve designers more flexibility when sizing and scaling desuperheater valves. FIG. 8 illustrates an inner inlet seat ring support 43 which would accommodate the coolant nipple 17 if it were to be placed inside the seat injection ring 16 .
[0036] The desuperheater valve can be made out of various temperature and pressure tolerant materials. For example, the desuperheater valve can be made out of carbon steel, stainless steel and other types of low alloy steel.
[0037] The processes and devices in the above description and drawings illustrate examples of only some of the methods and devices that could be used and produced to achieve the objects, features, and advantages of embodiments described herein and embodiments of the present invention can be applied to indirect dry, direct dry and wet type heat exchangers. Thus, they are not to be seen as limited by the foregoing description of the embodiments, but only limited by the appended claims. Any claim or feature may be combined with any other claim or feature within the scope of the invention.
[0038] The many features and advantages of the invention are apparent from the detailed specification, and, thus, it is intended by the appended claims to cover all such features and advantages of the invention which fall within the true spirit and scope of the invention. Further, since numerous modifications and variations will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation illustrated and described, and, accordingly, all suitable modifications and equivalents may be resorted to that fall within the scope of the invention.
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The present invention relates to an apparatus and method of deploying a desuperheater with a Seat-Ring designed to provide coolant injection at high temperature differential. The present invention's robust design provides for a high level of flexibility that allows operating at high temperature differentials between the coolant and the superheated fluid. The desuperheater Seat-Ring is made as a split hollow ring with a perpendicular slit traversing the ring's circumference. The opened slit design provides a high level of flexibility, which allows the seat ring to sustain severe temperature extremes by reducing thermal stress. The coolant is supplied to the seat ring through a specially designed coolant nipple liner connected to the seat-ring.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a National Phase Entry of International Patent Application No. PCT/FR2015/050207, filed on Jan. 29, 2015, which claims priority to French Patent Application Serial No. 14/50693, filed on Jan. 29, 2014, both of which are incorporated by reference herein.
FIELD
[0002] The invention relates to the field of electromagnetic actuators comprising several mechanically independent members moving in a linear direction.
BACKGROUND
[0003] U.S. Pat. No. 6,098,288 relates to an electric razor comprising an electromagnetic linear actuator that moves the moving member in a coming and going movement and a second member of the blade type that interacts to cut the hairs. These moving members are magnetised. The European application EP2320543 is also known that describes an actuator comprising a set of permanent magnets magnetised in a direction that is perpendicular to the direction of movement of the movement system, such that the magnetic poles having different polarities alternate on the polar magnetic surfaces of the magnets in the direction of movement, a stator comprising the first and second magnetic poles on both sides of the row of permanent magnets, in a direction that is perpendicular and comprising each one of the magnetic poles facing the magnetic pole surface, a single phase coil exciting the parts of the magnetic poles forming the first and second units of magnetic polar parts.
[0004] The international application WO 2000063556 describes an oscillating piston drive, especially designed for an oscillating piston vacuum pump, comprising a housing (2) in which is located a cylinder (3), a piston (4) that can carry out a back and forth movement in the said cylinder, as well as an electromagnetic control component for the piston (4) and comprising an electromagnet (11) on the stator side and at least one permanent magnet on the piston side (18, 19). In order to improve the service life of this oscillating piston drive, permanent magnets (15, 16) are placed on the stator side, and the permanent magnet or magnets (18, 19) are designed and placed such that the piston (4) occupies a substantially central axial position, in the rest state.
[0005] U.S. Patent Publication No. 2013/193780 describes an actuator with a fixed part comprising a stator pole a coil fixed to the stator pole, a first moving member that comprises a first magnet magnetised in a direction from the inside towards the outside and placed to cover the external peripheral surface on an extremity in an axial direction from the fixed part, which is mounted elastically on the stator pole, and which is mobile in the axial direction. A second moving part comprises a second magnet that is magnetised in the direction from the interior to the exterior and placed to cover the outer periphery surface of the other end in the axial direction of the fixed part, which is mounted elastically on the stator pole, and which is mobile in the axial direction. When the current flows in the coil, the first moving section and the second moving section move in opposite directions. The coil axis is mounted in a horizontal direction.
[0006] The prior solutions have different disadvantages. Most of the proposed structures are mechanically and/or magnetically imbalanced giving rise to vibrations and sound pollution. Furthermore, the moving elements are, in the prior art solutions, combined with magnets that increase the weight and inertia and therefore deteriorate the performances of such actuators.
SUMMARY
[0007] Thus, the purpose of the invention is to propose an actuator that allows two independent movements while solving the problems experienced by the skilled person seeking to adapt the previous systems. Specifically, the main purpose of the invention is to propose an actuator allowing to balance the transverse forces that are applied to the moving elements, by the advantageous positioning of permanent magnets within the structure. By doing this, the previously identified overhang present in prior art actuators is significantly reduced or even compensated. The actuator can thus be most accurately sized to meet given specifications (for example to create an axial force to combat a load).
[0008] Another purpose of the invention is to create an actuator that provides the possibility of generating an antagonistic movement of the moving elements with a single electric control coil supplied in a double-polar manner or with two imbricated or concentric coils controlled in a single pole manner. This embodiment makes it possible to design a compact actuator, especially in the transverse direction to the movement. Another purpose of the invention is to allow the production of an oscillating actuator or a monostable actuator or a bistable actuator, i.e. having respectively no, one or two stable positions without any current at the extremities of the stroke for both independent moving members (the term “independent” means the absence of a mechanical connection between the two moving members).
[0009] More specifically, the invention concerns a linear electromagnetic actuator comprising a stator excited by at least one electric coil arranged around an axis of symmetry and two ferromagnetic stator poles positioned axially on either side of the coil, as well as at least two, independent moving members, each of the said moving members being formed of a ferromagnetic material, characterised in that the said linear electromagnetic actuator comprises at least three magnetised poles arranged inside the coil, with respectively a first magnetised pole positioned in the vicinity of the median plane separating the two moving members and containing the axis of the coil, and a second and third magnetised pole arranged laterally on either side of the said moving members and the coil. The term “magnetised pole” refers to a magnetic pole that is permanently magnetised in the absence of current.
[0010] Furthermore, the moving members are only made from soft ferromagnetic material and are separate from the magnetised poles, static in relation to the moving members. The moving members on the one hand, and the magnetised poles on the other, are separate elements, the magnets being fixed and static. Preferably, the moving members move in identical but opposing directions.
[0011] To this effect, the first, second and third magnetic poles are magnetised in a transverse direction, orthogonal to the coil axis and the second and third magnetised poles are magnetised in identical and opposing directions to the direction of magnetisation of the first magnetised pole. The second and third magnetised poles can be attached to each other or be separate parts. In a specific embodiment, the second and third magnetised poles are comprised of a single diametrically magnetised ring.
[0012] In a specific embodiment, the two stator poles have axially directed outcrops in the form of pole tips to favour an input of power at the start of the stroke. The actuator may comprise two electrically independent coaxial coils which can, furthermore, be imbricated in order to be able to use a single pole supply for each coil. Similarly; the electric coil can have an asymmetrical rotating geometry for the purposes of easier production and an optimisation of its shape factor. In another specific embodiment, the electric coil is borne by a body that has the properties of a permanent magnet and the second and third magnetised poles are comprised, at least partially, of the said magnetised body.
[0013] A position sensor indicating the position of at least one of the moving members can be used advantageously placed in a housing in the vicinity of the moving members. In order to optimise the mechanical interface with the external elements to be moved, the moving members are advantageously extended by exit shafts placed on the moving members. Different materials for the exit shaft and the moving member can also be used depending on the required mechanical output. Finally, one of the advantages of the invention and of the use of the exit shafts is the possibility of obtaining a spacing of the moving members that is different from the spacing of the output shafts.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] Other characteristics and advantages of the invention will become apparent upon reading the following description of particular embodiments of the invention that respectively represent.
[0015] FIG. 1 : a first embodiment with the positioning of the magnets, the coils and the moving members as well as 4 stable actuator positions noted (a), (b), (c) and (d), in the absence of current in the coils, as well as the main flux paths for each magnet and the direction of the applied forces;
[0016] FIG. 2 : the 2 stable positions in the presence of current in the first embodiment;
[0017] FIG. 3 : a second embodiment with an actuator with three parallelepiped magnets and a rectangular coil;
[0018] FIG. 4 : a third embodiment with an actuator with lateral tile shaped magnets and an axisymetric coil;
[0019] FIG. 5 : a fourth embodiment with a cylindrical coil presenting an actuator where the lateral 2 magnets are replaced by a double-pole ring magnet;
[0020] FIG. 6 : a fifth embodiment presenting an actuator where the 3 magnets are recomposed using 2 radially magnetised cylindrical magnets;
[0021] FIG. 7 : a sixth embodiment with an actuator of the which coil body is made from a magnetisable material;
[0022] FIG. 8 : an alternative embodiment presenting the side view of a stator with pole teeth;
[0023] FIG. 9 : a second alternative embodiment showing pole teeth and moving members with conical ends;
[0024] FIG. 10 : an alternative embodiment with amagnetic blocks;
[0025] FIG. 11 : an embodiment allowing the asymmetry of the force in the actuator current;
[0026] FIG. 12 : an embodiment of a vibrating actuator with a double antagonistic output;
[0027] FIG. 13 : an embodiment including a sensor making it possible to determine the position of the moving members;
[0028] FIG. 14 : an embodiment with parallelepiped magnets, having additional magnets;
[0029] FIG. 15 : two alternative embodiments with stators with polar teeth placed in the space between the magnets and the stator;
[0030] FIG. 16 : an alternative embodiment in which the central magnetised pole is formed by two magnets on either side of a ferromagnetic part making it possible to drive the flux; and
[0031] FIG. 17 : an alternative embodiment in which the central magnet comprises polar parts.
DETAILED DESCRIPTION
[0032] FIGS. 1 and 2 schematically show a transverse cross section of the structure of an actuator according to the terms of the invention in a first embodiment. A set of ferromagnetic parts forms a ferromagnetic stator yoke ( 1 ) that contains an electric coil ( 2 ) surrounded by an axis ( 15 ) of symmetry. Inside this coil are placed two (soft) ferromagnetic moving members ( 7 ) independent of each other and three permanent magnets. The first magnetised pole ( 4 ) is positioned in the median plane separating the two moving members ( 7 ) and two other magnetised poles ( 4 ) on either side of the moving members ( 7 ). The magnetisation of the magnetised poles ( 4 , 5 ) is orthogonal to the coil axis ( 2 ), and the direction of the magnetisation ( 22 ) of the central magnetised pole ( 4 ) is opposed to the magnetisation direction ( 23 ) of the lateral magnets. On either side of the coil ( 2 ), axially, are located two stator poles ( 13 , 14 ), in a soft ferromagnetic material. Each one of the stator poles ( 13 , 14 ) participates in the different magnetic circuits defined on FIGS. 1 ( a ) to 1( d ) to help loop the magnetic flux around the coil ( 2 ). In the example in FIGS. 1 and 2 , the stator poles ( 13 , 14 ) are in the form of straight or rectilinear poles, but they can be in the form of pole tips as shown in FIG. 9 .
[0033] FIG. 1 shows the behaviour of the actuator in the absence of current with four stable positions, cases (a) and (b) showing the moving members ( 7 ) in stable positions on two opposite sides while cases (c) and (d) show the moving members ( 7 ) in stable positions on the same side, respectively bottom and top. It is to be noted that in the positions presented in FIG. 1 . c and FIG. 1 . d , the magnetic flux ( 20 ) of the central magnet and the magnetic flux ( 21 ) of the corresponding lateral magnet in a moving member have an opposing direction to that of the fluxes in the other moving member ( 7 ). In FIG. 1 . a and FIG. 1 . b , the direction of the magnetic flux ( 20 ) of the central magnet and the magnetic flux ( 21 ) of the corresponding lateral magnet have the same direction on both moving members ( 7 ). In all cases, the forces perpendicular ( 30 ) to the coil ( 2 ) axis tend to compensate each other, thereby limiting the overhang suffered by the moving members ( 7 ). The working force ( 31 ) produced by the actuator is therefore mainly oriented along the axis of movement of each of the moving members ( 7 ).
[0034] FIG. 2 shows the behaviour of the actuator in the presence of current. In this case, the electric coil ( 2 ) creates a magnetic field that imposes a direction ( 25 ) on the magnetic flux. The moving members ( 7 ) will place themselves so that the flux from the central magnet ( 20 ) and the flux from the lateral magnets ( 21 ), have the same direction in the moving members ( 7 ) as that of the flux due to the current ( 25 ).
[0035] Due to this, according to the terms of the invention, the actuator can operate in two different ways.
Without the contribution of an external force and supplied by alternating current, the moving members ( 7 ) oscillate between the positions in FIG. 2 . a and that of FIG. 2 . b in an alternating and antagonistic movement, each moving member ( 7 ) alternatively coming into contact with the stator pole ( 13 ) or the stator pole ( 14 ). In the presence of an external force that can place the actuator in the positions in FIG. 1 . c or FIG. 1 . d , the actuator will be able to move, once the electric power supply is established, by moving a single moving member ( 7 ), either to the position in FIG. 2 . a , or to the position in FIG. 2 . b depending on the direction of the electric current ( 24 ) supplying the coil ( 2 ).
[0038] FIG. 3 shows an easy to produce embodiment. The coil body ( 3 ) has 3 notches to place the magnetised poles ( 5 ) and the magnetised pole ( 4 ) and 2 passages for the moving members ( 7 ). The upper stator cover ( 1 ) is made from folded sheet metal, and the magnetised pole ( 4 ) and the magnetised poles ( 5 ) are parallelepipeds magnetised according to their thickness. However, the magnetisation direction of the central magnet ( 22 ) is opposite to that of the other two magnets ( 23 ).
[0039] In this example of embodiment in FIG. 3 , the exit of the movement outside the actuator is not achieved by the moving members ( 7 ) but via the exit shafts ( 8 ) attached to the moving members ( 7 ) by a choice of screwing, tapping, gluing or any other known technique allowing to attach two parts together. For example, a ball and socket type contact can also be envisaged to allow the rotation of the exit shaft ( 8 ) without the rotation of the moving member ( 7 ) and therefore allowing to withstand external torques that would apply to the exit shafts without damaging the moving members ( 7 ). The exit shafts ( 8 ) are preferably amagnetic or very slightly magnetic (relative permeability of a few units) in order to avoid magnetic leaks that are prejudicial to the forces created by the actuator.
[0040] FIG. 4 shows an embodiment of the actuator with an optimised coil ( 2 ) because it has a more favourable rounded form reducing the intrinsic resistance by a smaller wind length. This embodiment imposes the use of tile shaped magnetised poles ( 5 ). Their magnetisation ( 23 ) can be diametrical or radial.
[0041] FIG. 5 shows an embodiment of the actuator with a cylindrical coil ( 2 ) which makes it possible to obtain the lowest intrinsic resistance. This embodiment also makes it possible to more easily envisage the use of two coaxial electric coils that can be superimposed or imbricated (“twin-wire” coiling). The use of two coils will thus make it possible to use two single pole electricity supplies as opposed to the double-pole supply that would have to be used if a single coil was used. This embodiment uses a double-pole ring magnet ( 5 ) instead of the 2 lateral magnets. The second and third magnetised poles ( 5 ) of the invention are indeed magnetised parts that can be attached or separate depending on the selected embodiment. The magnetisation of the outer magnet ( 23 ) can be radial or diametric.
[0042] FIG. 6 shows a specific embodiment where 2 radially magnetised ( 23 ) ring magnets ( 5 ) are used, one on the inside and the other on the outside. By placing them against each other we obtain the same type of magnetisation as in the general case of an actuator with 3 flat magnets. This solution makes it possible to use moving members ( 7 ) of a cylindrical shape and makes the actuator insensitive to their rotation. In the example in FIG. 6 , an amagnetic block ( 9 ) is used to hold the magnets.
[0043] FIG. 14 shows a specific embodiment where, using an embodiment with parallelepiped magnets for the central pole ( 4 ) and the lateral poles ( 5 ) and by adding four additional magnetised poles ( 32 ), the magnetic flux in the moving members is maximised while keeping a simple magnet shape. The figure shows an actuator with a coil body made from a magnetisable material used to replace the lateral magnets ( 5 ). In its centre is has a receptacle for the magnetised pole ( 4 ) that must be positioned at a height using blocks ( 9 ). In its most simple version, this magnet can be manufactured by injection (plastic binder magnet) and magnetised in a single pass.
[0044] FIG. 8 and FIG. 15 show stator ( 1 ) embodiments with polar tips ( 6 ) used to strengthen the stable position exit force in one direction of movement. In the example in FIG. 8 , the polar tip ( 6 ) is attached to the stator ( 1 ) and is located below the moving member ( 7 ). When the moving member ( 7 ) opposite it is in the high position, the proximity of the polar tip ( 6 ) makes it possible to generate a calling force by the effect of a favourable variable reluctance and eventually allows movement even in critical cases (critical temperatures, abnormal friction).
[0045] In the examples in FIG. 15 , the stator polar tips ( 6 ) placed in the space between the magnets ( 4 ) and ( 5 ) and the stator ( 1 ) are used, allowing to have a simple shape for the moving member ( 7 ). FIGS. 15 . a and 15 . b show the case of polar tips ( 14 ) placed on only one side of the actuator making it possible to have a calling force in one direction of the movement. FIGS. 15 . c and 15 . d show the case of polar tips ( 14 ) placed on both sides of the stator ( 1 ) to obtain a calling force in both directions of the movement.
[0046] FIG. 9 shows an embodiment of the stator ( 1 ) with polar tips ( 6 ) on the stator ( 1 ) on either side of the moving members ( 7 ). The moving members ( 7 ) are of a conical shape that is complementary to the stator ( 7 ) shape, allowing to increase the produced magnetic force. This is an actuator based on the embodiment shown in FIG. 6 with the advantages of the presence of polar tips explained previously.
[0047] FIG. 16 shows an embodiment of the central magnetised pole by the superimposition of two magnets ( 4 ) and a ferromagnetic part ( 33 ) allowing the passage of the flux. This structure makes it possible to reduce the size of the central magnet when the actuator spacing is large and to reduce the weight of the moving members ( 7 ).
[0048] FIG. 17 shows an embodiment similar to that in FIG. 16 , with a single central magnet ( 4 ) and two ferromagnetic polar parts ( 33 ) on either side. The purpose of this structure is to reduce the moving weight and to balance the weight of the moving members ( 7 ) around the exit axis ( 8 ).
[0049] FIG. 10 shows an embodiment of the actuator with a possible stroke longer than the sought after working stroke. The presence of amagnetic blocks ( 9 ) indeed allows to reduce the possible stoke to the working stroke without altering the actuator. An actuator according to the terms of the invention can, depending on the sizing, have a holding force (called “sticking”) between the moving member ( 7 ) and the stator ( 1 ) that is too strong, limiting the possibility of leaving this position with a low electric power. The use of blocks thereby makes it possible to modulate the required sticking force and thus increase the level of the force with current when the moving members ( 7 ) leave the stable position (called “unsticking”). The moving member ( 7 ) on the right in FIG. 10 is in the sticking position against the amagnetic block ( 9 ).
[0050] The embodiment of this FIG. 10 also makes it possible to appreciate the interest of presenting the exit shafts ( 8 ) that are carried over onto the moving members ( 7 ). Besides the effects already described concerning FIG. 3 , these exit shafts make it possible to generate two exits of which the space ES is different from the space EO of the moving members ( 7 ) within the actuator. On the example in FIG. 10 , the ES space between the exit shafts ( 8 ) is thus bigger than the space EO between the moving members ( 7 ). The fact that these exit shafts ( 8 ) are carried over also makes it possible to make the creation of different alternatives highly flexible, which would be differentiated by the different ES spacings but also by different exit shaft ( 8 ) diameters.
[0051] FIG. 11 shows an embodiment that makes it possible to obtain different forces without current for each moving member by using the relative position of the lateral magnetised poles ( 5 ) between each other and relative to the stator ( 1 ). The case shown in FIG. 11 makes it possible to obtain a higher sticking force on one side than on the other for a given moving member ( 7 ) and in the opposite direction to that of the other moving member ( 7 ) by approaching, and respectively distancing, the magnets from the end positions. Embodiments making it possible to increase the force on a single side of the actuator for both moving members ( 7 ) can be created by varying the position of the inner magnetised pole ( 4 ).
[0052] FIG. 12 shows an embodiment where the moving members ( 7 ) are suspended using springs ( 10 ). This makes it possible to obtain two types of actuator depending on the selected spring stiffness ( 10 ). Either the stiffness is high and the force of the actuator with current does not make it possible to maintain the sticking on the stator ( 1 ) poles, in this case a vibrating actuator with a simple double antagonistic exit is obtained. Or the stiffness is not sufficiently high to prevent the sticking on the stator ( 1 ) poles and an actuator with 3 stable states is obtained for each moving member ( 7 ): 2 with the magnetic sticking on either side of the stroke, and 1 in the central position by the elastic force of the springs ( 10 ).
[0053] FIG. 13 shows an embodiment that includes a position sensor ( 11 ) making it possible to determine the position of each moving member ( 7 ) as soon as power is applied. In this embodiment, the sensor ( 11 ) takes the form of two magnetically sensitive sensors that are placed on the upper part of the actuator in the vicinity of the moving members ( 7 ) in a free housing ( 12 ), here lateral, generated between the coil body ( 3 ) and the moving members ( 7 ). These magnetically sensitive sensors can be of the digital type, i.e. of the “on-off” type differentiating the upper and lower position of the moving members ( 7 ), or of the analogue type, i.e. determining the position of the moving members ( 7 ) along their entire stroke.
[0054] In the example on FIG. 13 , two magnetically sensitive sensors are used, the purpose of which is to differentiate the position of each moving member ( 7 ). It can be envisaged to only use one magnetically sensitive sensor covering only one moving member ( 7 ). Similarly, in the example in FIG. 13 , both sensors are different and independent elements. The use of the presented magnetically sensitive sensors can be envisaged in a single common box, or to use a single sensor with several independent axes of sensitivity.
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A linear electromagnetic actuator includes a stator excited by at least one electric coil arranged around an axis of symmetry and two ferromagnetic stator poles positioned axially on either side of the coil, as well as at least two independent moving members, each of the moving members being formed of a ferromagnetic material, where the linear electromagnetic actuator includes at least three magnetized poles arranged inside the coil, with respectively a first magnetized pole positioned in the vicinity of the median plane separating the two moving members and containing the axis of the coil, and a second and third magnetized pole arranged laterally on either side of the moving members, between the moving members and the coil.
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RELATED APPLICATIONS
[0001] The present application claims the benefit under 35 U.S.C. § 119(e) of Provisional Application Ser. No. 60/715,029, filed Sep. 7, 2005 and Provisional Application Ser. No. 60/832,172, filed Jul. 19, 2006, both of which are titled Air Induction Improvement to Existing Hard Surface Cleaning Tools, which applications are incorporated herein by reference in their entireties.
BACKGROUND
[0002] Surface cleaning apparatuses vary in both shape and design. However, almost all traditional solid surface cleaning apparatuses include a water source that provides water and/or cleaning agents to a number of high pressure jets. The high pressure jets impart a force on the surface to be cleaned, thereby removing unwanted debris and material.
[0003] Many solid surface cleaning apparatuses include a rotating jet system. According to these traditional systems, one or more jets are positioned at the end of an arm. The arm is then coupled to a high speed rotating coupler. According to this traditional system, the high pressure jets at the end of the arm are placed at a relatively extreme angle relative to the surface being cleaned, so that they may impart a horizontal force component on the arm, thereby inducing rotation of the arm about the high speed rotating coupler. However, these traditional solid surface cleaning apparatuses are often plagued by less than satisfactory cleaning swaths or an inability to clean recessed areas on solid surfaces. Often, the inability to clean recessed areas on solid surfaces is attributed to the high angle needed on a rotating cleaning head to produce head rotation.
SUMMARY
[0004] According to one exemplary embodiment, an apparatus for cleaning solid surfaces includes a housing configured to substantially encapsulate a surface being cleaned, a vacuum port traversing the housing, a high speed rotating coupler assembly rotatably coupled to the housing, a plurality of impeller blades coupled to the high speed rotating coupler, at least one fluid jet coupled to the impeller blades, and at least one air pathway configured to pass input air past the impeller blades to rotatably drive the impeller blades.
[0005] According to one exemplary embodiment, the at least one air pathway includes a plurality of air inlet ports formed in the housing adjacent to the plurality of impeller blades, wherein the impeller blades are configured to rotate the high speed rotating coupler by air induced from the plurality of air inlet ports.
[0006] According to one alternative embodiment, the at least one air pathway includes a water/air pickup path leading to a system vacuum hose. According to one exemplary embodiment, the use of air to drive the rotation of the high speed rotating coupler assembly of a solid surface cleaning tool imparts a rotating force on the jet assembly, allowing for a more perpendicular spray jet angle and improved surface cleaning at lower speeds.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The accompanying drawings illustrate various embodiments of the present system and method and are a part of the specification. The illustrated embodiments are merely examples of the present system and method and do not limit the scope thereof.
[0008] FIG. 1 illustrates a partial cross-sectional view of the present solid surface cleaning head, including an air-flow path, according to one exemplary embodiment.
[0009] FIG. 2 illustrates a full cross sectional view of the present solid surface cleaning head including the multiple air induction ports, according to one exemplary embodiment.
[0010] FIG. 3 illustrates a bottom view of the present solid surface cleaning head, according to one exemplary embodiment.
[0011] FIG. 4 illustrates a jet angle cleaning recessed surface imperfections, according to one exemplary embodiment.
[0012] FIG. 5 illustrate a cross-sectional side view of a solid surface cleaning head configured to drive a turbine with both intake air and dirty water, according to one exemplary embodiment.
[0013] Throughout the drawings, identical reference numbers designate similar, but not necessarily identical, elements.
DETAILED DESCRIPTION
[0014] An exemplary system and method for forming an air driven solid surface cleaning apparatus are disclosed herein. Specifically, the exemplary solid surface cleaning apparatus includes an air pathway, such as one or more air inlet ports in its housing or a water/air take up pathway, and a number of impeller blades coupled to the high speed rotating coupler assembly to impart a rotating force on the jet assembly, allowing for a more perpendicular spray jet angle and improved surface cleaning at lower speeds. Embodiments and examples of the present exemplary systems and methods will be described in detail below.
[0015] Unless otherwise indicated, all numbers expressing quantities, measurements, and so forth used in the specification and claims are to be understood as being modified in all instances by the term “about.” Accordingly, unless indicated to the contrary, the numerical parameters set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the present disclosure.
[0016] In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the present system and method. It will be apparent, however, to one skilled in the art, that the present method may be practiced without these specific details. Reference in the 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. The appearance of the phrase “in one embodiment” in various places in the specification are not necessarily all referring to the same embodiment.
[0000] Exemplary System
[0017] FIGS. 1 and 3 illustrate an air driven surface cleaning apparatus, according to one exemplary embodiment. As illustrated in FIGS. 1 and 3 , the air driven surface cleaning apparatus ( 100 ) includes a number of components including, but in no way limited to, an outer housing ( 110 ) and a raised inner housing ( 170 ) defining a cleaning space. As shown, the space located between the outer housing ( 110 ) and the raised inner housing ( 170 ) form a vacuum port ( 120 ) that leads to a vacuum source ( 125 ). Additionally, as illustrated in FIG. 1 , a plurality of water jets ( 140 ) are rotatably coupled to a high speed rotating coupler ( 130 ). According to one exemplary embodiment, a pressurized water source (not shown) provides pressurized water and/or cleaning solvents and materials to the water jets ( 140 ), causing the water jets to impart a high pressure cleaning stream onto a desired surface located below the defined cleaning space.
[0018] As mentioned, traditional hard surface cleaning apparatuses included many of the above-mentioned components. However, in contrast to traditional cleaning systems, the present exemplary surface cleaning apparatus ( 100 ) also includes a fan blade or impeller ( 150 ) coupled to the high speed rotating coupler ( 130 ). According to the exemplary embodiment illustrated in FIG. 1 , the fan blade or impeller ( 150 ) is coupled to the high speed rotating coupler assembly ( 130 ) such that the blades of the impeller are disposed near the top of the inside of the cleaning space. According to one exemplary embodiment, the fan blade or impeller ( 150 ) is coupled to the high speed rotating coupler assembly ( 130 ) by any number of coupling methods including, but in no way limited to, an adhesive, welding, and/or any number of mechanical fasteners, and the like.
[0019] In addition to the high speed rotating coupler ( 130 ), one or more air inlet ports ( 160 ) were added just above the impeller blades ( 150 ) through the outer housing ( 110 ) of the exemplary surface cleaning apparatus ( 100 ). Moreover, according to one exemplary embodiment, the existing vacuum relief port found on traditional surface cleaning apparatuses (not shown) is removed or otherwise blocked. According to one exemplary embodiment described in further detail below, the inclusion and placement of the air induction ports ( 160 ) on the outer surface ( 110 ) of the present exemplary cleaning apparatus ( 100 ) adjacent to the fan blades or impellers ( 150 ) provides for driving rotation of the water jets ( 140 ) about the high speed rotating coupler ( 130 ).
[0020] Additionally, according to one exemplary embodiment illustrated in FIG. 1 , the inclusion of the air induction ports ( 160 ) on the outer surface ( 110 ) of the present exemplary cleaning apparatus ( 100 ) adjacent to the fan blades or impellers ( 150 ) allows for a modified orientation of the water jets ( 140 ), according to one exemplary embodiment. Specifically, as mentioned previously, traditional spinning surface cleaners orient the relative angle of the water jets at an extreme angle to provide a rotational force for the spinning of the apparatus. However, due to the placement of the air induction ports ( 160 ) on the outer surface ( 110 ) of the present exemplary cleaning apparatus ( 100 ) relative to the fan blades or impellers ( 150 ), the required driving force from the jets ( 140 ) is significantly reduced and/or eliminated. Consequently, the water jets ( 140 ) of the present exemplary cleaning apparatus ( 100 ) can be oriented to not only provide slight propulsion to spin the rotating coupler ( 130 ), but also to provide enhanced agitation for cleaning. Specifically, the water jets ( 140 ) of the present exemplary cleaning apparatus may be oriented, according to one exemplary embodiment, at between approximately 80 and 90 degrees relative to the plane defined by the bottom of the outer housing ( 115 ). According to one exemplary embodiment, the angle of orientation by the water jets ( 140 ) actually causes the leading edge ( 400 ; FIG. 4 ) of the spray to be pointed at a negative angle against the direction of rotation (R; FIG. 4 ), as shown in FIG. 4 . Further details of the operation of the present exemplary cleaning apparatus ( 100 ) will now be provided below with reference to FIGS. 2 through 4 .
[0000] Exemplary Operation
[0021] Exemplary FIG. 2 illustrates an exemplary operation of the present exemplary cleaning apparatus ( 100 ), according to one exemplary embodiment. As illustrated in FIG. 2 , once the tool ( 100 ) comes in contact with a surface being cleaned, vacuum is applied by the vacuum source ( 125 ) and a cleaning or rinsing solution is applied through the water jets ( 140 ) by any number of methods including, but in no way limited to, a machine for powering such tools such as a truck mounted or portable cleaning machine (not shown).
[0022] As the vacuum is introduced by the vacuum source ( 125 ), air is introduced to the housing ( 110 ) through the open air induction ports ( 160 ) above the impeller ( 150 ). Specifically, the vacuum created by the vacuum source ( 125 ) pulls air through the open air induction ports ( 160 ) and into the vacuum source, as indicated by the dashed arrows in FIG. 2 . As illustrated, this air flow from the air induction ports ( 160 ) passes through the impeller ( 150 ) and out of the cleaning tool ( 100 ) to the vacuum producing source ( 125 ). As the air flow passes the impeller ( 150 ), a force is imparted on the surface of the blades of the impeller ( 150 ) causing the impeller to spin. As the impeller ( 150 ) begins to rotate, the high speed rotating coupler ( 130 ) also begins to spin. Rotation of the high speed rotating coupler ( 130 ) also rotates the water jets ( 140 ), causing the cleaning agent emitted from the water jets to be forced under pressure onto the surface being cleaned.
[0023] Specifically, according to one exemplary embodiment, the present exemplary system and method uses the introduction of air to drive the rotation of the jets ( 140 ) rather than solely using the water from the jets ( 140 ). According to the present exemplary embodiment, the use of a secondary propulsion input allows for the modified angle of the water jets ( 140 ) to be slightly less than a 90° angle. This extreme angle allows for the use of lower cleaning and rinsing solution pressures, thereby reducing the risk of damaging the surface being cleaned.
[0024] Further, as illustrated in FIG. 4 , turning the jet angle ( 140 ) of spray more towards the direction of rotation allows for more intricate detailed cleaning of cracks or grooves ( 410 ) in the surface being cleaned. Particularly, the leading edge ( 400 ) of the spray may be pointed at a negative angle against the direction of rotation (R), allowing for more complete coverage of the surfaces of the cracks or grooves ( 410 ).
[0025] Moreover, the introduction of air via the inlet ports ( 160 ) provides positive air induction to the surface being cleaned. Consequently, the present exemplary system also completes dryer times more quickly and efficiently and eliminates the need for vacuum relief ports.
[0026] Referring now to FIG. 5 , the driving of the impeller ( 150 ) may also be performed by a combination of air flow entering the apparatus ( 100 ) due to the existence of a vacuum and soiled water that has been used in the cleaning of a desired surface. As illustrated in FIG. 5 , the air driven turbine ( 150 ) may be placed in the path between the vacuum port ( 120 ) and the vacuum hose leading to the vacuum source ( 125 ). Consequently, when the air and/or water that is present below the water jets is forced into the vacuum port(s) ( 120 ), the air and/or water may impart a force on the air driven impeller ( 150 ), imparting a rotational force thereon.
[0027] As shown in FIG. 5 , the placement of the air driven impeller ( 150 ) in the path of the air and/or water that is passed to the vacuum source ( 125 ) efficiently utilizes the energy present in the system without necessitating extreme nozzle angles and other disadvantages of the prior art.
[0028] In conclusion, the present exemplary system and method use air and/or water to drive the rotation of a high speed rotating coupler assembly of a surface cleaning tool, thereby imparting a rotating force on the jet assembly. According to one exemplary embodiment, the present exemplary systems and methods allow for a more perpendicular spray jet angle and improved surface cleaning at lower speeds
[0029] The preceding description has been presented only to illustrate and describe exemplary embodiments of the present system and method. It is not intended to be exhaustive or to limit the system and method to any precise form disclosed. Many modifications and variations are possible in light of the above teaching. It is intended that the scope of the system and method be defined by the following claims.
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An apparatus for cleaning solid surfaces includes a housing configured to substantially encapsulate a surface being cleaned, a vacuum port traversing the housing, a high speed rotating coupler assembly rotatably coupled to the housing, a plurality of impeller blades coupled to the high speed rotating coupler, at least one fluid jet coupled to the impeller blades, and at least one air pathway configured to pass input air past the impeller blades to rotatably drive the impeller blades.
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BACKGROUND
1. Field of the Invention
The present invention relates to a method for preparing germinated brown rice having improved texture, cookability without microbial contamination and to a germinated brown rice obtained therefrom. More specifically, the present invention relates to a method for preparing germinated brown rice that has better texture, is easier to cook at homes and has higher safety from microbial contamination compared with conventional germinated brown rice, by controlling the conditions for the germination process, and to a germinated brown rice obtained therefrom.
2. Discussion of Related Art
The structure of brown rice consists, from the topmost layer, of the rice bran layer that comprises three layers such as pericarp, testa and aleurone layer, and the embryo occupying a small portion of the base of the rice grain, and the endosperm occupying most of the remaining part. This endosperm, which is filled dominantly with starch, is the edible rice portion.
Compared with milled rice, unpolished brown rice is stable in storage and less susceptible of being damaged by insects or microbes, and does not lose in much nutrients. Therefore, it is rich in fats, proteins, vitamins B 1 and B 2 compared with milled rice, and does not undergo reduction in the quantity owing to processing. However, in spite of these benefits aspects of brown rice, it is not widely popular because it is less tasty than milled rice, its nutritious ingredients are not sufficiently digested and assimilated, and it is not easy to cook. Consequently, germinated brown rice is drawing more interest.
Germinated brown rice results from germination of the embryo of brown rice through various physiological changes within the rice grain under conditions suitable for germination. Compared with conventional brown rice, germinated brown rice is effectively digested and assimilated in the body, and it is recognized as a functional food with high contents of nutrients beneficial to the human body, such as γ-aminobutyric acid (referred to as GABA), ferulic acid, diet fiber and the like.
However, germinated brown rice has problems of producing offensive fermentation smell and bad odor during the germination process because of the metabolism of brown rice itself as well as the growth of microbes that are attached to the surface of the grain, and undergoing putrefaction during the germination process. Thus, these problems occurring in the germination process should be avoided for the preparation of high quality germinated brown rice. The aforementioned problems should be necessarily recognized in order to satisfy the demand of consumers, and in fact quality control of germinated brown rice through controlling various conditions in the process for preparing germinated brown rice is required.
According to the results of many researches on germinated brown rice, it is reported that as brown rice undergoes germination, its texture becomes soft to a certain extent owing to the physiological activity of brown rice itself and activities of various enzymes, and thereby preparation of a rice which is very easy to cook and has soft texture, compared with normal brown rice, is possible. However, practically there is limit in overcoming such dissatisfaction on conventional brown rice only by adopting the germination process, and the product quality is much too low to satisfy the fastidious demand of consumers. Thus, techniques such as follows are being introduced as a result of researches to improve various properties of brown rice (e.g., texture, cookability, etc.).
Korean Patent No. 247686 discloses a method for making germinated brown rice wherein rice grains still covered with the husks are immersed in brine to sort out those grains with high germinating potential, and then these selected rice grains are partially polished to brown rice, which are subjected to processes of germinating in water and germinating in air repeatedly.
Korean Patent Publication No. 2000-37091 describes a germinating apparatus for repeating the germination process comprising the steps of washing brown rice while circulating water in the germination bath, germinating brown rice in water, discharging water from the germination bath regularly while germination, and injecting air into the bath by an air injection motor.
Korean Patent Publication No. 2002-71208 discloses a device for drying germinated brown rice rapidly to a water content of 25 to 42%, and a method for drying and packaging germinated brown rice comprising the step of drying of germinated brown rice followed by heat treatment. This patent discloses data on the improvement of the cookability of brown rice at homes.
Korean Utility Model Publication No. 2000-07517 discloses an electric heater for the preparation of edible germinated brown rice, which is used to cook brown rice.
Korean Patent Publication No. 2001-111002 discloses a method for preparing germinated brown rice having good cookability, texture and preserving property, wherein germinated brown rice prepared by controlling the water content, degree of gelatinization and the efficiency of water absorption during immersion in water, is subjected to steaming or moist heating, followed by drying.
However, in spite of aforementioned various techniques, there has been a continued desire to improve the quality of the geminated brown rice because the techniques could not resolve completely the problems such as the prolonged process of germination, prolonged cooking and inconvenience in cooking, the rough texture and abnormal odor of brown rice remained after cooking.
In this regard, the inventors of the present invention have conducted researches to solve the technical problems in quality and preparation process that conventional germinated brown rice products have and to develop a high-quality germinated brown rice which has high safety against microbial contamination, highly nutritious, and easy to cook at homes, and found that the texture of germinated brown rice can be improved by lightly grinding brown rice to partially remove its outermost skin, putrefaction of germinated brown rice can be prevented and its abnormal odor can be removed through controlling appropriately the germination conditions such as pH and temperature of the germination water, air injection, change interval of the germination water and so on, and treatment of germinated brown rice under high temperature and high pressure can lead to the improvement of the safety against microbial contamination and cookability as well as further improvement of the texture of brown rice.
Therefore, the object of the present invention is to provide a method for preparing germinated brown rice that has high safety against microbial contamination, highly nutritious, easy to cook at homes and soft in texture after cooking.
Another object of the invention is to provide a germinated brown rice prepared by the method according to the present invention.
SUMMARY OF THE INVENTION
The present invention is directed to a method for preparation of germinated brown rice having excellent texture, cookability and safety against microbial contamination, characterized in that comprises the steps of: grinding brown rice to an after-grinding weight level of 94.4% to 98.8% by weight based on the weight of raw brown rice in order to partially remove the outermost skin of brown rice; germinating brown rice by immersing grinded brown rice into slightly acidic germination water, injecting air therein and changing the germination water at an interval of 5 to 10 hours for a time period of 10 to 30 hours; and treating germinated brown rice at a high temperature of 100 to 140° C. and high pressure for 5 to 40 minutes.
The germination water used in the germinating step preferably has a pH value of 3 to 7 and a temperature of 20 to 50° C.
In the step of treatment under high temperature and high pressure, germinated brown rice is washed with water, packaged with sealing, subjected to high temperature and high pressure and then rapidly cooled. In this case, the final water content of germinated brown rice is at a level of 32 to 40% by weight.
Subsequently, germinated brown rice treated under high temperature and high pressure is dried at a temperature of 40 to 70° C. to achieve the final water content at a level of 10 to 20% by weight, in order to allow convenient distribution and to facilitate use of the product at homes.
One aspect of the present invention is to provide a germinated brown rice having improved texture, cookability and safety against microbial contamination prepared by grinding brown rice to partially remove its outermost skin, germinating brown rice by immersing grinded brown rice into slightly acidic germination water, injecting air therein and changing the germination water at regular intervals, and treating germinated brown rice under high temperature and high pressure.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows the process flow for preparation of germinated brown rice according to a preferred embodiment of the present invention.
FIG. 2 shows the texture of the brown rice prepared according to the present invention compared with that of conventional brown rice.
Hereinafter, the present invention is explained in more detail referring to the drawings.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIG. 1 , the method for preparation of germinated brown rice according to the present invention may start from the step of selecting impurities from brown rice (S 11 ), an optional step. Subsequently, the step of grinding selected brown rice (S 12 ) is carried out. The grinding step herein means the process of partially removing the outermost skin of brown rice. The weight of brown rice after-grinding is in the range 94.4% to 98.8%, and preferably 96% to 98.8% based on the weigh of raw brown rice. Grinding of brown rice to a certain level in the present invention are carried out for the following reasons.
If brown rice is not grinded or is grinded to a level below the said range, the texture of cooked rice becomes rough and hard so that it is difficult to eat, and the brown rice needs a long time for swelling before cooking, thus it makes to cook at home undesirable. On the other hand, excessive grinding to a level over said range would lead to the removal of the embryo of brown rice and consequent loss of the function as germinated brown rice, making it undesirable. Ultimately, by grinding brown rice to a level of 94.4%–98.8% by the weight based on the weight of raw brown rice, it is possible to protect the embryo that is essential in germination and to produce brown rice having soft texture without losing the functions beneficial to the human body imparted by many nutrients.
The grinding step (S 12 ) is followed by a germinating step (S 13 ). In the preparation process of germinated brown rice, since sufficient water absorbing brown rice is generally maintained at a constant temperature for a long time during the germinating step, the preservation property worsen due to microbial growth, and the problems of putrefaction and abnormal odor of brown rice may occur during the germinating step. Therefore, it is important to set the conditions in the germinating step (S 13 ) to prevent above-mentioned problems. In the germinating step (S 13 ) of the present invention, grinded brown rice is immersed into the germination bath which is filled with the slightly acidic germination water at a temperature of 20 to 50° C. for 10 to 30 hours, while injecting air into the germination bath through the air injection device installed in the lower part of the bath, thereby preventing the putrefaction of brown rice during the germinating step (S 13 ). Further, the used germination water is replaced automatically and regularly at a time interval of 5 to 10 hours to prevent abnormal tasting and smelling of germinated brown rice. More preferred conditions for germination are such that the germination water is replaced regularly while injecting air for 15 to 30 hours at a temperature of 25 to 45° C., with the pH of the germination water being between 3 and 7.
In other words, among the conditions for germination as described above, if the pH of germination water is value of below 3 namely strongly acidic, the germination of brown rice is inhibited, thereby the contents of nutrients such as GABA and so on produced therein being reduced, and also the softening of the texture of brown rice becomes weakened by insufficient germination. Meanwhile, a pH value of 7 or higher of the germination water is not preferable because brown rice may putrefy during germination.
When the time for germination is shorter than 10 hours, the improvement of nutrients and texture of brown rice is not sufficient because germination cannot fully occur. When the time for germination is longer than 30 hours, it is not preferable because excessive germination results in lowered the contents of nutrients other than the diet fiber, excessively grown sprout makes the appearance of brown rice undesirable, and the production efficiency is lowered. If the temperature for germination is lower than 20° C., it will take long time to reach the desired level of germination. On the other hand, if the temperature is higher than 50° C., the rice may undesirably putrefy.
Therefore, germination of brown rice under the conditions for germination according to the present invention makes it possible to prepare a germinated brown rice of good quality efficiently in a short period of time by suppressing the generation of the undesirable putrefaction odor during germination, which may cause problem in product quality, and further the germination process leads to an increase in the contents of the various nutrients present in brown rice that are beneficial to human.
The germinated brown rice according to germinating step (S 13 ) of the present invention is washed with clean water and is subjected to the step of packaging with tight sealing (S 14 ), prior to the treatment under high temperature and high pressure. The germinated brown rice that has been washed and packaged then goes through the step of treating the rice under high temperature and high pressure (S 15 ). Specifically, the step of treating under high temperature and high pressure (S 15 ) is carried out by heat treating the washed and packaged brown rice at a temperature of 100 to 140° C. for 5 to 40 minutes and then cooled the treated rice with cold water. More preferably, the treatment under high temperature and high pressure is carried out under the conditions of a temperature of 100 to 130° C. for 10 for 20 minutes. Said treatment is preferably carried out such as to obtain the F 0 value of 5 to 30. As a unit representing the degree of thermal sterilization of food, the F value indicates the thermal destruction time which, expressed in minutes, is the time taken to annihilate a specific microbe by heating at a pre-determined temperature. More particularly, as a unit representing the time in minutes to annihilate a specific microbe by heating at 121.1° C., the F 0 value indicates the thermal destruction time for the microbe when the z value (the temperature increment required to reduce the heating time to one tenth, which time is required to reduce the number of the microbe to one tenth) is 10 at the heating temperature of 121.1° C.
If the treating temperature or time for the above-mentioned step ( 15 ) are lower and shorter, respectively, than the said range, the starch in the germinated brown rice does not gelatinize sufficiently, and thus the texture quality as well as the effect of destroying microbes are undesirably lowered. On the other hand, if the treating temperature and time are higher and longer, respectively, than the said range, gelatinization of the starch in the brown rice occurs excessively, thereby undesirably lowering the quality of the germinated brown rice to a large extent.
Moreover, examples of the equipment that may be used in the step of the treatment under high temperature and high pressure of the present invention are retort, autoclave and the like which are commonly used in heat treatment of processed foods. As the starch in the germinated brown rice is gelatinized through the treatment under high temperature and high pressure, the texture of the rice is soften, and destruction of the microbes that once increased during germination allows assurance of safety from microbial contamination. Subsequently, it is preferable to rapidly cooling the heat-treated germinated brown rice in order to prevent deterioration of the product.
The final water content of the germinated brown rice that has been treated under high temperature and high pressure becomes 32 to 40% by weight. Then, the germinated brown rice having the water content within said range is subjected to the drying step (S 16 ), and this drying step (S 16 ) is carried out by removing the packaging from the germinated brown rice previously treated under high temperature and high pressure and drying the rice in a dryer at a temperature ranging from 40 to 70° C. to obtain the final water content at a level of 10 to 20% by weight. Here, if the water content is lower than 10% by weight, individual grains of the germinated brown rice tend to form cracks or break in pieces, thus causing the damaged savor of the cooked germinated brown rice. On the other hand, if the water content exceeds 20% by weight, there occur problems microbes such as fungi, bacteria or the like readily grow, and preservation property deteriorates. Hence, appropriate drying process allows obtaining convenience in transportation and usage as well as assuring safety against secondary microbial contamination from small packages. The drying manner can be carried out by any one selected from those drying manners generally used in this field, for example, but not limited to, convectional drying, radiation drying, indirect drying, homogeneous heating by microwaves, vacuum drying or freeze drying.
For the preparation of germinated brown rice as described above, either non-glutinous rice or glutinous rice can be used.
The germinated brown rice prepared according to the above-described process has high contents and excellent composition of nutrients, does not produce the abnormal odor and the putrefaction odor caused by germination, and is safe from microbial contamination. Further, this germinated brown rice can be easily cooked at homes, and its texture is superior to that of conventional brown rice.
The germinated brown rice according to the present invention may be marketed in sealed packages in specific quantities, and it is also preferable to enclose packets of deoxygenating agent within the sealed packages in order to enhance safety of the product.
Further, the germinated brown rice may be cooked alone or in combination with polished rice, or may be used as the raw material for processed foods such as rice cookies, powdered cereal, uncooked cereal, porridge or bread.
In addition, if necessary, the germinated brown rice can be coated or treated by other appropriate manner such as absorption with a variety of functional ingredients in order to reinforce the nutriment of the brown rice.
The present invention will be explained in more detail through the Examples below. The Examples are presented only to illustrate the preferred embodiments of the present invention and not intended in any way to limit the scope of the present invention
EXAMPLE 1
Non-glutinous brown rice was grinded to the level of 98.8 wt % based on the weight of raw brown rice, and then the brown rice was immersed into germination water of pH 6 at 40° C. filled within a germination bath. After immersion, while air was injected through the air injection line installed in the lower part of the germination bath, the brown rice was germinated for 20 hours with changing the germination water twice at an interval of 7 hours. The germinated brown rice obtained from the germinating step was washed with clean water and packaged with sealing, and then the rice was treated under high pressure at a temperature of 121° C. for 20 minutes by injecting steam to the jacket of the autoclave. After that, the brown rice was rapidly cooled with cold water. Subsequently, the germinated brown rice obtained from the step of treatment under high temperature and high pressure was dried, using hot air at 60° C., to the final water content of 15% by weight.
EXAMPLE 2
Non-glutinous brown rice was grinded to the level of 98.8 wt % based on the weight of raw brown rice, and then the brown rice was immersed into germination water of pH 6 at 40° C. filled within the germination bath. After immersion, while air was injected through the air injection line installed in the lower part of the germination bath, the brown rice was germinated for 20 hours with changing the germination water twice at an interval of 8 hours. The germinated brown rice obtained from the germinating step was washed with clean water and packaged with sealing, and then the rice was treated under high pressure at a temperature of 121° C. for 20 minutes by injecting steam to the jacket of the autoclave. Subsequently, the brown rice was rapidly cooled with cold water to produce a germinated brown rice product having the water content of 34% by weight.
EXAMPLE 3
Non-glutinous brown rice was grinded to the level of 97.6 wt % based on the weight of raw brown rice, and then the brown rice was immersed into germination water of pH 6 at 40° filled within the germination bath C. After immersion, while air was injected through the air injection line installed in the lower part of the germination bath, the brown rice was germinated for 20 hours with changing the germination water twice at an interval of 8 hours. The germinated brown rice obtained from the germinating step was washed with clean water and packaged with sealing, and then the rice was treated under high pressure at a temperature of 121° C. for 20 minutes by injecting steam to the jacket of the autoclave. After that, the brown rice was rapidly cooled with cold water. Subsequently, the germinated brown rice obtained from the step of treatment under high temperature and high pressure was dried, using hot air at 60° C., to the final water content of 15% by weight.
EXAMPLE 4
Non-glutinous brown rice was grinded to the level of 97.6 wt % based on the weight of raw brown rice, and then the brown rice was immersed into germination water of pH 6 at 40° C. filled within the germination bath. After immersion, while air was injected through the air injection line installed in the lower part of the germination bath, the brown rice was germinated for 20 hours with changing the germination water twice at an interval of 8 hours. The germinated brown rice obtained from the germinating step was washed with clean water and packaged with sealing, and then the rice was treated under pressure at a temperature of 121° C. for 20 minutes by injecting steam to the jacket of the autoclave. Subsequently, the brown rice was rapidly cooled with cold water to produce germinated brown rice product having the water content of 34% by weight.
EXAMPLE 5
Glutinous brown rice was grinded to the level of 98.8 wt % based on the weight of raw brown rice, and then the brown rice was immersed into germination water of pH 6 at 40° C. filled within the germination bath. After immersion, while air was injected through the air injection line installed in the lower part of the germination bath, the brown rice was germinated for 20 hours with changing the germination water twice at an interval of 8 hours. The germinated brown rice obtained from the germinating step was washed with clean water and packaged with sealing, and then the rice was treated under high pressure at a temperature of 121° C. for 20 minutes by injecting steam to the jacket of the autoclave. After that, the brown rice was rapidly cooled with cold water. Subsequently, the germinated brown rice obtained from the step of treatment under high temperature and high pressure was dried, using hot air at 60° C., to the final water content of 15% by weight.
EXAMPLE 6
Glutinous brown rice was grinded to the level of 98.8 wt % based on the weight of raw brown rice, and then the brown rice was immersed into germination water of pH 6 at 40° C. filled within the germination bath. After immersion, while air was injected through the air injection line installed in the lower part of the germination bath, the brown rice was germinated for 20 hours with changing the germination water twice at an interval of 8 hours. The germinated brown rice obtained from the germinating step was washed with clean water and packaged with sealing, and then the rice was treated under high pressure at a temperature of 121° C. for 20 minutes by injecting steam to the jacket of the autoclave. Subsequently, the brown rice was rapidly cooled with cold water to produce germinated brown rice product having the water content of 38% by weight.
EXAMPLE 7
Glutinous brown rice was grinded to the level of 96.8 wt % based on the weight of raw brown rice, and then the brown rice was immersed into germination water of pH 6 at 40° C. filled within the germination bath. After immersion, while air was injected through the air injection line installed in the lower part of the germination bath, the brown rice was germinated for 20 hours with changing the germination water twice at an interval of 8 hours. The germinated brown rice obtained from the germinating step was washed with clean water and packaged with sealing, and then the was treated under high pressure out at a temperature of 121° C. for 20 minutes by injecting steam to the jacket of the autoclave. After that, the brown rice was rapidly cooled with cold water. Subsequently, the germinated brown rice obtained from the step of treatment under high temperature and high pressure was dried, using hot air at 60° C., to the final water content of 15% by weight.
EXAMPLE 8
Glutinous brown rice was grinded to the level of 96.8 wt % based on the weight of raw brown rice, and then the brown rice was immersed into germination water of pH 6 at 40° C. filled within the germination bath. After immersion, while air was injected through the air injection line installed in the lower part of the germination bath, the brown rice was germinated for 20 hours with changing the germination water twice at an interval of 8 hours. The germinated brown rice obtained from the germinating step was washed with clean water and packaged with sealing, and then the rice was treated under high pressure at a temperature of 121° C. for 20 minutes by injecting steam to the jacket of the autoclave. Subsequently, the brown rice was rapidly cooled with cold water to produce germinated brown rice product having the water content of 37.5% by weight.
Evaluation
The germinated brown rice obtained from the above Examples was compared with milled rice or normal brown rice and evaluated with respect to the nutrition, safety against microbes, texture and other properties. The results are summarized in Tables 1 to 4 below.
Evaluation on Nutrition
Analyses for the nutrients and their compositions of the germinated brown rice obtained from Examples 1 and 2 and of normal polished rice were made by the Korea Health Industry Development Institute (KHIDI), and the results are presented in Table 1 below.
TABLE 1
Component
Example 1
Example 2
Milled rice
Ash (%)
0.4
0.5
0.4
Crude Fat (%)
2.0
2.3
0.6
Crude Protein (%)
5.3
5.4
5.0
Vitamin E (mg/100 g)
0.4
0.3
0.1
Carbohydrate (%)
59.1
70.2
72.1
Calories (Kcal)
267.2
313.4
310.7
Iron (%)
0.6
0.7
0.0
Phosphorus (mg/100 g)
101.3
111.5
70.2
Magnesium (mg/100 g)
30.7
38.4
15.5
Calcium (mg/100 g)
8.5
8.2
4.0
Sodium (mg/100 g)
6.9
3.2
4.0
Total Diet Fiber (%)
2.2
2.4
0.8
γ-oryzanol (mg/100 g)
15.9
23.1
1.2
Potassium
49.3
59.7
61.7
(The water contents of the sample rice are 15%)
As shown in Table 1 above, the germinated brown rice of Examples 1 and 2 according to the present invention contains more beneficial nutrients in large quantities compared with milled rice.
Evaluation on the Safety Against Microbes
The brown rice which was subjected to the processes of grinding, germinating and treating under high temperature and high pressure according to the present invention in Example 1 above, and untreated normal brown rice were investigated for microbial contamination, and the results are presented in Table 2 below.
The evaluation on safety against microbes was performed according to the counting method for bacteria (general bacteria) and fungi (yeast and filamentous fungus) among the microbial testing methods suggested in the Food Code (Korea Foods Industry Association).
TABLE 2
General bacteria
Yeast/Fungi
Remarks
Before germination
4 × 10 5
1.7 × 10 3
After treatment under
0
0
high temperature and
pressure
As shown in Table 2 above, after the treatment under high temperature and high pressure, any of general bacteria and yeast/fungi were not found, and this implies that the conditions for the treatment under high temperature and high pressure according to the present invention are suitable for assuring safety against microbes.
Evaluation on Texture
The germinated brown rice of Examples 1 and 2, and as the objects for comparison, ungerminated brown rice, a Korean germinated brown rice (Chang Se-Soon Taecho™ germinated brown rice products) and a foreign germinated brown rice were evaluated for the texture after cooking, and the evaluation was carried out by performing the Two Bite Test with a texture profile analyzer, with the terms for the texture being divided into hardness, fracturability, adhesiveness, gumminess and chewiness. The analysis results are presented in Table 3 and in FIG. 2 as a graph.
TABLE 3
hard-
ness
fracturability
adhesiveness
gumminess
chewiness
Exam-
817.9
965.7
−20.0
0.28
618.7
ple
1
Exam-
316.1
391.2
−23.3
0.27
62.4
ple
2
Unger-
1374.5
1541.5
−22.1
0.34
728.7
minated
brown
rice
Foreign
974.5
902.9
-23.1
0.34
925.5
ger-
minated
brown
rice
Korean
1060.5
1164.0
-20.0
0.29
650.0
ger-
minated
brown
rice *1
*1 Chang Se-SoonTaecho ™ geminated brown rice product)
As shown in Table 3 and FIG. 2 , the germinated brown rice of Examples 1 and 2 according to the present invention were superiorly mitigated in hardness compared with the ungerminated brown rice or other germinated brown rice. Similarly, the germinated brown rice according to the present invention was also superior or similar to the other testing objects in fracturability, adhesiveness, gumminess and chewiness. This implies that the germinated brown rice according to the present invention is of superior quality in overall.
Evaluation on Quality
A large-scale consumer survey (250 persons in each group) was conducted with respect to the cooked rice prepared with a 50:50 mixture of the germinated brown rice of Example 1 and polished rice, to investigate the product quality. The quality investigation was carried out using the five-point grading method. The cooked rice for comparison was prepared with a 50:50 mixture of Korean germinated brown rice and polished ice.
TABLE 4
50% of germinated
brown rice of Example
50% of Korean
Evaluation Terms
1
germinated brown rice
Savor in general
3.78
2.87
Texture on
3.76
2.58
mastication
Degree of tastiness
3.69
3.46
Odor of cooked rice
3.45
2.85
Aftertaste
3.73
3.06
Preference
3.77
2.46
in glutinousness
Shape/state of rice
3.64
2.99
grains
Degree of tasteful
3.68
2.75
appearance
Degree of
4.08
3.04
digestion/assimilation
Degree of
4.30
3.03
masticability
Color in general
3.54
2.75
Preference in the
3.60
2.45
degree of roughness
Degree of glossiness
3.53
2.30
Preference in the
3.84
3.00
degree of thickness
Therefore, the germinated brown rice according to the present invention has high contents of nutrients and excellent composition, does not produce abnormal odor and putrefaction odor due to germination, and has high safety from microbial contamination. Further, it is possible to cook conveniently using common rice cookers, without the need to wash/selecting, and also to prepare a germinated brown rice product having excellent texture compared with conventional brown rice.
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The present invention relates to a method for preparing germinated brown rice that has better texture, is easier to cook and has higher safety from microbial contamination compared with conventional germinated brown rice, by controlling the conditions for the germination process, and to a germinated brown rice obtained therefrom. More particularly, improved germinated brown rice can be obtained by at least partially removing the skin, germinating the altered rice in slighted acid germination water and treating the germinated brown rice at elevated temperatures and pressures.
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BACKGROUND OF THE INVENTION
[0001] This invention relates generally to electrical connectors, and, more particularly, to low profile connectors for mounting to substrates and connecting wires thereto.
[0002] Recent advances in illumination technology have resulted in the prolific use of distributed lighting assemblies in many applications. Distributed lighting assemblies are desirable, for example, for interior and exterior illumination of a vehicle, for decorative, accent, and safety lighting in business, homes, and outdoor illumination of sidewalks, swimming pools, steps, and even for directional and advertisement signage.
[0003] Conventional distributed light assemblies include a high intensity light source and a plurality of light transmission conduits (e.g., fiber optic cables, light pipes, and the like) for illuminating locations remote from the light source. A plurality of light sources (e.g., incandescent bulbs, halogen lamps, and the like) have been employed with an equal plurality of light transmission members to produce distributed lighting effects. It is difficult, however, to produce even lighting from the multiple light sources, and the assemblies are not as reliable as desired. Tubular light sources (e.g., neon, fluorescent, and the like) have been utilized to produce more even lighting, but are notably disadvantaged as requiring high voltage power supply converters to operate the tubes. Additionally, tubular light sources have poor impact resistance, rendering them unsuitable for many applications.
[0004] Recent technological advances in low voltage light sources, such as light emitting diodes (LEDs), now present low voltage light sources as viable candidates as light sources for distributed lighting assemblies. Low voltage light sources operate at a small fraction of the electrical power of conventionally used light sources and are an attractive option for use in distributed lighting assemblies due to generally lower cost and higher efficiency than conventionally used light sources. Thus far, however, obtaining a reliable and even light output from low voltage light sources in a distributed lighting assembly has proven difficult.
[0005] In certain applications, low voltage light devices including LEDs are connected to an aluminum substrate in use, and connecting wires from the low voltage light devices are hand soldered to the substrate. It would be desirable to provide a lower cost and more time efficient manner of connecting the low voltage lighting devices to the substrates. Known connectors, however, are disadvantaged for purposes.
[0006] For example, known connectors are typically too large to be effectively used with low voltage lighting devices such as LED packages, because when mounted to the substrate the relative sizes of the connectors and the LED packages can lead to shadows and a non-uniform light emission from the LEDs. Additionally, mounting the connectors to the substrate and retaining the connector to the substrate can itself become problematic due to the low profile of the LED packages.
BRIEF DESCRIPTION OF THE INVENTION
[0007] According to an exemplary embodiment, a low profile connector assembly comprises at least one contact having a surface mount portion and a wire engagement portion extending from the surface mount portion, and a housing insertable over the at least one contact and retained to the at least one contact. The housing encloses the wire engagement portion and has a wire receiving aperture therethrough. The wire receiving aperture provides access to the wire engagement portion when the housing is retained to the contact.
[0008] Optionally, the housing and contact define a low profile dimension of approximately 10 mm or less measured substantially perpendicular to a substrate to which the surface mount portion is mounted. The wire engagement portion may include an insulation displacement contact section, a plurality of deflectable fingers configured to engage a wire, a contact beam pivoting in a plane parallel to the surface mount portion when a wire is engaged thereto, or a box clamp contact. The wire engagement portion may be configured for two stage engagement with the housing. A plurality of contacts may be provided, and the contacts may be staggered or offset from one another on opposite sides of the housing.
[0009] According to another exemplary embodiment, a low profile connector assembly for mounting to a substrate is provided. The connector assembly comprises a housing, first and second contacts each having a surface mount portion and a wire engagement portion extending from the surface mount portion, and a housing insertable over the first and second contacts and retained to the at least one contact. The housing encloses the wire engagement portion and has a first wire receiving aperture and a second wire receiving aperture each configured to receive respective wires. The wire engagement portions of the first and second contacts are configured to engage and retain the wires, wherein the first and second contacts define a low profile dimension of about 10 mm or less measured perpendicularly to the substrate on which the surface mount portions are to be mounted.
[0010] According to another exemplary embodiment, a low profile connector assembly for mounting to a substrate is provided. The connector assembly comprises a housing, and first and second contacts each having a surface mount portion and a wire engagement portion extending from the surface mount portion. Each wire engagement portion comprises a deflectable contact beam extending obliquely to a distal end of the surface mount portion. A housing is insertable over the first and second contacts and is retained to the first and second contacts. The housing encloses the contact beams and has a first wire receiving aperture and a second wire receiving aperture configured to receive respective wires. The contact beams deflect and clamp the wires within the housing.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 is a perspective view of a first exemplary embodiment of a low profile connector assembly formed in accordance with the present invention.
[0012] FIG. 2 is an exploded view of a second exemplary embodiment of a low profile connector assembly formed in accordance with the present invention.
[0013] FIG. 3 is an exploded view of a third exemplary embodiment of a low profile connector assembly formed in accordance with the present invention.
[0014] FIG. 4 is an exploded view of a fourth exemplary embodiment of a low profile connector assembly formed in accordance with the present invention.
[0015] FIG. 5 is a sectional view of a portion of FIG. 4 along line 5 - 5 .
[0016] FIG. 6 is an exploded view of a fifth exemplary embodiment of a low profile connector assembly formed in accordance with the present invention.
[0017] FIG. 7 is an assembled view of the connector assembly shown in FIG. 7 .
DETAILED DESCRIPTION OF THE INVENTION
[0018] While various embodiments low profile connectors are described below in an exemplary application of interfacing low voltage lighting devices, such as light emitting diode (LED) packages, it is understood that the low profile connector of the present invention may be beneficial in other applications as well. Low voltage lighting applications are but one potential application of the present invention, and the invention is not intended to be limited to any particular end use or application. The following embodiments are therefore provided for illustrative purposes only.
[0019] FIG. 1 is a perspective view of a first exemplary embodiment of a low profile connector assembly 100 formed in accordance with the present invention. The connector assembly 100 includes a substrate 102 , contacts 104 mounted to the substrate 102 , and a housing 106 inserted over the contacts 104 and retained thereto.
[0020] The substrate 102 is generally flat and planar, and in one embodiment is fabricated from aluminum or another substrate material familiar to those in the art. The contacts 104 are fabricated from a conductive material and in an illustrative embodiment include generally flat and planer surface mount portions 108 in an abutting relationship with the substrate 102 , and wire engagement portions 110 extending generally perpendicularly from the surface mount portions 108 . The wire engagement portions 110 in one embodiment are insulation displacement contact sections having a wire receiving channel 112 and upper edges (not shown in FIG. 1 ) configured to pierce outer insulation of a connecting wire (not shown in FIG. 1 ) in a manner known in the art. The insulation displacement sections of the contacts 104 allow connection to connecting wires of, for example, low voltage lighting devices and LED packages, without stripping the connecting wires of insulation and without hand soldered connections, and thus result in time and cost savings for installing the connector assembly 100 . The connector assembly 100 has an assembled configuration and a terminated configuration (achieved by downward insertion of the housing 106 in the direction of arrow A.
[0021] The housing 106 has T-shaped end walls 120 , 122 , front and rear sides 124 and 126 , and top and bottom surfaces 128 and 130 . The end walls 120 , 122 have a first width W 1 near the bottom surface 130 and a second width W 2 near the top surface 128 that is greater than the width W 1 . Due to the difference in widths W 1 and W 2 , overhanging ledges 129 are formed in the housing 106 between the top and bottom surface 128 and 130 .
[0022] Contact cavities 132 are formed in the housing 106 and extend from the top surface 128 to the underside of the overhanging ledges 129 opposite the top surface 128 . The contact cavities 132 receive the wire engagement portions 110 of the respective contacts 104 when the housing 106 is inserted downwardly over the contacts 104 in the direction of arrow A. The wire engagement portions 110 of the contacts 104 are retained to the housing 106 with an interference fit, or by other locking and latching arrangements known in the art.
[0023] The contacts 104 in the illustrated embodiment are arranged in first and second rows corresponding the housing cavities 132 , and accordingly the housing 106 includes three contact cavities 132 arranged in a row along the housing front side 124 , and two contact cavities arranged in a row along the housing rear side 126 . The contact cavities 132 along the rear side 126 are staggered or offset in relation to the contact cavities 132 extending along the front side 124 . As such, the housing 106 may accommodate five contacts 104 oriented in opposite directions along the housing front and rear sides 124 and 126 . Greater or fewer contact cavities 132 and associated contacts may be provided in similar or different arrangements in alternative embodiments.
[0024] The housing 106 further includes wire receiving apertures 134 in communication with the housing contact cavities 132 such that a connecting wire may be inserted through the wire receiving apertures 134 and into the contact cavities 132 . Once the wires are inserted in into the contact cavities 132 , the housing 106 may be fitted downwardly onto the contacts 104 from above. As the housing 106 is moved downward in the direction of arrow A, the wire engagement portions 110 of the contacts 104 are received in the contact cavities 132 through the overhanging ledges 129 , and the wires are brought into mechanical and electrical engagement with the wire engagement portions 110 of the contacts 104 . Because the wire engagement portions 110 include insulation displacement sections, the insulation displacement sections penetrate the wire insulation and the wire conductors are received in the wire channels 112 .
[0025] The connector 100 , in the assembled configuration, may be surface mounted to the substrate 102 using known surface mount soldering techniques. Wires are inserted into the apertures 34 and terminated to the contacts 104 by being pressed downward in the direction of arrow A to a terminated configuration. The wires, therefore, need not be individually terminated to the substrate 102 , but rather may be collectively and simultaneously engaged to the contacts 104 by virtue of the housing 106 . The wires need not be stripped of insulation, and tools are not necessary to connect the wires, thereby simplifying installation and reducing installation time and cost.
[0026] Further, because the wire engagement portions 110 of the contacts 104 extend upwardly in an L-shape configuration from the contact surface mount portions 108 , the connector assembly has a particularly low profile and is amenable for use with low voltage light sources, such as LED packages in distributed lighting assemblies. For example, the connector assembly 100 may extend for a total low profile dimension H, measured generally perpendicular from the top surface of the substrate 102 to the top surface 128 of the housing 106 , of about 10 mm or less, and thus, unlike known connectors, the connector assembly 100 may be used with low voltage lighting devices on the substrate 102 without creating shadows in the emitted light from the devices. In a particular embodiment, H is approximately 6.35 mm when the housing 106 is fully installed over the contacts 104 , although greater or lesser low profile dimensions H may be employed in other embodiments.
[0027] Additionally, the staggered contacts 104 and housing contact cavities 132 provides a compact, space saving configuration providing multiple connections in comparison to other known connectors.
[0028] FIG. 2 is an exploded view of a second exemplary embodiment of a low profile connector assembly 150 formed in accordance with the present invention.
[0029] The connector assembly 150 includes a substrate 152 , contacts 154 mounted to the substrate 152 , and a housing 156 inserted over the contacts 154 and retained thereto.
[0030] The substrate 152 is generally flat and planar, and in one embodiment is fabricated from aluminum or another substrate material familiar to those in the art. The contacts 154 are fabricated from a conductive material and in an illustrative embodiment include generally flat and planer surface mount portions 158 in an abutting relationship with the substrate 152 , and wire engagement portions 160 extending generally perpendicularly from the surface mount portions 158 . The wire engagement portions 160 in one embodiment are insulation displacement contact sections having a wire receiving channel 162 and upper edges 164 configured to pierce outer insulation of a wire 166 in a manner known in the art. The insulation displacement sections of the contacts 154 allow connection to connecting wires 166 of, for example, low voltage lighting devices, without stripping the wire of insulation, and thus result in time and cost savings for installing the connector assembly 150 .
[0031] The housing 156 has end walls 170 , 172 , front and rear sides 174 and 176 , and top and bottom surfaces 178 and 180 . Contact cavities 182 are formed in the housing 156 and extend from the top surface 178 through the bottom surface 180 . The contact cavities 182 receive the wire engagement portions 160 of the respective contacts 154 when the housing 156 is inserted downward over the contacts 154 in the direction of arrow B. The wire engagement portions 160 of the contacts 154 include an upper pair of notches 184 and a lower pair of notches 186 which cooperate with retaining features or projections in the housing cavities 182 to retain the housing 156 to the contacts 154 . More specifically, the upper notches 186 receive the housing retaining features at a first elevation relative to the substrate 152 , and the lower notches 186 receive the housing retaining features at a second elevation relative to the substrate 152 that is lower and closer to the substrate than the first elevation. When the housing is engaged to the upper notches 186 , wires 166 may be inserted into the housing 156 , and the housing may then be moved to downward in the direction of arrow B to engage the housing 156 to the lower notches 186 , wherein the wires are fully engaged to the contacts 154 .
[0032] The housing 156 includes wire receiving apertures 188 in communication with the housing contact cavities 182 such that a wire 166 may be inserted through the wire receiving apertures 182 and into the contact cavities 182 . Once the wires 166 are inserted into the contact cavities 182 , the housing 156 may be fitted downwardly onto the contacts 154 from above to enclose and protect the contacts 154 . As the housing 156 is moved downward in the direction of arrow B toward the contacts 154 , the wire engagement portions 160 of the contacts 154 are received in the contact cavities 182 and the wires are brought into mechanical and electrical engagement with the wire engagement portions 160 of the contacts 154 . Because the wire engagement portions 154 include insulation displacement sections, the insulation displacement sections penetrate the wire insulation and the wire conductors are received in the wire channels 162 .
[0033] The connector 150 , in a pre-assembled state wherein the housing 156 is engaged to the upper notches 184 of the contacts 154 , may be surface mounted to the substrate 152 using known surface mount soldering techniques. The wires 166 are then inserted into the housing 156 through the apertures 188 and into the contact cavities 182 . Once the wires 166 are inserted, the housing 156 may be moved downwardly to engage the lower notches 186 of the contacts 154 . Because of the insulation displacement sections of the contact wire engagement portions 160 , the wires 166 need not be individually terminated to the substrate 102 , but rather may be collectively and simultaneously engaged to the contacts 104 by virtue of the downward movement of the housing 106 . The wires 166 need not be stripped of insulation, and tools are not necessary to connect the wires, thereby simplifying installation and reducing installation time and cost.
[0034] Further, because the wire engagement portions 160 of the contacts 154 extend upwardly in an L-shape configuration from the contact surface mount portions 158 , the connector assembly 150 has a particularly low profile and is amenable for use with low voltage light sources, such as LED packages in distributed lighting assemblies. For example, the connector assembly 150 may extend for a total low profile dimension, measured generally perpendicularly from the top surface of the board to the top surface 178 of the housing 156 , of about 10 mm or less, although greater or lesser low profile dimensions H may be employed in other embodiments. Unlike known connectors, the connector assembly 150 may therefore be used with low voltage lighting devices on the substrate 102 without creating shadows in the emitted light from the devices.
[0035] FIG. 3 is an exploded view of a third exemplary embodiment of a low profile connector assembly 200 formed in accordance with the present invention. The connector assembly 200 is similar is some aspects to the connector assembly 150 (shown in FIG. 2 ). Like elements of the connector assembly 200 and the connector assembly 150 are therefore indicated with like reference characters in FIG. 3 .
[0036] The connector assembly 200 includes the substrate 152 , contacts 202 mounted to the substrate 152 , and a housing 156 inserted over the contacts 202 and retained thereto.
[0037] The contacts 202 are fabricated from a conductive material and in an illustrative embodiment include generally flat and planer surface mount portions 204 in an abutting relationship with the substrate 152 , and wire engagement portions 206 extending generally perpendicularly from the surface mount portions 204 . The wire engagement portions 206 in one embodiment are poke-in wire engagement sections having a generally rectangular frame 208 and deflectable contact fingers 210 extending inwardly from the frame 208 to define a four sided web extending from the inner periphery of the frame 208 . When a wire 212 is stripped of insulation 214 on one end thereof to expose inner conductors 216 of the wire, the conductors 216 are received through the inner web of the contact frame 208 and the fingers 210 are resiliently deflected around the respective sides of the conductors 216 to mechanically and electrically engage the conductors 216 to contacts 202 . The poke-in wire engagement portions 206 allow for termination of the wires 212 to the contacts 202 with relative ease, especially in comparison to hand soldered termination of the wires 212 which is common to known distributed lighting assemblies.
[0038] While the contacts 202 in the illustrated embodiment include four deflectable fingers 210 defining a contact web, it is understood that other numbers of contact fingers (e.g., two contact fingers) may likewise be employed in alternative embodiments while still achieving the benefits of the instant invention.
[0039] The housing 156 has end walls 170 , 172 , front and rear sides 174 and 176 , and top and bottom surfaces 178 and 180 . Contact cavities 182 are formed in the housing 156 and extend from the top surface 178 through the bottom surface 180 . The contact cavities 182 receive the wire engagement portions 206 of the respective contacts 202 when the housing 156 is inserted downward over the contacts 202 in the direction of arrow B. The wire engagement portions 206 of the contacts 202 are retained to the housing 156 with an interference fit in the contact cavities 182 , although it is appreciated that other retention features may be employed that are known in the art to retain the contacts 202 to the housing 156 .
[0040] The housing 156 includes wire receiving apertures 188 in communication with the housing contact cavities 182 such that a wire 212 may be inserted through the wire receiving apertures 182 and into the contact cavities 182 . Once the housing 156 is retained to the contacts 202 , wires 212 may be inserted though the housing apertures 188 to engage the wire receiving portions 206 of the contacts 202 . Because of the poke-in wire engagement portions 206 of the contacts 202 , the wires 212 may be reliably connected to the contacts with reduced installation time and cost.
[0041] Further, because the wire engagement portions 206 of the contacts 202 extend upwardly in an L-shape configuration from the contact surface mount portions 204 , the connector assembly 200 has a particularly low profile and is amenable for use with low voltage light sources, such as LED packages in distributed lighting assemblies. For example, the connector assembly 200 may extend for a total low profile dimension, measured generally perpendicularly from the top surface of the substrate 152 to the top surface 178 of the housing 156 , of about 10 mm or less, although greater or lesser low profile dimensions may be employed in other embodiments. Unlike known connectors, the connector assembly 200 may therefore be used with low voltage lighting devices on the substrate 152 without creating shadows in the emitted light from the devices.
[0042] FIG. 4 is an exploded view of a fourth exemplary embodiment of a low profile connector assembly 250 formed in accordance with the present invention.
[0043] The connector assembly 250 includes the substrate 152 , contacts 252 mounted to the substrate 152 , and a housing 254 inserted over the contacts 252 and retained thereto.
[0044] The contacts 252 are fabricated from a conductive material and in an illustrative embodiment include generally flat and planer surface mount portions 256 in an abutting relationship with the substrate 152 , and wire engagement portions 258 extending generally perpendicularly from the surface mount portions 256 . The wire engagement portions 258 in one embodiment are box clamp contact sections having a top wall 260 and opposite side walls 262 extending from the top wall 260 in a rectangular configuration. The side walls 260 and 262 include cutout portions or windows 264 therein which cooperate with latching features on the housing 254 to retain the housing 204 to the contacts 252 . The top wall 260 of the box clamp wire engaging portions 258 includes a deflectable contact beam 266 which clamps to conductors 216 of a wire 212 in the manner explained below.
[0045] The housing 254 has end walls 270 , 272 , front and rear sides 274 and 276 , and top and bottom surfaces 278 and 280 . Contact cavities 282 are formed in the housing 254 and extend from the top surface 278 through the bottom surface 280 . The contact cavities 282 receive the wire engagement portions 258 of the respective contacts 252 when the housing 254 is inserted downward over the contacts 252 in the direction of arrow B and the housing 254 is latched to the retention windows 264 of the contacts 252 . The housing 254 also includes wire receiving apertures 288 in communication with the housing contact cavities 282 such that a wire 212 may be inserted through the wire receiving apertures 288 , into the contact cavities 282 , and engaged to the wire engagement portions 258 of the contacts 252 .
[0046] FIG. 5 is a sectional view of one of the contacts 252 surface mounted to the substrate 152 , and illustrating the box clamp connection of one of the wires 212 to the wire engaging portion 258 . As seen in FIG. 5 , the top wall 260 of the wire engaging portion 258 includes the deflectable contact beam 266 extending obliquely from the top wall 260 into the path of the wire 212 when inserted between the side walls 262 of the box clamp section. The beam 266 is deflectable in the direction of arrow D away from the wire 214 and toward the top wall 260 when contacted by the conductors 216 of the wire 212 to a loading position indicated in phantom in FIG. 5 . A bottom wall 290 of the box clamp section includes a guide ramp 292 to guide the conductors 216 of the wire 212 into the beam 266 and toward the loading position. When the wire conductors 216 are sufficiently inserted between the contact side walls 262 , the contact beam returns 266 toward its original position, thereby clamping the wire conductors 216 between the contact beam 266 and the guide ramp 292 of the contact bottom wall 290 .
[0047] Because of the box clamp wire engagement portions 258 of the contacts 252 , the wires 212 may be reliably connected to the contacts with reduced installation time and cost. Further, the side walls 262 of the contact wire engagement portions 258 extend upwardly in a substantially perpendicular manner to the contact surface mount portions 256 , and the connector assembly 250 has a particularly low profile and is amenable for use with low voltage light sources, such as LED packages in distributed lighting assemblies. For example, the connector assembly 250 may extend for a total low profile dimension, measured generally perpendicular from the top surface of the substrate 152 to the top surface 278 ( FIG. 5 ) of the housing 254 of about 10 mm or less, although greater or lesser low profile dimensions may be employed in other embodiments. Unlike known connectors, the connector assembly 250 may therefore be used with low voltage lighting devices on the substrate 152 without creating shadows in the emitted light from the devices.
[0048] FIG. 6 is an exploded view of a fifth exemplary embodiment of a low profile connector assembly 300 formed in accordance with the present invention.
[0049] The connector assembly 300 includes the substrate 152 , contacts 302 mounted to the substrate 152 , and a housing 304 inserted over the contacts 302 and retained thereto.
[0050] The contacts 302 are fabricated from a conductive material and in an illustrative embodiment each contact 302 includes a generally flat and planer surface mount portion 306 in an abutting relationship with the substrate 152 , a housing engagement section 308 extending substantially perpendicular to the surface mount portions 306 , and a wire engagement portion 310 extending from the housing engagement section 308 .
[0051] The contact surface mount portions 306 are generally rectangular in an illustrative embodiment and lie in a common plane tangential to the substrate 152 . The housing engagement portion 308 of the contacts 302 are generally flat and planar and extend perpendicularly or in an L-shape configuration from the surface mount portions 306 . The housing engagement portions 308 include retaining projections or bumps 309 extending outwardly therefrom. The housing engagement portions 308 of the contacts 302 are received in slots (not shown) in the housing 304 and are retained thereto with an interference fit by virtue of the retaining projections or bumps 309 .
[0052] The wire engagement portions 310 of each contact 302 includes a deflectable contact beam 312 extending obliquely from the housing engagement section 308 and also extending over and vertically spaced from the surface mount portion 306 . The contact beams 312 extend along a longitudinal axis which is parallel to the surface mount portions 306 , and also extend obliquely to the edges of the surface mount portion 306 . That is, the contact beam 308 of each contact 302 extends at an angle with the each of the side edges of the rectangular surface mount portion 306 so that a distal end 313 of the contact beam 212 extends beyond and overhangs the distal end 315 of the surface mount portions 306 opposite the housing engagement portions 308 . In an exemplary embodiment, the contacts 302 are oriented inversely to one another in a mirror image arrangement with the contact beams 312 extending in opposite directions and away from one another. The contact beams 312 are constructed to pivot, rotate or deflect about a respective vertical axis 316 extending normally or perpendicularly to the surface mount portions 306 when engaged by a wire 212 . Stated another way, the contact beams 312 may rotate in the direction of arrow E about the axis 316 such that the longitudinal axis of the contact beams 312 are deflected in a plane parallel to the plane of the surface mount portions 306 when engaged by a wire 212 . That is, the distal ends 313 of the contact beams 212 are moved inwardly in the direction of arrows F and G toward the respective engagement portions 208 when engaged by a wire 212 , or more particularly the conductors 216 of the wire 212 .
[0053] The housing 304 has end walls 320 , 322 , front and rear sides 324 and 326 , and top and bottom surfaces 328 and 330 . Contact cavities (not shown in FIG. 6 ) are formed in the housing 320 and extend from the top surface 328 through the bottom surface 330 . The contact cavities receive the wire engagement portions 310 of the respective contacts 302 when the housing 304 is inserted downwardly over the contacts 302 in the direction of arrow B. The housing 320 also includes wire receiving apertures 332 in communication with the housing contact cavities such that a connecting wire 212 may be inserted through the wire receiving apertures 332 into the contact cavities and engaged to the wire engagement portions 310 of the contacts 302 . The connector 300 may be surface mounted to the substrate 152 using known surface mount soldering techniques.
[0054] FIG. 7 is an assembled view of the connector assembly 300 illustrating the contacts 302 secured to the housing 304 via the housing engagement portions 308 ( FIG. 6 ) and located in contact cavities 340 extending through the housing bottom surface 330 . The surface mount portions 306 of the contact 302 are exposed through the housing bottom surface 330 for surface mounting to the substrate 152 ( FIG. 6 ), and the contact beams 312 are angled toward the end walls 320 and 322 of the housing 304 such that the distal ends 313 of the contact beams 312 are located adjacent the respective housing end walls 320 and 322 . When a connecting wire 212 is passed through the wire receiving apertures 332 of the housing front side 324 , the wire conductors 216 deflect the contact beams 312 , and the wire conductors 216 are clamped between the distal ends 313 of the contact beams 212 and the housing end walls 320 , 322 .
[0055] The contact beams 312 provide for reliable connection to the contacts 302 with reduced installation time and cost. Further, the oblique contact beams 312 result in a particularly compact profile of the contacts 302 and the housing 304 . The connector assembly 300 is therefore amenable for use with low voltage light sources, such as LED packages in distributed lighting assemblies. For example, the connector assembly 300 may extend for a total low profile dimension H 1 , measured generally perpendicularly from the top surface of the substrate 152 ( FIG. 6 ) to the top surface 328 of the housing 304 of about 10 mm or less, and in a particular embodiment H 1 is about 3.28 mm and may therefore accommodate smaller lighting devices in comparison to known connectors. It is appreciated, however, that greater or lesser low profile dimensions H 1 may be employed in other embodiments. Unlike known connectors, the connector assembly 300 may therefore be used with low voltage lighting devices on the substrate 152 without creating shadows in the emitted light from the devices.
[0056] While the invention has been described in terms of various specific embodiments, those skilled in the art will recognize that the invention can be practiced with modification within the spirit and scope of the claims.
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A low profile connector assembly comprises at least one contact having a surface mount portion and a wire engagement portion extending from the surface mount portion, and a housing insertable over the at least one contact and retained to the at least one contact. The housing encloses the wire engagement portion and has a wire receiving aperture therethrough. The wire receiving aperture provides access to the wire engagement portion when the housing is retained to the contact.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation application of U.S. Ser. No. 11/531,042, filed Sep. 12, 2006, the disclosures of which are incorporated by reference herein in their entirety.
GOVERNMENT INTEREST
[0002] This invention was made with Government support under contract No.: NBCH3039004 awarded by Defense Advanced Research Projects Agency (DARPA). The government has certain rights in this invention.
TRADEMARKS
[0003] IBM® is a registered trademark of International Business Machines Corporation, Armonk, New York, U.S.A. Other names used herein may be registered trademarks, trademarks or product names of International Business Machines Corporation or other companies.
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] This invention relates to employing an instruction reorder buffer, and particularly to a technique that takes at least two processors that are optimized to execute dependence chains, and co-locate the processors with a superstructure called SuperROB (Super Re-Order Buffer).
[0006] 2. Description of Background
[0007] Many processors designed today are optimized for execution of tight dependence chains. A dependence chain is a sequence of instructions in a program in which a temporally sequential instruction is data-dependent on a temporally previous instruction. Examples of key data dependence paths that processors optimize are: load-compare-branch, load-load, load-compute, and compute-compute latencies. Examples of such processors are: the PPE (Power Processing Element) core on the Sony-Toshiba-IBM Broadband Engine, the IBM Power3 core, Itanium cores from Intel®, and almost all of the modem cores implementing z/Architecture technologies.
[0008] Current research in processor technology and computer architecture is motivated primarily by the desire for greater performance. Greater performance may be achieved by increasing parallelism in execution. There are two kinds of parallelism in typical program workloads. These are Instruction Level Parallelism (ILP) and Thread Level Parallelism (TLP). Some modem computer processors are specifically designed to capture ILP in programs (for example, IBM Power4 & 5, Intel Pentium), while multiprocessor systems are designed to capture TLP across threads or processes. Processor cores that are optimized to execute dependence chains are often also expected to execute ILP workloads. ILP workloads have more than one concurrent dependence chain, and overlapped execution of the chains is typically possible, provided the ILP between the chains has been exposed and exploited by the machine.
[0009] The evolution of microprocessor design has led to processors with higher clock frequencies to improve single-tread performance. These processors exploit ILP to speed up single-threaded applications. ILP attempts to increase performance by determining, at run time, instructions that can be executed in parallel. The trade-off is that ILP extraction requires highly complex microprocessors that consume a significant amount of power.
[0010] Thus, it is well known that different processor technologies utilize the ILP and TLP workloads differently to achieve greater processor performance. However, in existing ILP and TLP system architectures it is difficult to optimize the processor for both high-throughput TLP-oriented and ILP-oriented applications. It is very cumbersome to map ILP applications on one or more TLP cores. Thus, alternative processor architectures are necessary for providing ILP extraction on demand, for allowing global communication, for allowing efficient ILP exposition, extraction, and exploitation, and for efficiently operating across a plurality of TLP cores.
SUMMARY OF THE INVENTION
[0011] The shortcomings of the prior art are overcome and additional advantages are provided through the provision of a method for operating a plurality of processors that each includes an execution pipeline for processing dependence chains, the method comprising: configuring the plurality of processors to execute the dependence chains on execution pipelines; implementing a Super Re-Order Buffer (SuperROB) in which received instructions are re-ordered for out-of-order execution when at least one of the plurality of processors is in an Instruction Level Parallelism (ILP) mode and at least one of the plurality of processors has a Thread Level Parallelism (TLP) core; detecting an imbalance in a dispatch of instructions of a first dependence chain compared to a dispatch of instructions of a second dependence chain with respect to dependence chain priority; determining a source of the imbalance; and activating the ILP mode when the source of the imbalance has been determined.
[0012] The shortcomings of the prior art are overcome and additional advantages are provided through the provision of a system for operating a plurality of processors that each includes an execution pipeline for processing dependence chains, the system comprising: a network; and a host system in communication with the network, the host system including software to implement a method comprising: configuring the plurality of processors to execute the dependence chains on execution pipelines; implementing a Super Re-Order Buffer (SuperROB) in which received instructions are re-ordered for out-of-order execution when at least one of the plurality of processors is in an Instruction Level Parallelism (ILP) mode and at least one of the plurality of processors has a Thread Level Parallelism (TLP) core; detecting an imbalance in a dispatch of instructions of a first dependence chain compared to a dispatch of instructions of a second dependence chain with respect to dependence chain priority; determining a source of the imbalance; and activating the ILP mode when the source of the imbalance has been determined.
[0013] Additional features and advantages are realized through the techniques of the present invention. Other embodiments and aspects of the invention are described in detail herein and are considered a part of the claimed invention. For a better understanding of the invention with advantages and features, refer to the description and the drawings.
TECHNICAL EFFECTS
[0014] As a result of the summarized invention, technically we have achieved a solution that takes at least two processors that are optimized to execute dependence chains, and co-locate the processors with a superstructure called SuperROB (Super Re-Order Buffer).
BRIEF DESCRIPTION OF THE DRAWINGS
[0015] The subject matter, which is regarded as the invention, is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other objects, features, and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0016] FIG. 1 illustrates one example of an Instruction Level Parallelism (ILP) workload;
[0017] FIG. 2 illustrates one example of a Thread Level Parallelism (TLP) workload;
[0018] FIG. 3 illustrates one example of a Single Instruction, Multiple Data (SIMD) vector workload;
[0019] FIG. 4 illustrates one example of a TLP chip and a TLP & ILP Chip including a SuperROB;
[0020] FIG. 5 illustrates one example of an in-order core for the TLP workload;
[0021] FIG. 6 illustrates one example of a Super Re-Order Buffer (SuperROB);
[0022] FIG. 7 illustrates one example of a SuperROB operated in the TLP workload mode;
[0023] FIG. 8 illustrates one example of a SuperROB operated in the ILP workload mode;
[0024] FIG. 9 illustrates one example of a SuperROB per entry diagram;
[0025] FIG. 10 illustrates one example of a manner in which two cores are connected to each other by a SuperROB structure;
[0026] FIG. 11 illustrates one example of a SuperROB in ILP mode having an Ifetch working with a single trace cache line; and
[0027] FIG. 12 illustrates one example of a SuperROB shown as a series of queues.
DETAILED DESCRIPTION OF THE INVENTION
[0028] One aspect of the exemplary embodiments is a superstructure called SuperROB (Super Re-Order Buffer) that operates across a plurality of TLP cores. Another aspect of the exemplary embodiments is a method of mapping ILP applications on a TLP core by providing for ILP extraction on demand.
[0029] For a long time, the secret to more performance was to execute more instructions per cycle, otherwise known as ILP, or decreasing the effective latency of instructions. To execute more instructions each cycle, more functional units (e.g., integer, floating point, load/store units, etc.) had to be added. In order to more consistently execute multiple instructions, a processing paradigm called out-of-order processing (OOP) may be used. FIG. 1 illustrates one example of an ILP workload using such processing paradigm.
[0030] In FIG. 1 , there are three semi-independent chains of dependences that contain load instructions. Key data dependence paths that the processor optimizes are compute-compute latencies. Furthermore, high-accuracy branch prediction is usually a necessary condition to improve the performance of high-ILP workloads. In order to achieve high execution performance in a program area having high instruction-level parallelism, the processor contains large computational resources. On the contrary, in a program area having low instruction-level parallelism, even a processor containing small computational resources can achieve sufficient performance.
[0031] Furthermore, concerning FIG. 1 , the ILP program contains multiple chains of instructions such that the instructions in each chain are clearly data dependent upon each other, but the chains themselves are mostly data-independent of each other. As shown, there are three data-dependence chains in the program, and the first 10 and the third 14 chains of dependences are dependent on the last operation in the middle 12 chain. Chain 10 , in turn, dependent on the chain on the last operation in the rightmost chain, chain 14 . Across the three chains 10 , 12 , 14 , there is opportunity to overlap the execution of computation instructions with that of other computation instructions, and execution of long-latency memory accesses with other that of computations. It is usually necessary to provide highly accurate branch prediction hardware so as to be able to continue the supply of non-speculative instructions to the main pipeline. This nature of ILP programs can be exploited by processor hardware, which allows multiple-issue of data-independent instructions. Examples of processor hardware that falls in this category are: IBM Power4 and Power5 processors, AMD Opteron processor, and Intel Pentium4 processor.
[0032] FIG. 2 illustrates one example of a TLP workload. In FIG. 2 , there is one semi-independent chain of dependence that contains load instructions. The key data dependence path that the processor optimizes is a compute-compute latency. TLP is the parallelism inherent in an application that runs multiple threads at once. This type of parallelism is found largely in applications written for commercial servers, such as databases. By running many threads at once, these applications are able to tolerate the high amounts of I/O and memory system latency their workloads can incur. As a result, while one thread is delayed waiting for a memory or disk access, other threads can do ‘useful’ work in order to keep the processor running efficiently.
[0033] Furthermore, concerning FIG. 2 , the program in the center of the figure is a pure data-dependence chain 16 . Each instruction in the program is data-dependent on the immediately previous instruction. Thus, the execution of an instruction cannot begin until the result datum or the outcome of the previous instruction is available. The hardware complexity of processor hardware with multiple, independent instruction issue hardware capability proves to be unnecessary burden when executing a data-dependence chain program. In addition, thread-level parallelism in a multiprocessor architecture considerably depends on how efficient parallel algorithms are, as well as how efficient a multiprocessor architecture itself is. Scalability of the parallel algorithms is a significant characteristic since running large algorithms in the multiprocessor architecture is essential.
[0034] FIG. 3 illustrates a SIMD workload. In computing, SIMD (Single Instruction, Multiple Data) is a set of operations for efficiently handling large quantities of data in parallel, as in a vector processor or array processor. First popularized in large-scale supercomputers (as opposed to MIMD parallelization), smaller-scale SIMD operations have now become widespread in personal computer hardware. Today the term is associated almost entirely with these smaller units. An advantage is that SIMD systems typically include only those instructions that can be applied to all of the data in one operation. In other words, if the SIMD system works by loading up eight data points at once, the “add” operation being applied to the data occurs to all eight values at the same time. Although the same is true for any superscalar processor design, the level of parallelism in a SIMD system is typically much higher.
[0035] SIMD architectures are essential in the parallel world of computers. The ability of the SIMD to manipulate large vectors and matrices in minimal time has created a phenomenal demand of these architectures. The power behind this type of architecture can be realized when the number of processor elements is equivalent to the size of the vector. In this situation, component-wise addition and multiplication of vector elements can be done simultaneously. Even when the size of the vector is larger than the number of processor elements available, the speedup is immense. There are two types of SIMD architectures. The first is the True SIMD and the second is the Pipelined SIMD.
[0036] Furthermore, concerning FIG. 3 , the program is a data-parallel program, and is shown in the rightmost program representation. The instructions in a data-parallel program operate on data structures that are vectors, rather than scalars. Data-parallel programs can be either of the ILP nature, or may be a data-dependence chain.
[0037] The exemplary embodiments of the present invention provide a mechanism to “morph” a computer processor complex, each element of which is designed and optimized to perform work of one kind, into a complex, which can, with relatively high efficiency, perform another kind of work. In doing so, the processor complex transforms itself, on demand, into a single processing structure. Each pair of cores on the TLP chip is connected with each other using a SuperROB (super-instruction re-order buffer). The concept of SuperROB is an extension of the re-order buffer (ROB) used in modern ILP processors.
[0038] The SuperROB is shown as a queue 44 in FIG. 4 . The top portion of FIG. 4 is a TLP chip 40 and the bottom portion of FIG. 4 is a TLP & ILP chip 42 configuration. The basic idea is that when presented with an ILP program, the two cores transform themselves into behaving as one. Therefore, instructions are supplied to the two cores by means of the SuperROB and the state of each instruction is captured in a single entry in the SuperROB. Also, the architected state of the program is captured in the register file of one of the two cores. The SuperROB thus is a mechanism of global communication of program values, and a mechanism to expose, explore, and exploit the instruction-level parallelism inherent in an ILP program. The plurality of cores supplied for the purposes of TLP are combined in an innovative fashion to also target ILP programs.
[0039] FIG. 5 illustrates an in-order core for TLP workloads. FIG. 5 depicts an instruction memory 50 , instruction data 52 , stored data 54 , “data memory” data 56 , and a data memory 58 . In FIG. 5 , there are several semi-independent chains of dependences that contain load instructions. Key data dependence paths that the processor optimizes are compute-compute, load-to-use, and compare-to-branch latencies. Furthermore, the in-order processor comprises multiple execution pipelines, there is no register renaming in the processor pipeline, and no mechanism to enforce orderly completion of instructions to maintain sanctity of architectural state. Thus, the instructions are not issued out of order.
[0040] The out-of-order instruction processing in OOP necessitates a mechanism to store the instructions in the original program order. If a temporally later instruction causes an exception before a temporally earlier instruction, then the exception must be withheld from recognition until the temporally earlier instruction has completed execution and updated the architected state as appropriate. To help alleviate this problem, a larger number of instructions are stored in program order in a buffer called the re-order buffer to allow precise exception handling. While precise exception handling is the primary motivation behind having a reorder buffer, it has also been used to find more instructions that are not dependent upon each other. The size of reorder buffers has been growing in most modem commercial computer architectures with some processors able to store as many as 126 instructions in-flight. The reason for increasing the size of the reorder buffer is that spatially related code also tends to be temporally related in terms of execution (with the possible exclusion of arrays of complex structures and linked lists). These instructions also have a tendency to depend upon the outcome of prior instructions. With a CPU's ever increasing amount of required code, the only current way to find and accommodate the execution of more independent instructions has been to increase the size of the reorder buffer. However, using this technique has achieved a rather impressive downturn in the rate of increased performance and in fact has been showing diminishing returns. It is now taking more and more transistors to achieve the same rate of performance increase. Instead of focusing intently upon uniprocessor ILP extraction, it is desired to focus on super re-order buffers that may co-locate a plurality of buffers within a superstructure.
[0041] FIG. 6 illustrates one example of a Super Re-Order Buffer (SuperROB). FIG. 6 depicts a first instruction memory 60 , a first TLP core 62 , a first data memory 64 , a SuperROB 66 , a second instruction memory 68 , a second TLP core 70 , and a second data memory 72 . The SuperROB architecture provides for ILP extraction on demand, it operates across a plurality of TLP cores, it allows for global communication, and it allows for efficient ILP exposition, extraction, and exploitation. FIG. 6 shows two TLP cores that are separated by a buffer (SuperROB). The SuperROB acts as the communication mechanism between the two TLP cores. When the processor is in TLP mode, then the SuperROB is turned off When the processor is in ILP mode, then the SuperROB is turned on.
[0042] All contemporary dynamically scheduled processors support register renaming to cope with false data dependences. One of the ways to implement register renaming is to use the slots within the Reorder Buffer (ROB) as physical registers. In such designs, the ROB is a large multi-ported structure that occupies a significant portion of the die area and dissipates a sizable fraction of the total chip power. The heavily ported ROB is also likely to have a large delay that can limit the processor clock rate. However, by utilizing a SuperROB these delays may be minimized.
[0043] The method of using a reorder buffer for committing (retiring) instructions in sequence in an out of order processor has been fundamental to out of order processor design. In the case of a complex instruction set computer (CISC) architecture complex instructions are cracked (mapped) into sequences of primitive instructions. Nullification in case of an exception is a problem for these instructions, because the exception may occur late in the sequence of primitive instructions.
[0044] FIG. 7 illustrates one example of a SuperROB operated in the TLP workload mode and FIG. 8 illustrates one example of a SuperROB operated in the ILP workload mode. As noted above, in the TLP mode, the SuperROB is turned off However, in the ILP mode, the SuperROB is turned on in order to facilitate instruction management. Also, received instructions are received from at least two of the plurality of processors from a single input source. In other words, renaming based on a SuperROB uses a physical register file that is the same size as the architectural register file, together with a set of registers arranged as a queue data structure. This facilitates faster processing. Moreover, the cache may be accessed every alternate fetch cycle, thus providing even greater processing performance. The ICache is shared, and one of the cores (which one is a matter of convention) places requests for the two subsequent cache lines to fetch instructions from. “Next line A” is sent to the first core, and the ‘next-next line B’ is sent to the other core. The fetch logic for each of the two cores places their instructions in the SuperROB in the original program order. After that point in time, the available instructions in the SuperROB could be picked up and worked on by either of the two cores.
[0045] In FIG. 8 , as instructions are issued, they are assigned entries for any results they may generate at the tail of the SuperROB. That is, a place is reserved in the queue. Logical order of instructions within this buffer is maintained so that if four instructions are issued, e.g., i to i+3 at once, i is put in the reorder buffer first, followed by i+1, i+2 and i+3. As instruction execution proceeds, the assigned entry is ultimately filled in by a value, representing the result of the instruction. When entries reach the head of the SuperROB, provided they have been filled in with their actual intended result, they are removed, and each value is written to its intended architectural register. If the value is not yet available, then it is required for the user to wait until the value does become available. Because instructions take variable times to execute, and because they may be executed out of program order, it may be found that the SuperROB entry at the head of the queue is still waiting to be filled, while later entries are ready. In this case, all entries behind the unfilled slot must stay in the SuperROB until the head instruction completes its operations.
[0046] FIG. 9 shows the structure of each entry in the SuperROB. Each entry has a back or front pointer field, which is used by the ROB management hardware as a circular queue of ROB entries. That is followed by a set of status flags per entry, which indicate if the entry is being worked on by a core, or is available to be worked on. Next are two fields used exclusively to hold the prediction and the outcome of branch instructions. Next is a series of three fields, two for source register operands in the instruction, and one for the target register operand. Each source register field holds the id or number of the ROB entry that produced the value, which is useful in determining if the instruction is ready for execution. The target register field holds the architected register name into which the target register value must be committed when the instruction is retired. The value of the operand is also held along with each register field. For a store instruction which has no target register operand, the target register value is used to hold the datum to be stored in memory. More fields could be added on a per-instruction basis, and managed as needed.
[0047] Therefore, the processor, via the SuperROB, becomes a pure dataflow micro-architecture, where each entry in the SuperROB holds all the data pertaining to a single instruction in flight. The data contained may be source register values (as and when available), target register values (as values are produced), memory store values (for store instructions), and branch outcome values (predicates). The instructions are fetched in program order by using a protocol followed by two TLP front-ends, as illustrated in FIG. 9 . One SuperROB entry is allocated for each decoded instruction. Also, each fetched instruction could be from separate ICaches, Trace Cache or other cache types. As further shown in FIG. 9 , the decode logic of each pipeline operates independently of each other. Thus, both pipelines of cores A and B of FIG. 8 monitor the SuperROB, and pick up the work, and do the work when work is available. The results of the work are written back to the appropriate SuperROB entry.
[0048] Moreover, independently decoupled state machines operate in a purely dataflow fashion. In other words, a state machine decodes instructions to rename its source operands (to the temporally preceding SuperROB entry numbers, or fetch values from architected registers). The state machine also fetches values from SuperROB entries and updates the sources of the waiting instructions. The state machine also marks the instructions that are ready to be executed and dispatches instructions to the execution backend. The backend logic updates the appropriate SuperROB entry upon completion. As a result, there are no separate bypasses between the two independent execution backends and all the communication between the two pipelines is carried out via the SuperROB.
[0049] In addition, the exemplary embodiments of the present application are not limited to the structures in FIGS. 1-9 . In other words, more than two cores could be connected to ‘morph’ the processor. Also, it is possible to hold actual values in a separate future/history file (with or without a separate architected register file). The state machine may also fetch instructions every alternate cycle from the Icaches or from an Ifetch buffer. Therefore, there may be variations based on pre-decode information that is available from the ICaches. Also, a split of the SuperROB is possible. The split may be for a register data-flow and for a memory data-flow (separate load/store associative lookup queue). Furthermore, variations on the contents of SuperROB entries is allowed, variations based on the basic nature of the TLP core are allowed, and variations based on Simultaneous Multithreading Processor (SMT) or not-SMT is allowed.
[0050] Referring to FIG. 10 , a manner in which two cores, individually designed for efficient execution of data-dependence chain code, are connected to each other by means of the SuperROB structure. The SuperROB is a queue of instructions, with each entry also holding other information about the instruction. The computer system operates in either TLP (thread-level parallel) mode, or ILP mode. When in TLP mode, it is understood that the programs to be executed on the system are data-dependence chains programs. When in ILP mode, the programs to be executed on the system are ILP programs. The SuperROB is disabled when the computer is in TLP mode, and it is enabled when the computer is in ILP mode. Change of mode could be carried out in a variety of ways, for example, under explicit control of the programmer, or under implicit control of the OS or the HyperVisor, or under pure hardware control with the processor having monitoring hardware that watches the amount of dependence nature of instructions temporally and switches the mode from TLP to ILP or vice-versa.
[0051] Referring to FIG. 11 , in the ILP mode, the instruction fetch logic is shown working with a single trace cache line A (prediction for which is supplied by one of the two cores). The trace cache now holds a single ILP program (which is unified rather than shared as in the TLP mode). Parts of the trace line are placed in SuperROB by one core, and the remaining part is placed by the other core.
[0052] Referring to FIG. 12 , the SuperROB is shown as a series of queues, the previous queue feeding the next, as a physical implementation of a logically single SuperROB structure. This could work with a regular ICache or a trace cache.
[0053] Moreover, instructions are placed in the SuperROB, in program order, by one or both the IFetch stages of logic connected to it. Once placed in the SuperROB, the Decode stages of logic from both the cores carry out the task of instruction decode, and update the status of instructions. The Issue logic stages from the two cores pick up decodes instructions, and issue them to their respective execution back-ends. One of the two register files is used to hold the architected state of the program, which one, is decided by convention. The other one is not used. When an instruction completes execution on either of the Execute logic stages or the Access logic stages, the instruction's status is updated in the SuperROB. This general manner of execution continues until the mode of the machine remains the ILP mode. It is to be generally understood that the ICache shown in the figure above holds a single program for execution when in ILP mode.
[0054] The capabilities of the present invention can be implemented in software, firmware, hardware or some combination thereof
[0055] As one example, one or more aspects of the present invention can be included in an article of manufacture (e.g., one or more computer program products) having, for instance, computer usable media. The media has embodied therein, for instance, computer readable program code means for providing and facilitating the capabilities of the present invention. The article of manufacture can be included as a part of a computer system or sold separately.
[0056] Additionally, at least one program storage device readable by a machine, tangibly embodying at least one program of instructions executable by the machine to perform the capabilities of the present invention can be provided.
[0057] The flow diagrams depicted herein are just examples. There may be many variations to these diagrams or the steps (or operations) described therein without departing from the spirit of the invention. For instance, the steps may be performed in a differing order, or steps may be added, deleted or modified. All of these variations are considered a part of the claimed invention.
[0058] While the preferred embodiment to the invention has been described, it will be understood that those skilled in the art, both now and in the future, may make various improvements and enhancements which fall within the scope of the claims which follow. These claims should be construed to maintain the proper protection for the invention first described.
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A method and a system for operating a plurality of processors that each includes an execution pipeline for processing dependence chains, the method comprising: configuring the plurality of processors to execute the dependence chains on execution pipelines; implementing a Super Re-Order Buffer (SuperROB) in which received instructions are re-ordered after out-of-order execution when at least one of the plurality of processors is in an Instruction Level Parallelism (ILP) mode and at least one of the plurality of processors has a Thread Level Parallelism (TLP) core; detecting an imbalance in a dispatch of instructions of a first dependence chain compared to a dispatch of instructions of a second dependence chain with respect to dependence chain priority; determining a source of the imbalance; and activating the ILP mode when the source of the imbalance has been determined.
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PRIORITY CLAIM TO EARLIER FILED APPLICATION
This application claims priority from Provisional Patent Application No. 60/270,657, filed Feb. 22, 2001.
BACKGROUND OF THE INVENTION
The instant invention relates a switch mechanism that has an improved method of operation for use in flashlights. More specifically, this invention relates to an internal, inline switch mechanism for a flashlight that operates in a reverse direction to increase the reliability of the switch and provide an extended switch contact duration.
Flashlights of varying sizes and shapes are well known in the art. A number of such designs are known that utilize two or more batteries as their source of electrical energy, carried in series in a tubular body, where the tubular body also serves as a handle for the flashlight. Typically, an electrical circuit is established from one terminal of the battery, through a conductor to an external switch and then through another conductor to one contact of a bulb. After passing through the filament of the bulb, the electrical circuit emerges through a second contact of the bulb in electrical contact with a conductor, which in turn is in electrical contact with the flashlight housing. The flashlight housing provides an electrically conductive path to the other terminal at the rear of the battery. Actuation of the external switch completes the electrical circuit enabling electrical current to pass through the filament of the bulb, thereby generating light that is then typically focused by a reflector to form a beam of light.
In general, these flashlight switch mechanisms operate in two basic manners. The first mechanism is a pushbutton type switch on the side or bottom of the light. The user depresses the switch, which locks into the engaged position, turning the flashlight on. To turn the light off, the user again depresses the switch, unlocking it and turning the light off. Often, if a watertight seal is desired, a rubberized material is installed into the body of the flashlight as a covering over the switch mechanism. This design has several drawbacks. One drawback is that the increased number of parts creates additional assembly steps and increases the difficulty of assembly process. Another drawback is the possibility of leaks developing as the rubber membrane wears out from the stretching action resulting from continuous use.
In an attempt to resolve the drawbacks noted above with respect to the push-button type switches, a second type of rotatable switch was developed for in-line use in flashlights. In one design, an end cap is rotatably secured to the flashlight body. To establish the required electrical contact, the end cap is rotated making contact to illuminate the lamp bulb. A number of such prior art designs feature rotatable end caps which are rotated to move the batteries longitudinally within the flashlight body towards the lamp bulb, thereby causing contact between the battery contact and the base contact of the lamp bulb. In the open position, the battery is typically spring biased away from the base contact of the bulb.
In other designs, miniature flashlights have been designed where the rotatable switch is located in the reflector end of the flashlight body. The lamp bulb is located within an insulated receptacle at the reflector end of the flashlight with one or more conductive pins being rotatably aligned by movement of the switch portion of the device to establish electrical contact. While these switch mechanisms are internal to the device and thus less subject to damage, they are overly complicated in design and more costly to manufacture and require higher assembly tolerances.
In addition, the types of switches described above all generally operate in a forward direction, meaning that as the user turns the head or tail of the flashlight, tightening it onto the body of the flashlight, switch contact is eventually made thereby turning the flashlight on. Electrical contact, in this type of switch, is achieved by bringing a spring contact on the inside of the flashlight into contact with one pole of the battery contained within the body. These types of switches are problematic because the components of the flashlight are not always firmly holding the batteries in place. For example, when the flashlight is in the off position, the head is generally partially unscrewed from the body of the flashlight, preventing the spring on the back of the head from contacting the battery. This arrangement, however, also prevents the battery from being restrained, allowing the battery to freely float within the flashlight body. In addition, the range of switch contact is very limited, thus providing a very low tolerance switch mechanism that does not operate smoothly.
It is therefore and object of the present invention to provide an improved flashlight switching mechanism that is entirely self contained and completely waterproof. It is a further object of the present invention to provide a switching mechanism for a flashlight that has improved operating characteristics, such as increased contact duration and smoother operation. It is yet another object of the present invention to provide an in-line flashlight switching mechanism that is completely enclosed within the body of a flashlight thereby eliminating the possibility of contamination and damage from external forces.
SUMMARY OF THE INVENTION
In this regard, and in furtherance of the above stated objectives, the present invention provides a unique inline switch mechanism that is fully integrated into a flashlight head to provide a completely self contained and waterproof switching mechanism. The present invention further provides an inline flashlight switch mechanism that operates in a reverse direction whereby the switch makes electrical contact as the flashlight head is unscrewed. This is in contrast to the above-described switches that generally operate in a forward direction. This manner of operation allows the present invention to provide an extended operational range of positive electrical contact duration, while also producing a smoothly operating switch having broad operational tolerance.
The basic structure of the switch contains several operational components including a switch housing, a contact tube, a plunger, a contact spring, an insulator disk and a secondary spring. All of the components are electrically conductive with the exception of the insulator disk and the switch housing. The switch housing contains all of the other operational components of the switch and serves to selectively isolate them electrically from the body of the flashlight. In the off position, the plunger floats, centered in the contact tube, with the contact end in electrical communication with the battery. The contact spring is disposed around and is frictionally retained at the end of the plunger opposite the contact end. Both the plunger and the contact spring are in electrical communication thereby making the contact spring and plunger electrically hot. The insulator disk is installed onto the back of the plunger, supporting in the center of the contact tube and electrically isolating it from the walls of the contact tube. The insulator disk is also disposed between the plunger and the secondary spring electrically isolating these two components from one another as well. The secondary spring at one end exerts pressure on the insulating disk and thereby on the plunger maintaining the plunger in contact with the battery at all times during the operational range of the switch. At the other end, the secondary spring is in electrical communication with one contact of the LED bulbs and is also in electrical communication with the walls of the contact tube.
In a normally open position, the contact spring is displaced from the bottom wall of the contact tube. As the flashlight head is unscrewed the switch mechanism, retained within the head of the flashlight, moves away from the batteries while the plunger remains in place in contact with the battery due to the force of the secondary spring. Once the head is displaced far enough, the bottom wall of the contact tube comes into electrical communication with the contact spring allowing electricity to flow to the LED's. Since the spring force of the contact spring is less than that of the secondary spring, the contact tube continues to move, further compressing the contact spring while maintaining contact with the contact spring and keeping the contact end of the plunger in electrical communication with the battery as the flashlight head is turned through several rotations.
Other objects, features, operational details and advantages of the invention shall become apparent as the description thereof proceeds when considered in connection with the accompanying illustrative drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
In the drawings which illustrate the best mode presently contemplated for carrying out the present invention:
FIG. 1 is a perspective view of a flashlight containing the reverse operating switch mechanism of the present invention;
FIG. 2 is an exploded perspective view thereof;
FIG. 3 is a cross-sectional view of the flashlight of the present invention in FIG. 1 along the section line 3 — 3 in the normally open, off position; and
FIG. 3 a is a cross-sectional view of the flashlight of the present invention in FIG. 1 along the section line 3 — 3 in the closed, on position.
DETAILED DESCRIPTION OF THE INVENTION
Referring now to the drawings, a completed flashlight assembly incorporating the reverse-acting switch mechanism of the present invention is generally indicated at 12 in FIGS. 1 — 3 a. While the reverse switch mechanism is shown incorporated into a flashlight in the description of the preferred embodiment, the present disclosure provides that the switch mechanism described can be incorporated into a variety of other devices that require an inline switch having the same or similar operational characteristics. As will hereinafter be more fully described, the present invention provides a fully contained waterproof inline flashlight switch that provides improved operating features, higher durability and easier assembly as compared to similar flashlights in the prior art. The entire assembly is contained in a simple housing to provide a useful, novel and improved light source.
The flashlight 12 generally includes an elongated housing 14 , batteries 16 disposed in the housing 14 , and a flashlight head portion 10 .
The flashlight head 10 has an outer enclosure 18 that at least partially encloses at least one light emitting diode (LED) 20 , and a circuit component 22 , as well as the reverse switch assembly.
The reverse switch assembly is best shown in FIG. 2, and includes a spring 24 , an insulator disk 26 , a contact spring 28 , a plunger 30 , a contact tube 32 , and a switch housing 34 . The flashlight head 10 further includes a lower enclosure 36 assembled in a permanent fashion to the outer enclosure 18 to enclose both the switching assembly and light source 20 of the flashlight 12 inside the flashlight head 10 .
Turning to FIG. 1 an assembled view of the flashlight 12 of the present invention is shown. The outer shape of the flashlight 12 is formed by the battery housing 14 and the outer enclosure 18 of the flashlight head 10 where the battery housing 14 also serves as the handle for the flashlight 12 . Both the battery housing 14 and the outer enclosure 18 are formed of a metallic material such as milled aluminum or stainless steel. This allows both of these components to be electrically conductive and employed as components of the overall circuitry of the flashlight 12 as will be further described below.
FIG. 2 shows the flashlight 12 and the flashlight head 10 of the present invention in an exploded perspective view, illustrating the general relationship between all of the components in the overall device. The battery housing 14 is generally tubular in shape having a closed bottom and an open top. The battery housing 14 is generally hollow with an opening 38 that is of a diameter particularly suited to receive batteries 16 . In the preferred embodiment, the battery housing 14 is shown of a dimension to accept two batteries 16 , however, the present invention will operate equally well using one, three, four or more batteries 16 and the length of the battery housing 14 will be adjusted accordingly to accommodate the number of batteries 16 used. The inner surface of the open end 38 of the battery housing 14 has female threads 40 that are designed to engage corresponding male threads 42 on the lower enclosure 36 thereby maintaining the flashlight 12 in an assembled condition and allowing the head portion 10 to be rotated relative to the battery housing 14 . Rotation of the head 10 relative to the housing 14 selectively adjusts the relative positions to one another. When the batteries 16 are installed into the battery housing 14 one contact of the battery 16 is in electrical communication with the bottom of the battery housing 14 . Since the battery housing 14 is metallic, electricity is therefore conducted from the battery 16 contact, through the bottom of the battery housing 14 and up through the battery housing 14 into the flashlight head 10 as will be further described below.
The head 10 portion of the flashlight 12 has an outer enclosure 18 that receives and houses all of the switching components and the light source of the flashlight. The outer enclosure 18 is also formed of a machined metallic material that is electrically conductive, such as machined aluminum or stainless steel. The outer enclosure 18 is cylindrically shaped, having an opening at one end into which all of the remaining components are installed and several smaller openings 44 at the other end through which the installed LED lamps 20 protrude. Circuit assembly 22 is typically a printed circuit board onto which the LED lamps 20 are mounted. The circuit assembly 22 has circuit traces connecting one pole of each LED 20 to a metal connection tab 46 and the other pole of each LED 20 to a central connection point 52 on the bottom surface of the circuit assembly 22 . Once the LED lamps 20 are installed onto the circuit assembly 22 , it is slid into the opening in the outer enclosure 18 , so that the LED lamps 20 protrude through the openings 44 in the outer enclosure 18 . The connection tab 46 is in electrical communication with the wall of the outer enclosure 18 , thereby completing a path of electrical conductivity from the first contact of battery 16 , through the battery housing 14 up into the outer enclosure 18 of the head and into the circuit assembly 22 through connection tab 46 . The remaining portion of the electrical circuit is completed through the switch components as will be discussed below. In addition to providing paths of conductivity to each of the LED lamps 20 , the circuit assembly 22 may also include additional circuitry for controlling the flow of current through the LED lamps 20 or to provide additional functionality, such as flashing, to the flashlight 12 .
The principal component of the switch mechanism is plunger 30 . The plunger 30 is substantially cylindrical and formed from a metallic material such as machined brass. One end of the plunger 30 is in contact with the second contact end of the battery 16 when the flashlight 12 is fully assembled. The opposite end of the plunger has a raised shoulder 48 . The raised shoulder 48 serves to retain contact spring 28 in an operative position on the plunger 30 . During assembly, the contact spring 28 is slid onto the plunger 30 and is pressed onto the raised shoulder 48 so that the spring is frictionally retained and in firm electrical communication with the plunger 30 . Further, insulator disk 26 is attached to the end of the plunger 30 opposite the battery 16 contact. This sub-assembly (plunger 30 , contact spring 28 and insulator disk 26 ) is then slid into contact tube 32 .
Contact tube 32 is a cylindrically shaped tube that is open on the top end and has a bottom wall. The bottom wall has an opening 54 that has a diameter slightly greater than the diameter of the plunger 30 . The remaining portion of the bottom wall forms switch contact 50 . The plunger 30 , contact spring 28 and insulator disk 26 are slid into the open end of the contact tube allowing the contact end of the plunger to protrude through the opening 54 in the bottom wall of the contact tube 32 without making physical or electrical contact with switch contact 50 . In this regard, the insulator disk 26 is sized to have a diameter that is only slightly smaller than the diameter of the contact tube 32 . This allows the insulator disk 26 to slide freely up and down inside the contact tube 32 while supporting the plunger 30 in the center of the contact tube 32 and preventing the plunger 30 from contacting the sides of the contact tube 32 . The insulator disk 26 is formed from a non-conductive material and is preferably a plastic material. Biasing spring 24 is then installed into the contact tube 32 behind the insulator disk 26 . The biasing spring 24 has a diameter that is also only slightly smaller than the inner diameter of the contact tube 32 and is in electrical communication with the inner walls of contact tube 32 and with the central connection point 52 on the circuit assembly 22 when the entire flashlight head 10 is assembled. The contact tube 32 including the switch components described above is installed into the switch housing 34 , which consists of cylindrical support housing that is electrically insulative and designed to isolate contact tube 32 from the rest of the flashlight head assembly 10 .
The switch housing 34 , after the above-described assembly, is then placed into the lower enclosure 36 . The lower enclosure 36 is a metallic component having an opening in its center into which the entire switching assembly is placed. The lower enclosure has an opening in its center to allow the plunger 30 to protrude and contact the battery 16 in an assembled position. The lower enclosure 36 also has male threads 42 that correspond to the female threads 40 on the interior of the battery housing 14 . To complete the assembly of the head 10 , the lower enclosure 36 containing all of the switching components, is pressed into the outer enclosure 18 using a hydraulic press (not shown) or similar method known in the art. This provides a completed flashlight head 10 that is sealed, having no parts that are accessible by the user. The head 10 is then threaded into the battery housing 14 , which already contains batteries 16 to complete the assembly of the flashlight 12 . To further seal the flashlight assembly 12 and prevent water infiltration, an O-ring gasket 56 is provided in a groove 58 in the side of lower enclosure 36 . The O-ring gasket 56 serves to seal the operable junction between the flashlight head 10 and the battery housing 14 prevent infiltration of water or other contaminants. Additionally, sealant 60 in the form of a UV curable potting compound is installed in the gap between the LED lamps 20 and the openings 44 in the outer enclosure 18 to further prevent infiltration to the interior of the flashlight 12 .
Turning to FIGS. 3 and 3 a , a section is shown of the flashlight 12 of the present invention in the operational state. FIG. 3 shows the flashlight 12 in the normally open, off state, and FIG. 3 a shows the flashlight 12 in the closed, on state. In FIG. 3 the flashlight head 10 is shown threaded completely into the battery housing 14 . In this state, as can be seen, there is a gap between contact spring 28 and the bottom surface of the switch contact 50 . This gap is a break in the electrical circuit of the flashlight 12 and prevents the batteries 16 from energizing the LED lamps 20 . While plunger 30 is spring biased by the force of spring 24 in the direction of the batteries 16 , it is not allowed to move in the direction of the batteries 16 because of the proximity of the batteries 16 to the flashlight head 10 . In other words, when the flashlight head 10 is screwed entirely onto the battery housing 14 , the batteries 16 force the plunger upwardly against spring 24 . Because the spring 28 is connected to the top of the plunger, the contact spring 28 is moved out of electrical contact with the bottom of the contact tube 32 .
In FIG. 3 a, the battery housing 14 is shown as being slightly unscrewed from the flashlight head 10 as indicated by the arrow 62 , or vice versa, the head 10 is unthreaded from the body 14 . This displacement of the battery housing 14 results in displacement of the batteries 16 from the flashlight head 10 by the same distance. Since the plunger 30 is spring biased in the direction of the batteries 16 by spring 24 , this linear displacement of the batteries 16 allows the spring 24 to expand and thus displace the plunger 30 rearwardly by the same distance as the battery housing 14 and the batteries 16 . Once the distance of displacement of the plunger 30 is sufficient, the contact spring 28 comes into contact with switch contact 50 . When this contact is made it can be seen that a complete electrical circuit is provided starting at the top battery 16 contact through the plunger 30 , the contact spring 24 , switch contact 50 , contact tube 32 , secondary spring 24 , central contact 52 , into the circuit assembly 22 and the LED lamps 20 , through contact tab 46 , back into the outer housing 18 , through the lower housing 36 , into the battery housing 14 and finally to the bottom contact of battery 16 . Therefore, by translating the battery housing 14 in a rearward direction 62 from the flashlight head 10 an electrical circuit is completed thereby energizing the flashlight 12 .
It can also be seen in FIG. 3 a that at the point where contact spring 28 initially contacts switch contact 50 , the contact spring 28 is not compressed. Since the spring force in the secondary spring 24 is greater than the spring force in the contact spring 28 , further displacement of the battery housing 14 and batteries 16 in the rearward direction 62 allows the plunger 30 to also be further displaced in the rearward direction 62 . As the plunger 30 is further displaces by secondary spring 24 , contact spring 28 is further compressed allowing the plunger 30 to remain in contact with the battery 16 until the contact spring 28 is completely compressed. The use of the contact spring 28 and secondary spring 24 in this manner provide for the extended operational range provided for under the present invention.
It can therefore be seen that the instant invention provides a compact inline flashlight switching mechanism that is fully enclosed and sealed against infiltration of water of other contaminants. It can be further seen that the present invention provides a novel reverse acting switch design that provides for smooth operation and an extended operational range through the use of spring contacts. For these reasons, the instant invention is believed to represent a significant advancement in the art, which has substantial commercial merit.
While there is shown and described herein certain specific structure embodying the invention, it will be manifest to those skilled in the art that various modifications and rearrangements of the parts may be made without departing from the spirit and scope of the underlying inventive concept and that the same is not limited to the particular forms herein shown and described except insofar as indicated by the scope of the appended claims.
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The present invention discloses an inline switch mechanism that operates in a reverse direction, making electrical contact as the flashlight head is unscrewed. The switch has an outer housing, an inner contact tube, a plunger, a contact spring, an insulator disk and a secondary spring. All of the components are electrically conductive with the exception of the insulator disk and outer housing. In the off position, the plunger floats, centered in the contact tube, with a contact end in electrical communication with the battery. A contact spring is disposed around and in electrical communication with the plunger. The insulator disk is on the back of the plunger supporting it and isolating it from the contact tube and is disposed between the plunger and the secondary spring. The secondary spring at one end exerts pressure on the insulating disk and thereby the plunger maintaining contact on the battery and at the other end contacts one side of the LED bulbs and is in electrical communication with the contact tube.
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CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application claims the benefit of Korean Patent Application No. 10-2009-0116790, filed on Nov. 30, 2009, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein by reference.
BACKGROUND
[0002] 1. Field of the Invention
[0003] The present invention relates to a hybrid prediction apparatus and method for entropy to encoding, and more particularly, to a hybrid prediction apparatus and method that may include and selectively a plurality of predictors to perform a per-pixel prediction with respect to an image frame.
[0004] 2. Description of the Related Art
[0005] Generally, an entropy encoding scheme indicates a scheme that may perform a prediction using a correlation between pixels of an image, and may encode a difference between the pixels of the image.
[0006] In the case of a conventional entropy encoding scheme, an H.264 standard of the International Telecommunication Union Telecommunication Standardization Sector (ITU-T)-affiliated Video Coding Expert Group (VCEG), a Moving Picture Expert Group (MPEG)-4 part10 Advanced Video Coding (AVC) standard of the International Organization for Standardization/International Electrotechnical Commission (ISO/IEC)-affiliated MPEG, and the like have been proposed as standards for a video compression scheme.
[0007] The video compression scheme may be configured as a Context Adaptive Variable Length Coding (CAVLC) scheme, a Context Adaptive Binary Arithmetic Coding (CABAC) scheme, and the like.
[0008] However, a substantially compressed image may have a different compressibility according to a performance of a predictor used for each compression scheme and a corresponding configuration scheme. The predictor may cause an excessive prediction error according to a type of the predictor or a characteristic of the predictor.
SUMMARY
[0009] An aspect of the present invention provides a hybrid prediction apparatus and method for entropy encoding that may enhance an existing image compression scheme and prediction scheme by including and selectively using a plurality of predictors configured to perform a per-pixel prediction of an image frame.
[0010] Another aspect of the present invention also provides a hybrid prediction apparatus and method for entropy encoding that may supplement a performance of a used prediction scheme by comparing and analyzing prediction patterns with respect to the same pixel, and thereby using a prediction pattern having a relatively small amount of errors.
[0011] According to an aspect of the present invention, there is provided a hybrid prediction apparatus for entropy encoding, the apparatus including: at least two predictors, each to output a prediction pattern with respect to an input image frame using a correlation between pixels of the image frame; a selection processor to acquire per-pixel errors of prediction patterns output by the at least two predictors, and to thereby select, from among the output prediction patterns, a prediction pattern having a relatively small amount of errors; and an entropy coder to perform entropy encoding of the selected prediction pattern.
[0012] Each of the at least two predictors may output the prediction pattern of the image frame using a median edge detector (MED) scheme or a gradient-adjusted predictor (GAP) scheme.
[0013] The per-pixel error may correspond to a sum of an absolute difference (SAD) between a prediction value of each pixel and an actual pixel value.
[0014] The selection processor may include: a counting unit to count a predetermined value through a comparison for the at least two predictors by acquiring the per-pixel errors of the prediction patterns; and a selector to select the prediction pattern having the relatively small amount of errors from among prediction patterns with respect to the same pixel, using a counting result of the counting unit.
[0015] The counting unit may compare the per-pixel errors of the prediction patterns output by the at least two predictors to increase a count value of a prediction pattern of a predictor having a relatively small per-pixel error.
[0016] According to another aspect of the present invention, there is provided a hybrid prediction method of a hybrid prediction apparatus including at least two predictors, the method including: predicting, by each of the at least two predictors, a prediction pattern with respect to an input image frame using a correlation between pixels of the image frame; analyzing per-pixel errors of output prediction patterns to select, from among the output prediction patterns, a prediction pattern having a relatively small amount of errors; and performing entropy encoding of the image frame using the selected prediction pattern.
[0017] The predicting may include outputting the prediction pattern of the image frame using a MED scheme or a GAP scheme.
[0018] The per-pixel error corresponds to a sum of an SAD between a prediction value of each pixel and an actual pixel value.
[0019] The analyzing and the selecting may include: counting a predetermined value through a comparison for the at least two predictors by acquiring the per-pixel errors of the prediction patterns; and selecting the prediction pattern having the relatively small amount of errors from among prediction patterns with respect to the same pixel, using the count value.
[0020] The counting may include comparing the per-pixel errors of the prediction patterns output by the at least two predictors to increase a count value of a prediction pattern of a predictor having a relatively small per-pixel error.
EFFECT
[0021] According to embodiments of the present invention, even though an excessive prediction error occurs due to a particular pixel or a particular pattern when compressing an image, it is possible to achieve a mutual supplementation by employing a prediction pattern according to a different prediction scheme.
[0022] Also, according to embodiments of the present invention, it is possible to effectively compress an image and to reduce a capacity of the compressed image by selectively using a plurality of compression schemes.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] These and/or other aspects, features, and advantages of the invention will become apparent and more readily appreciated from the following description of exemplary embodiments, taken in conjunction with the accompanying drawings of which:
[0024] FIG. 1 is a block diagram illustrating a configuration of a hybrid prediction apparatus according to an embodiment of the present invention;
[0025] FIG. 2 is a diagram illustrating an example of a count value of a first predictor of FIG. 1 ;
[0026] FIG. 3 is a diagram illustrating an example of a count value of a second predictor of FIG. 1 ;
[0027] FIG. 4 is a flowchart illustrating an operation of a hybrid prediction apparatus according to an embodiment of the present invention; and
[0028] FIG. 5 is a flowchart illustrating a detailed process of selecting a prediction pattern of FIG. 4 .
DETAILED DESCRIPTION
[0029] Reference will now be made in detail to exemplary embodiments of the present invention, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. Exemplary embodiments are described below to explain the present invention by referring to the figures.
[0030] When it is determined detailed description related to a related known function or configuration they may make the purpose of the present invention unnecessarily ambiguous in describing the present invention, the detailed description will be omitted here.
[0031] Also, terms used herein are defined to appropriately describe the exemplary embodiments of the present invention and thus may be changed depending on a user, the intent of an operator, or a custom. Accordingly, the terms must be defined based on the following overall description of this specification.
[0032] FIG. 1 is a block diagram illustrating a configuration of a hybrid prediction apparatus 10 according to an embodiment of the present invention.
[0033] Referring to FIG. 1 , the hybrid prediction apparatus 10 may include a first predictor 100 , a second predictor 200 , a selection processor 300 , and an entropy coder 400 .
[0034] When a predetermined image frame is input, each of the first predictor 100 and the second predictor 200 may output a prediction pattern using a correlation between pixels of the image frame.
[0035] In the case of the first predictor 100 and the second predictor 200 , at least two predictors may be provided and thereby employ different compression schemes. In the present embodiment, it is assumed that the first predictor 100 employs a median edge detector (MED) scheme of predicting a pixel value of the image frame and outputting three prediction patterns, and the second predictor 200 employs a gradient-adjusted predictor (GAP) scheme of predicting the pixel value of the image frame and outputting seven prediction patterns.
[0036] Each of the first predictor 100 and the second predictor 200 may predict a pixel value of each location with respect to the image frame, using adjacent pixels of a corresponding pixel.
[0037] The selection processor 300 may acquire per-pixel errors of prediction patterns output by the first predictor 100 and the second predictor 200 , and thereby select, from among the output prediction patterns, a prediction pattern having a relatively small amount of errors.
[0038] For the above operation, the selection processor 300 may include a counting unit 310 and a selector 320 .
[0039] The counting unit 310 may count a predetermined value through a comparison for the first predictor 100 and the second predictor 200 by acquiring the per-pixel errors of the prediction patterns output by the first predictor 100 and the second predictor 200 .
[0040] The selector 320 may select the prediction pattern having the relatively small amount of errors from among prediction patterns with respect to the same pixel, using a counting result of the counting unit 310 .
[0041] Here, the selector 320 may select one prediction pattern from the prediction patterns, for example, Ω={PredictorA i,j ,PredictorB i,j } output by the first predictor 100 and the second predictor 200 , and may finally determine a prediction pattern P i,j according to the following Equation 1.
[0000]
P
i
,
j
=
arg
max
f
k
∈
Ω
C
k
[
Equation
1
]
[0042] The counting unit 310 may compare the per-pixel errors of the prediction patterns with respect to the first predictor 100 and the second predictor 200 , and may increase a count value C k of a prediction pattern corresponding to a predictor, for example, the first predictor 100 having a relatively small per-pixel error.
[0043] In this instance, the per-pixel error corresponds to a sum of an absolute difference (SAD) between a prediction value of each pixel and an actual pixel value.
[0044] Accordingly, the counting unit 310 may count a count value C PredictorA i,j of each prediction pattern of the first predictor 100 and a count value C PredictorB i,j of each prediction pattern of the second predictor 200 according to a procedure disclosed in the following Equation 2.
[0000] if(SAD PredictorA i,j <SAD PredictorB i,j ) C PredictorA i,j =C PredictorA i,j +1;
[0000] elseif(SAD PredictorA i,j ==SAD PredictorB i,j ){ C PredictorA i,j =C PredictorA i,j +1;
[0000] C PredictorB i,j =C PredictorB i,j +1;}
[0000] else C PredictorB i,j =C PredictorB i,j +1; [Equation 2]
[0045] The first predictor 100 employs the MED scheme of outputting three patterns and thus, may have prediction patterns of i={1, 2, 3}. Also, the second predictor 200 employs the GAP scheme of outputting seven patterns and thus, may have prediction patterns of j={1, 2, 3, 4, 5, 6, 7}.
[0046] FIG. 2 is a diagram illustrating an example of a count value for each prediction pattern of the first predictor 100 when the procedure of Equation 2 is performed, and FIG. 3 is a diagram illustrating an example of a count value for each prediction pattern of the second predictor 200 when the procedure of Equation 2 is performed.
[0047] In FIG. 2 and FIG. 3 , the count value for each prediction pattern may be counted based on an amount of errors for each pixel according to the procedure of Equation 2. Accordingly, as the count value increases, a corresponding prediction pattern and a corresponding predictor may have a relatively small amount of errors.
[0048] Also, since the count value is processed by combining three patterns of the first predictor 100 and seven patterns of the second predictor 200 , 21 count values may exist. The counting unit 310 may store the count value by using 21 bits for each frame of an image.
[0049] The selector 320 may select a prediction pattern having a relatively small amount of errors from among prediction patterns output by the first predictor 100 and the second predictor 200 with respect to the same pixel, using a counting result of the counting unit 310 .
[0050] For example, when it is assumed that a prediction pattern of the first predictor 100 is i=1 and a prediction pattern of the second predictor 200 is j=3, the selector 320 may compare “ 474 ” corresponding to a case where i=1 and j=3 in FIG. 2 with “ 450 ” corresponding to a case where i=1 and j=3 in FIG. 3 . Here, “ 474 ” indicates a count value of the prediction pattern of the first predictor 100 , and “ 450 ” indicates a count value of the prediction pattern of the second predictor 200 .
[0051] Accordingly, the selector 320 may select a prediction pattern having a relatively great count value and the corresponding predictor, that is, the first predictor 100 having “ 474 ”.
[0052] The entropy coder 400 may perform entropy encoding using the prediction pattern selected by the selection processor 300 .
[0053] The entropy coder 400 may enable compression of the image frame by encoding a difference between a pixel value of the selected prediction pattern and an actual pixel value. The entropy coder 400 may employ various entropy coding schemes.
[0054] FIG. 4 is a flowchart illustrating an operation of the hybrid prediction apparatus 10 according to an embodiment of the present invention.
[0055] Referring to FIG. 4 , in operation S 10 , each of the first predictor 100 and the second predictor 200 may output a prediction pattern using a correlation between pixels of an image frame.
[0056] In operation S 20 , the selection processor 300 may select a prediction pattern having a relatively small amount of errors by analyzing a per-pixel error of each output prediction pattern.
[0057] In operation S 30 , the entropy coder 400 may perform entropy encoding of the image frame using the selected prediction pattern.
[0058] The hybrid prediction apparatus 10 may perform entropy encoding at a relatively high compressibility by selectively using prediction patterns of the image frame that are output according to various prediction schemes, for example, the MED scheme and the GAP scheme.
[0059] According to an embodiment of the present invention, operation S 20 may include operations S 21 through S 23 of FIG. 5 .
[0060] In operation S 21 , the counting unit 310 may acquire the per-pixel error of each prediction pattern output in operation S 10 of FIG. 4 .
[0061] In operation S 22 , the counting unit 310 may count a predetermined value by comparing the acquired per-pixel values for the first predictor 100 and the second predictor 200 .
[0062] Here, the counting unit 310 may increase a count value of a prediction pattern corresponding to a prediction pattern, for example, the first predictor 100 having a relatively small per-pixel error according to the procedure of Equation 2.
[0063] In operation S 23 , the selector 320 may select a prediction pattern having a relatively small count value from among the prediction patterns output by the first predictor 100 and the second predictor 200 with respect to the same pixel, using the count value.
[0064] Accordingly, a hybrid prediction apparatus according to an embodiment of the present invention may supplement a particular pattern having a low compressibility by selecting, from among prediction patterns of the image frame, a prediction pattern having a relatively low count value with respect to the same pixel.
[0065] The above-described exemplary embodiments of the present invention may be recorded in computer-readable media including program instructions to implement various operations embodied by a computer. The media may also include, alone or in combination with the program instructions, data files, data structures, and the like. Examples of program instructions include both machine code, such as produced by a compiler, and files containing higher level code that may be executed by the computer using an interpreter.
[0066] Although a few exemplary embodiments of the present invention have been shown and described, the present invention is not limited to the described exemplary embodiments. Instead, it would be appreciated by those skilled in the art that changes may be made to these exemplary embodiments without departing from the principles and spirit of the invention, the scope of which is defined by the claims and their equivalents.
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Provided are a hybrid prediction apparatus and method for entropy encoding that may enhance an existing image compression scheme and prediction scheme by including and selectively using a plurality of predictors configured to perform a per-pixel prediction of an image frame, and may also supplement a performance of a prediction scheme, excessively occurring in a particular pixel.
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CROSS-REFERENCE TO A RELATED APPLICATION
This application is a continuation-in-part of Ser. No. 08/113,608 filed Aug. 27, 1993 (now U.S. Pat. No. 5,387,615) which is a continuation of Ser. No. 975,284 filed Nov. 12, 1992, (now U.S. Pat. No. 5,276,057) which is a continuation-in-part of Ser. No. 643,452 filed Jan. 18, 1991 (abandoned), which is a continuation-in-part of Ser. No. 576,011 filed Aug. 31, 1990 (U.S. Pat. No. 5,151,449).
BACKGROUND OF THE INVENTION
"Normal aging" may be an oxymoron. In fact, `theories` on why mammals "age", meaning experience progressive decline in physiologic function compared with that expected for "young", but "mature" adults of the same species, are numerous. While theories abound, there is no generally recognized theory of aging, nor is there any recognized therapy to "retard the normal aging process".
Caloric restriction may be the most widely accepted means to retard `normal aging` (Schneider, E., and J. Reed. Modulations of Aging Processes. Perspectives on Aging and Mortality. Handbook of the Biology of Aging. 2nd ed. 1985. van Nostrand, Rineholt Co., N.Y. pp.45-76) and (Raloff, J. Searching out how a severe diet slows aging. Science News. Oct. 5, 1991, p. 215). As first described by McCay, he noted that laboratory rats, fed a nutritionally adequate but calorically deficient diet, had longer mean and maximum life expectancies than control rats (McCay, C., Crowell, M., and L. Maynard; The effect of retarded growth upon the length of life span and upon the ultimate body size. J. Nutrition. 10: 1935, pp.63-79). Since chronic caloric restriction also results in retarded growth, and is otherwise impractical, caloric restriction has largely remained a laboratory model.
Other current `theories of aging` include the `free radical` or `oxidative damage` hypothesis (Orr, W., and R. Sohal. Extension of Life-Span by Overexpression of Superoxide Dismutase and Catalase in Drosophila melanogaster. Science. 263: Feb. 25, 1994, pp. 1128-1130) and (Floyd, R. Oxidative Damage to Behavior During Aging. Science. 254: Dec. 13, 1991, p. 1597). Free radicals are small molecules, either oxygen free radicals or hydroperoxides that have an unpaired electron. These chemical species are extremely reactive and cause substantial damage to biomolecules such as proteins, DNA, RNA, and lipids. The resulting accumulative damage is thought to be associated with the declining physiologic functions considered `aging`. This theory has been directly demonstrated using the life span in mutant fruit flies (Orr, W., and R. Sohal. Extension of Life-Span by Overexpression of Superoxide Dismutase and Catalase in Drosophila melanogaster. Science. 263: Feb. 25, 1994, pp.1128-1130).
Selegiline is a selective monoamine oxidase-B (MAO-B) inhibitor, which is widely used as an adjunct in the treatment of Parkinson's disease. While its most common usage is for the treatment of Parkinson's disease, selegiline was originally developed as an antidepressant agent. Recent testing has indicated that selegiline may have some effect on increasing sexual response in aging animals, and also may have some effect, at least in rats, in increasing the natural life expectancy. However, to date selegiline has only been medically approved by regulatory agencies for use for treatment of Parkinson's disease.
The search for new lines of medication to improve the quality of life in senescence ever continues. This becomes especially important in modern-day society, especially in developed countries, where the proportion of citizens over 65 years of age continues to increase. In sum, the quality of life has become increasingly important in older years, as people continue to experience longer life expectancy.
There is, therefore, a continuing and real need for the development of medications which retard the normal deterioration of certain physiological functions.
It is a primary objective of the present invention to develop a dosage regimen for the use of selegiline to shift the survival curve for a longer lived mammal such as pet dogs, cats or horses. (`Life span` is the inate or inborn maximal biologic life of a species, whereas `life expectancy` is the predicted actual life or average life of a species. Rarely is the `life expectancy` as long or equivalent to the biologic `life span` of a species.) While selegiline is a known compound that has been used to extend the life expectancy of laboratory rodents (Knoll, J., Dallo, J. and T. T. Yen. Striatal Dopamine, Sexual Activity and Lifespan. Longevity of Rats Treated With (--)Deprenyl. Life Sciences. Vol. 45, no. 6. 1989. pp.525-531), (Milgram, N. W., et al. Maintenance on L-Deprenyl Prolongs Life In Aged Male Rats. Life Sciences. Vol. 47, no. 6. 1990. pp.415-420), (Kitani, K., et al. Chronic Treatment of (--)Deprenyl Prolongs The Life Span of Male Fischer 344 Rats. Further Evidence. Life Sciences. Vol. 52, no. 3. 1993. pp.281-288), there is no prior teaching that would allow extrapolation from a short lived species, such as laboratory rats, to the relatively longer lived species such as dogs, cats, horses or even humans.
Like most drugs, selegiline can have diverse physiological effects which are completely dependent upon the dose administered. In accordance with the present invention, selegiline can be used for successful methods of treatment to provide the desired physiological effects enumerated herein, providing that it is used at the dosage levels mentioned herein, and providing it is administered at the periodic intervals and for the time spans mentioned herein. Obviously, when different dosages and levels of treatment are used, the results expressed herein may not be achieved. In fact, at higher doses adverse behavioral effects may be encountered.
SUMMARY OF THE INVENTION
The present invention relates to the process of using a known compound, selegiline, for new uses. In particular, at the dosage levels described herein, providing that the dosage is used for at least the periods of time expressed herein, there is an observed shifting of the survival curve for dogs, providing an extended life expectancy. The treatment is especially useful for domesticated pets, like horses, dogs and cats, as they increase in age, but would be expected to have utility in any longer lived mammalian species, including humans.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a survival curve for the animals involved in Example 1.
DETAILED DESCRIPTION OF THE INVENTION
As earlier stated, the compound that is useful for the method or protocol of the present invention is a known compound, selegiline. Selegiline has the formula (--)-N-α-dimethyl-N-2-propynylbenzene-ethanamine. It can be illustrated by the following graphic formula: ##STR1##
Selegiline also is at times referred to as 1-deprenyl to illustrate that it is a levoratary isomer which is the active form for treatment of Parkinson's disease. Typically, it is provided in a pharmaceutically acceptable salt form thereof, such as the hydrochloride salt.
As used here, pharmaceutically acceptable salt form thereof means the following. Acceptable for use in the pharmaceutical or veterinary art, being nontoxic or otherwise not pharmaceutically or veterinary unacceptable. "Acceptable salt form thereof" means salts formed with inorganic acids such as hydrochloric acid, hydrobromic acid, sulfuric acid, nitric acid, phosphoric acid, and the like, and as well organic acids such as acetic acid, propionic acid, glycolic acid, pyruvic acid, oxalic acid, malic acid, malonic acid, succinic acid, maleic acid, fumaric acid, tartaric acid, citric acid, benzoic acid, cinnamic acid, mandelic acid, etc.
Administration of the therapeutically active compound selegiline to achieve physiological results of the present invention can be via any of the accepted modes of administration for systemically active substances. These methods include oral, parenteral, and otherwise systemic, aerosol, and topical forms, as well as sustained release systems, etc.
The compositions of the present invention may be any of those known in the pharmaceutical and veterinary arts which are suitable for the method of administration and dosage required in any particular circumstance. In the case of both pharmaceutical and veterinary applications, such compositions may include tablets, pills, capsules, powders, aerosols, suppositories, skin patches, parenterals, and oral liquids including oil/aqueous suspensions, solutions and emulsions. It may include long acting injectables and sustained release devices.
When the dosage is in solid form, solid pharmaceutical carriers such as starch, sugar, talc, mannitol, povidone, magnesium stearate, and the like may be used to form powders. Lactose and mannose are the preferred solid carrier. The powders may be used as such for direct administration to a patient or, instead, the powders may be added to suitable foods and liquids, including water, to facilitate administration.
The powders also may be used to make tablets, or to fill gelatin capsules. Suitable lubricants like magnesium stearate, binders such as gelatin, and disintegrating agents like sodium carbonate, in combination with citric acid, may be used to form the tablets.
Unit dosage forms such as tablets and capsules may contain any suitable predetermined amount of selegiline, advisably as a nontoxic acid addition salt, and may be administered one or more at a time at regular intervals as later described. Such unit dosage form, however, should, with a broad range guideline, contain a concentration of 0.1% to 10% by weight of one or more forms of the active selegiline.
A typical tablet may have the composition:
______________________________________ Mg.______________________________________ 1. Selegiline 10.0 2. Mannitol 100 3. Stearic acid 3______________________________________
A granulation is made from the mannitol. The other ingredients are added to the dry granulation and then the tablets are punched.
Another tablet may have the composition:
______________________________________ Mg.______________________________________1. Selegiline 102. Starch U.S.P. 573. Lactose U.S.P. 734. Talc U.S.P. 95. Stearic acid 6______________________________________
Powders 1, 2 and 3 are slugged, then granulated, mixed with 4 and 5, and tableted.
Capsules may be prepared by filling No. 3 hard gelatin capsules with the following ingredients, thoroughly mixed:
______________________________________ Mg.______________________________________1. Selegiline 52. Lactose U.S.P. 2003. Starch U.S.P. 164. Talc U.S.P. 8______________________________________
As earlier expressed, physiological functions effected by the treatment herein with selegiline are necessarily dosage dependent. Put another way, like most drugs, selegiline has diverse physiological effects, depending upon the dose administered. Unless the dose administered is within the levels set forth herein, the desired effects on shifting of the survival curve are not achieved without adverse effects.
While the example later described herein provides data only for dogs, the tests are a fair example for any longer lived mammal, including, without limitation, humans, cattle, horses, swine, dogs, cats, and the like. The treatment may even work for birds or fish.
Humans form quick and strong bonds with their domesticated pets, and these strong bonds increase the desire to keep the animals alive for many years, often well beyond the peak years of the animal species in question. Needless to say, the natural enjoyment of these pets by their owners would be significantly increased as the pets grow older if one could shift their mortality curve in a favorable direction.
The life expectancy of many mammals is now known. For example, while the majority of humans die before age 85, the maximum life span of humans is thought to be between 110 and 120 years. Likewise for dogs, while larger breeds of dogs grow older faster, in 7-10 years, smaller dogs become old between 10 and 13 years. Deeb, B. J., and N. S. Wolf. Studying longevity and morbidity in giant and small breeds of dogs. Veterinary Medicine (Supplement). July, 1994. pp.702-713. Shifting the mortality curve in a favorable direction, such that the pet dog would have an increased life expectancy, would be beneficial for the pet owner and for the pet.
In accordance with the present invention, it has been demonstrated that the dog survival curve can be shifted in a favorable fashion, increasing the dog's life expectancy, if the animal is treated periodically with small, but therapeutically effective, doses of selegiline. The administration must not begin at either a too young age or a too old age. Generally, best results are achieved if administration begins with about 50% of the normal life span completed, and generally within the range of 50% to 75% completed. If treatment begins outside of this range, the benefit may be reduced. This is true whether the treatment begins at a very young age or at an elderly age.
As hereinafter explained, the dosage regimen to achieve these desirable results shows usage at levels from about 0.01 mg/kg of body weight up to about 2.0 mg/kg of body weight from one to seven times weekly, but preferably on alternate days. Most preferably, the dosage level is 0.5 mg/kg of body weight given twice weekly, starting in middle age. Of course, it would be known to those in the art that sustained release systems can be used to provide less frequent dosing to achieve the required dosage level.
It is not known precisely why the use of selegiline at the dosage levels and periodicity expressed herein achieves these results. It is simply not known by what mechanism the compound works, except to say that it is critically important that the dosage be at levels expressed herein.
EXAMPLES
Forty-one pairs of age-matched dogs were maintained under Good Laboratory Practices in an established beagle research colony. The dogs ranged in age from 3.8 years to 16.4 years of age at the commencement of the trial. Half of the dogs were treated with selegiline tablets, given once per day orally, at a dosage of 1 mg/kg of body weight. The other dogs were given placebo tablets daily. The laboratory assistants were "blinded", not knowing which dogs were receiving placebo and which were receiving selegiline. The purpose of the study was to evaluate a variety of physiologic parameters in the animals as they `aged`.
After approximately 26 months, the study was terminated. In addition to voluminous psysiologic data that was periodically collected on these 82 dogs, a mortality table was prepared and analyzed.
The research laboratory has maintained extensive historical records on the life expectancy of laboratory beagles. They routinely begin to see an accelerated increase in mortality at about 10 years of age, with the median life span of 14 years. Thus, if a shifting of the mortality was to occur, one might expect to see the effect in the animals approximately 10 and 14 years of age. In fact, that is exactly what was encountered.
There was no significant mortality differences in those age-matched pairs that were 15 years of age or older at the start of the trial.
There were no significant mortality differences in those age-matched pairs that were less than 10 years of age at the start of the trial.
However, there was a statistically significant decrease in the mortality of selegiline treated dogs in the 34 age-matched dogs that were between 10 and 15 years of age at the commencement of the trial. Specifically, 11 of 18 (61%) of the controls died during the experimental period, whereas only 4 of the 16 (25%) treated dogs died during the experimental period.
Food consumption was monitored throughout the study, as were body weights. There was no difference in food consumption between the treated and control groups, ruling out caloric restriction as an alternative explanation for the shifting of the survival curve in the selegiline treated group.
FIG. 1 shows the survival curve for the study of this example. The population plotted is the dogs that were approximately 10 years old to 15 years old on the first day of treatment and received treatment for at least 6 months. As illustrated in the curve, one begins to see an increase in survivability in the colony of selegiline treated dogs at about 10 years of age (median life span of 14 years). Selegiline treatment significantly increased (P=0.024) the probability of surviving longer than untreated dogs, as demonstrated by shifting of the survival curve in selegiline treated dogs.
From the above example it can be seen that this invention accomplishes at least all of its stated objectives, particularly for dogs. As will be apparent to those of ordinary skill in the art, certain modifications may be made to the process described for the invention and still achieve the effect of the invention. It is intended that those modifications come within the spirit and scope of the appended claims.
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Selegiline, or a pharmaceutically acceptable salt form of selegiline, is administered to mammals commencing at a point in time at which at least 50% of the mammal's life span is completed, with the administration continuing on a periodic but regular basis over the remaining life span of the mammal. The treatment, which shifts the survival curve, is especially useful for dogs.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention pertains to a security package, and more particularly, pertains to a structure with a handle, a rectangular encompassing structure, and a locking assembly which encompasses an audio cassette, a video cassette box or a compact disk jewel box. This security package provides for easy package securement and for protection against shoplifting and pilfering.
2. Background of the Invention
There has been a need to secure the small and relatively expensive audio-visual articles such as audio cassette boxes, video cassette boxes, and now the very popular compact disk "jewel box" in security packages to inhibit shoplifting. These audio-visual products are packaged in plastic storage cases of such size as to easily lend themselves to theft through shoplifting. Due to the high price of audio and video cassettes and compact disks, the losses become expensive to the vendors and are significant even if only a few cassettes or disks are stolen per month.
The prior art solutions to the problem have not been entirely acceptable. Keeping the material away from customers, behind the counters and off the shelves is a door marketing technique, is not cost effective, let alone labor effective, and does not solve the problem of theft by employees of a vendor. Another problem is that some prior art packages, such as those made of a plastic film material, are easily opened so that anyone with a pocket knife can easily slit the package apart and steal the contents.
Prior art security package devices also required that stock personnel often were required to use an article such as a hammer or other striking object, or other expensive one-of-a-kind devices to close and secure a locking channel or tab over the contained merchandise, causing additional expense, back-room time and effort to be expended to actually get the product placed on the shelf.
The present invention provides a security package which is light-weight, secure and may be opened with devices such as cutting pliers, heavy knives or the like. The present invention also provides a security package into which the merchandise can be secured into the security package at "shelf-side" as the need arises with a modest amount of digital pressure applied to the security package locking mechanism without the need for other locking assist devices such as hammers, pliers, presses, or the like.
SUMMARY OF THE INVENTION
The general purpose of the present invention is a security package for holding an article such as cassette or compact disk box, and for securement of the article inside the package for prevention of shoplifting or other form of theft.
According to one embodiment of the present invention, there is provided a security package with a handle structure, a rectangular encompassing structure, and a swinging or rotating locking channel which retains a plastic box, such as that for an audio cassette box, a VCR cassette box, or compact disk box, within retainer bars and members of the encompassing structure, while still providing for viewing of the printed message.
The rotating locking channel mounts on a configured stationery channel with a living hinge therebetween, and rotates to engage one-way beveled latches on the rotating locking channel with latches in a stationary channel to secure a box within the confines of the rectangular encompassing structure. A plurality of latches and catches virtually eliminate the possibility of disengagement from each other without a special tool.
According to another embodiment of the present invention, there is provided a side wall handle rim portion containing a handle, planar members intersecting the encompassing side wall, lateral members between the opposing side wall members, a box like channel member on the interior sides of the two opposing side wall members, a rotating locking channel located adjacent to the box like channel members which swings on a living hinge on the channel, lower planar retainer member across the bottom of the encompassing side wall, a retainer bar across an upper end of the encompassing side wall and a rectangular encompassing structure for containment of a video, audio, or disk box and contents.
One significant aspect and feature of the present invention is a security package with a rotating locking channel used to secure a rectangular object within a rectangular encompassing member.
Another significant aspect and feature of the present invention is the use of beveled one-way latches on a rotating locking channel which positions into catches to secure the rotating locking channel in a fixed position.
A further significant aspect and feature of the present invention is the rotation of a rotatable locking channel about a living hinge.
Still another significant aspect and feature of the present invention is a sturdy, secure security package for audio or visual boxes which is not easily pocketable nor accommodating to a purse or bag without being obvious to an ordinary onlooker. The security package is a prevention against shoplifting.
Still another significant aspect and feature of the present invention is a security package with an rectangular encompassing structure which securely encloses a plastic box such as a cassette or disk box for protection against theft. An audio or disk box in the security package cannot be removed from the premises or a store without being obvious to someone during the removal.
A still further significant aspect and feature of the present invention is a security package which is suitable for placement on store shelves or sales racks, and is aesthetically pleasing for presentation of the goods.
Yet another significant aspect and feature of the present invention is a security package which easily and readily locks without any required external devices to secure merchandise within.
There is provided a plurality of one-way positive lock latch and catch mechanisms.
Having thus described the embodiments of the present invention, it is the principal object hereof to provide a security package with a rotating locking channel about a living hinge with one-way beveled latches and a channel member with one-way catches for the containment of video, audio or disk boxes therein in the security package.
BRIEF DESCRIPTION OF THE DRAWINGS
Other objects of the present invention and many of the attendant advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings, in which like reference numerals designate like parts throughout the figures thereof and wherein:
FIG. 1 illustrates a perspective view of a security package with a rotating locking channel;
FIG. 2 illustrates a top view of the rotating locking channel;
FIG. 3 illustrates a bottom view of the security package;
FIG. 4 illustrates a cross-sectional view of the security package taken along line 4--4 of FIG. 2;
FIG. 5 illustrates a cross-sectional view of the security package taken along line 5--5 of FIG. 2;
FIG. 6 illustrates a cross-sectional view taken along line 6--6 of FIG. 2;
FIG. 7 illustrates a perspective view of a one-piece latch;
FIG. 8 is illustrates an exploded view of FIG. 7 taken along line 8--8 of FIG. 7;
FIG. 9 illustrates a top view of the latch and catch port;
FIG. 10 illustrates an enlarged bottom view of the latching assembly;
FIG. 11 illustrates a view taken along line 11--11 of FIG. 9; and,
FIG. 12 illustrates the mode of operation of the locking assembly.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a perspective view of a positive lock security package 10 also known as the security package including an elongated handle structure 12, a rectangular encompassing structure 14, and a rotating locking channel 16 for retention of a cassette like box. The positive lock security package 10 is formed from and between a vertically oriented side wall handle rim 18 encompassing and surrounding other elements of the positive lock security package 10 which includes side wall handle rim portions 18a, 18b and 18c, side wall 18d, partial end side walls 18e and 18f, and side wall 18g. The side wall handle rim portions 18a-18c are shorter than the other portions of the side wall handle rim 18 by way of example and for purposes of illustration only and are not to be construed as limiting of the present invention.
The horizontally oriented flat perimeter member 20 includes longitudinal web portions 20a, 20b and 20c intersecting side wall 18a and 18g, as illustrated, and the longitudinal web portions 20d, 20e and 20f intersect side wall handle rim portion 18c and 18d as illustrated.
The horizontally oriented flat perimeter member 20 also includes internal lateral web portions 20g and 20h between end side walls 18a and 18c, and lateral web portions 20i between side walls 18d and 18g.
The rectangular encompassing structure 14 includes a horizontally oriented flat perimeter member 22 in the lower surface which includes horizontally oriented longitudinal perimeter members 22a and 22b and a lateral inner perimeter member 22c which intersects a stationary channel 24 as later described in detail. A planar retainer member 23 extends between the longitudinal inner perimeter portions 22a and 22b and between the lower portions of the side walls 18d and 18g.
Openings 26 and 28 in the elongated handle structure 12 are bounded by the longitudinal web portions 20a, 20d, 20b, internal lateral web portion 20h, and flat perimeter members 20b and 20c and web portions 20h and 20i, respectively. Opening 30 is bounded by longitudinal web portions 20c and 20f, internal lateral web portion 20i and one side of the stationery channel 24. Opening 32 is bounded by 15 longitudinal web portions 22a-22c and planar retainer member 23. Elongated handle structure 12 includes all members adjacent to the intersection of the side wall handle rim 18 and the horizontal oriented flat perimeter member 20, and the elements of the horizontal oriented flat perimeter member 20 intersect the center lines of the elements of the side wall handle rim 18.
An upper retainer bar 36 locates between the side wall handle rim portions 18d and 18g adjacent to partial end side walls 18e and 18f. The lower planar retainer member 23, and longitudinal perimeter members 22a and 22b position between and along the lower edge of the side wall handle rim portions 18d and 18g. The lateral internal perimeter member 22c intersects with the stationary channel 24. An orifice 40, for passage of a cassette like box into the rectangular encompassing structure 14, is bounded to the upper edges of side wall handle rim portions 18d and 18g, one side of the stationery channel 24, and the upper retainer bar 36. Beveled box like channel members 42 and 44 are located on the inner walls of side wall handle rim portions 18g and 18d, respectively, and are open on the bottom side as illustrated in FIG. 3. A vertical channel wall member 46 extends vertically and laterally between side wall handle rim portions 18g and 18d, and forms, in part, one wall of the beveled box like channel members 42 and 44. Another shorter channel wall member 48, as illustrated in FIG. 2, is positioned between the side wall handle rim portions 18d and 18g and forms one of the walls of the beveled box like channel members 42 and 44 and helps form a surface of stationery channel 24. A planar surface 50 extends between the beveled box like channel members 42 and 44 and includes a plurality of catch ports 52, 54, 56 and 58.
FIG. 2 illustrates a top view of the positive lock security package 10. The rotating locking channel 16 includes short vertical wall members 60 and 62 and another longer vertical wall 64 extending between the shorter vertical wall members 60 and 62. A horizontally aligned segmented upper planar surface 66 extends between the upper ends of the vertical wall members 60 and 62. A planar beveled member 68 extends between the short vertical wall members 60 and 62. A lower horizontally aligned planar member 70 extends along and across the bottom edges of the shorter vertical walls 60 and 62, the bottom edge of the planar beveled member 68 and the bottom edge of the long vertical wall 64 and extends towards the center of the positive lock security package 10. A ridge 72 extends along the edge of the lower horizontally aligned planar member 70. A plurality of latches including latches 74, 76, 78 and 80 extend upwardly from the segmented upper planar surface 66 of the rotating locking channel 16, and a plurality of support walls including walls 82a-82n extend downwardly from the segmented upper planar surface 66 to intersect the lower horizontally aligned planar member 70 and the planar beveled member 68. A living hinge 83 extends between the stationary channel 24 and the rotating locking channel 16. Cross sections of the rotating locking channel 16 are provided in FIG. 6. Each of the catch ports 52-58 contain pluralities of one-way locking teeth 59a-59n and 61a-61n which interlock with cavities in the latch members 74-80 as later described in detail.
FIG. 3 illustrates a bottom view of the security package 10 where all numerals correspond to those elements previously described. Illustrated in particular is the under side of the stationary channel 24 and the rotating locking channel 16 including views of the catch ports 52-58 and latches 74-80. Also illustrated is a plurality of strut members 85a-85n extending between the vertical channel wall member 46 and the shorter channel wall member 48. Another plurality of shorter strut members 89a-89n extend perpendicular to and between the plurality of strut members 85a-85n.
FIG. 4 illustrates a cross section of the security package 10 taken along line 4--4 of FIG. 2 and illustrates the cross-section of the beveled box like channel member 42 and the similar beveled box like channel member 44. All numerals correspond to those elements previously described.
FIG. 5 illustrates a cross section of the security package 10 taken along line 5--5 of FIG. 2 illustrating in particular the midsection of the stationary channel 24 and the rotating locking channel 16. All numerals correspond to those elements previously described.
FIG. 6 illustrates a cross section of the security package taken along line 6--6 of FIG. 2 illustrating a cross section through a latch 74 and a catch port 52. All numerals correspond to those elements previously described.
FIG. 7 illustrates a perspective view of a one-piece latch 80. The latch 80 includes a curved top 84, beveled ends 86 and 88 intersecting the curved top 84, end members 90 and 92, sides 94 and 96, longitudinal center member 106 between the end members 90 and 92, lateral center member 108, cavities 98 and 100 illustrated in this figure and cavities 102 and 104 as illustrated in FIG. 8.
FIG. 8 illustrates an exploded section view of FIG. 7 taken along line 8--8 of FIG. 7 where all numerals correspond to those elements previously described. The longitudinal center member 106 and the lateral center member 108 assist in the formation of cavities 98-104 which snap and frictionally engage the one-way locking teeth 59n and 61n as found in the catch port 58, as illustrated in FIG. 9. The curved top 84 and beveled ends 86 and 88 assist in alignment of the typical latch 80 in the typical one-way locking teeth 59n and 61n and also in the spreading of the one-way locking teeth 59n and 61n prior to engagement into the cavities 98-104. The latch 80 is similar to latches 74-78 and it only is fully illustrated for purposes of brevity.
FIG. 9 illustrates a close up top view of the latch 80 and catch port 58 where all numerals correspond to those elements previously described. Shown in particular are the cavities 98-104 in the latch 80. One-way locking teeth 59n includes individual downwardly inclined teeth members 110 and 112 separated by a notch 114. Another opposing one-way locking teeth 61n includes individual downwardly inclined teeth members 116 and 118 separated by a notch 120. Catch ports 52-56 include similar sets of teeth, but are not fully illustrated in detail for purposes of brevity and clarity.
FIG. 10 illustrates a close up enlarged bottom view of the latch 80 and catch port 58 of FIG. 9.
FIG. 11 illustrates a cross-sectional view of the latch 80 and the catch port 58 taken along line 11--11 of FIG. 9. It is particularly noted that the beveled surfaces 130 and 132 are canted with respect to the vertical axis of the illustrated latch 80. The particular angle of canting of each of the beveled surfaces 130 and 132 such as found in cavities 102-108 and each of the latches 74-80, is such that when the beveled surfaces 130 and 132 will be parallel with end surfaces 110a of the tooth 110 and end surface 116a of the tooth 116, the latch 80 is rotated to engage teeth 116 and 110 of the catch port 58 as illustrated in FIG. 12.
MODE OF OPERATION
FIG. 12 best illustrates the mode of operation where an audio cassette 150 is placed through orifice 40 and secured in the rectangular encompassing structure 14 by rotating the rotating locking channel 16 about the living hinge 83 to engage upper surface of the audio cassette 150. The rotating locking channel 16 is held secure in place by snapping engagement of the latches 74-80 with the catch ports 52-58. The operation of one latch 80 with a catch port 58 is described and illustrated herein, and engagement of latches 74-76 with catch ports 52-56 is similar. Latch 80 is illustrated engaging catch port 58. During engagement, the curved top 84 of the latch 80 presses against teeth pair 116 and 110, and teeth pair 112 and 118, forcing the teeth pairs apart until beveled surfaces 130 and 132 proceed past teeth surfaces 116a and 110a, thus allowing the teeth members 116 and 110 to spring back to their original shape and allowing tooth surface 116a to mate in a parallel fashion against beveled surface 132 of the latch 80 and to allow tooth surface 110a to mate in a parallel fashion against beveled surface 130 of the latch 80 in a like and similar manner. Simultaneously, teeth 116 and 110 engage cavities 100 and 104, respectively, and in a like and similar fashion teeth 118 and 112, each having like surfaces, engage cavities 98 and 102, respectively. Once engaged, latch 80 is secured in the catch port 58 and retraction of the latch is virtually impossible because of the engagement of four teeth in each catch port within the four cavities in each latch. Of course, more latch catch engagements, such as with a plurality of latches 74-80 engaged with a plurality of catch ports 52-58, provides for even more security for the positive lock security package 10.
Various modifications can be made to the present invention without departing from the apparent scope thereof. While the package is injection molded of polyethylene, any suitable polymer can be utilized.
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A security package for prevention of shoplifting including an elongated handle structure secured to a rectangular encompassing structure for holding an article such as an audio cassette box, video cassette box or a compact disk "jewel box". A rotating locking channel with latches for positive locking which engages catch ports in a stationary channel member adjacent to the rectangular encompassing structure to receive an article such as an audio, video or compact disk box. The rotating locking channel is rotated, and the article box in a rectangular encompassing structure area is captured by the rotating of the rotating locking channel with one-way beveled latches to secure the article box within the rectangular encompassing structure. A plurality of one-way locking latch and catch mechanisms are used to accomplish a package lock.
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BACKGROUND OF THE INVENTION
The present invention relates to collapsible three-dimensional displays such as Holiday decorations. In one embodied form, the unique decoration includes an internal metal frame formed, at least in part, from metal alloys imparted with suitable memory characteristics.
A portion of the disclosure of this patent document contains material, which is subject to copyright protection. The copyright owner has no objection to the facsimile reproduction by anyone of this patent document or the patent disclosure, as it appears in the U.S. Patent and Trademark Office patent file or records, but otherwise reserves all copyrights whatsoever.
Shape memory alloys (SMAs) are metals that “remember” their original shapes. SMAs are useful for a wide variety of products owing to their ability to “change shape, stiffness, position, natural frequency, and other mechanical characteristics” in response to a change in an applied force such as temperature or pressure. The potential uses for SMAs have broadened the spectrum of many applications. The diverse applications for these metals have made them increasingly important and visible to the world.
SMAs may have different kinds of shape memory effect. The two most common memory effects are the one-way and two-way shape memory.
For instance, the SMA material can return to some previously defined shape or its original size when not subjected to compression can be said to have a one-way shape effect. That is, SMA can be physically deformed at some prescribed range of exerted mechanical force and, upon release of such compressive force, the SMA material will return to its original shape.
In the art of three dimensional displays it is known to have one or more collapsible elements incorporated into the display device for ease of storage as well as a means to capture viewer interest. Among such conventional displays and devices are the following disclosures which are hereby incorporated by this reference.
Meschs in U.S. Pat. No. 6,592,426 discloses a device including a container having a releasable cover, which is biased by a compressible elastic member when the releasable cover is in a closed position. A molded rubber sheath encapsulates the compressed elastic member, and the rubber sheath provides a three dimensional figure which is collapsible in the closed position for storage in the container and which recovers to the three dimensional figures when release from the container. A release mechanism is provided in operative relationship with the releasable cover to permit the three dimensional figure to be released by the compressible elastic member when triggered by the release mechanism.
U.S. Pat. No. 6,284,330 B1 to Hermanson discloses an expandable three-dimensional display device is provided with a cover and a support post at least partially disposed within the cover. The sliding member slidably moves along the support post such that the plurality of extension members can be extended generally radially away from the support post or retracted to collapse, and lie along and be generally parallel to the support post. A cover is supported by the extension members and is expanded and collapsed as the extension members extend and retract. This mechanism may be similar to a conventional umbrella. The cover may be configured to represent an easily recognized holiday figure such as, for example, Santa Claus, the Easter Bunny or a snow man. Additionally, a light may be supported by the support post to illuminate the cover from within and render it visible after dark. The display device includes a mechanism associated with the cover and support post that is operable alternately to expand the cover to an enlarged configuration about the post to provide a three-dimensional display and collapse the covers to a collapsed configuration. A light is mounted within the cover to illuminate it. A portion of the display structure is formed to be mounted on the upper end of the support post which projects through the cover and additionally to be secured to the cover in order to provide the assembled display with further texture and interest.
Armstead in U.S. Pat. No. 4,847,123 discloses a pop-up artificial Christmas tree having an elongated trunk which is held vertical by a stand. The pop-up Christmas tree may be collapsed to a storage state when the guide sleeve is slid away from the lower-most stationary sleeve, the extension taken from the top, and the collapsed tree and extension taken from the top, and the collapsed tree and extension may be stored in a bag that also serves as an under-the-tree spread. From the storage stage, the pop-up artificial Christmas tree may be popped up again to the posture of a natural tree like one might pop up an umbrella.
U.S. Pat. No. 7,086,757 B2 to Wang discloses a formed lighting fixture having a frame, a plurality of bulbs, and a refracting layer, in which the frame is formed by gathering a plurality of rods and profiled in a specific contour, the bulbs are installed on the frame to serve as lighting ornaments, and the rod frame is coated with a refracting layer of a transparent material. A formed lighting fixture so constructed can offer a dazzling effect to thereby reduce bulb amount and facilitate production.
Gonzalez in U.S. Pat. No. 5,607,734 discloses an expansible ornament assembly comprising an expansible form having an open position and a closed position and constructed of a lightweight material such as tissue paper. When in the open position, the expansible ornament assembly is adapted to display a three dimensional object or another simulative representation such as a letter, phrase, or the like. The ornament assembly may be used in combination with a gift wrapping sheet which coordinates in some respect with the displayed three dimensional object.
While recognizing the desirability of collapsible design features in three dimensional displays and devices, these conventional structures have required relatively complex mechanisms to achieve such goal. Moreover, many of these structures provide only limited compactness when such display is stored and not in use.
Accordingly, those skilled in the art have recognized a significant need for collapsible three dimensional displays such as Seasonal Holiday decorations which may be conveniently reduced to a compact shape for shipment and storage without complicated construction. The present invention fulfills these needs.
These and other objects, features and advantages of the present invention will become apparent from the following detailed description of illustrative embodiments thereof, which is to be read in connection with the accompanying drawings.
SUMMARY OF THE INVENTION
Improved three dimensional displays such as seasonal Holiday decorations are provided. In one embodied form, the unique display constructions include a collapsible internal support frame imparted with suitable memory characteristics. The internal frame comprises “shape memory alloys” which “remember” their original shapes after deformation. Accordingly, the embodied displays of the present invention utilize a deformable frame as a spine that may be surmounted with suitable outer coverings such as elastic fabric or plastic film for the skin of the three dimensional display. The inventive display may include other decorative features such as interior lighting, sound and visual effects.
The support frame may be fabricated, at least in part, from from shape memory alloy material that can return to its originally defined shape when not subjected to a prescribed range of compressive force. The outer covering preferably is flexible and elastic to provide a complementary form fit with the internal support frame of the display. A releasable retaining element such as a clip or clasp member may be used to maintain the support frame in a deformed condition for shipping and storage of the display, but upon release will permit the frame to return to its original full size and three dimensional configuration.
In other embodiments, the display may include a vibration device coupled to the amusement device to produce vibrational motion of the three dimensional figure. The sheath may be clear, translucent or opaque and provide a paintable surface. The sheath may include means for attaching other display components such as three-dimensional molded details, body features, personal effects and appendages. The three dimensional display outer covering may include a molded image of one of a human, an animal, a fictional character, a cartoon character, a comic character, or inanimate object such as Christmas Tree or ornament. The display may include rigid parts attached to the flexible sheath and/or other collapsible elements and features connected to the outer sheath. The sheath may include wind slots, air holes and the like to provide for stability of the display during varying weather conditions and to provide ease in the deforming process when the display is to be stored and not in use.
These and other objects, features and advantages of the present invention will become apparent from the following detailed description of illustrative embodiments thereof, which is to be read in connection with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a front perspective view of one embodied form of the present invention illustrating the deformable internal frame having a generally spiral configuration;
FIG. 2 is a perspective view of a display incorporating the deformable frame as shown in FIG. 1 and further illustrating the display having an exterior sheath surmounting the deformable frame;
FIG. 3 is a front perspective view of one embodied form of the present invention illustrating the deformable internal frame having a generally rectangular shape;
FIG. 4 is a perspective view of a display incorporating the deformable frame as shown in FIG. 3 and further illustrating the display having an exterior sheath surmounting the deformable frame;
FIG. 5 is a front perspective view of one embodied form of the present invention illustrating the deformable internal frame having a generally combination of spiral and circular configurations;
FIG. 6 is a perspective view of a display incorporating the deformable frame as shown in FIG. 5 and further illustrating the display having an exterior sheath surmounting the deformable frame;
FIG. 7 is a front perspective view of one embodied form of the present invention illustrating the deformable internal frame having a generally contoured configuration incorporating spiral and multiple configurations;
FIG. 8 is a perspective view of a display incorporating the deformable frame as shown in FIG. 7 and further illustrating the display having an exterior sheath surmounting the deformable frame;
FIG. 9 is a front perspective view of one embodied form of the present invention illustrating the deformable internal frame having a generally contoured configuration incorporating spiral and multiple configurations; and
FIG. 10 is a perspective view of a display incorporating the deformable frame as shown in FIG. 9 and further illustrating the display having an exterior sheath surmounting the deformable frame.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The present invention provides improved three dimensional displays such as sculptures and seasonal decorations having a collapsible frame construction fabricated in total, or in pertinent part, from shape memory alloys (“SMA wire”). In one embodied form, a deformable metal frame having suitable shape memory characteristics is used as a spine and covered with a flexible outer skin of elastic web. The elastic web may be of knitted or woven fabric, or may be formed whole, or in part, from plastic films. The display may include other conventional features such as internal lighting, sound, motion and other visual effects.
In one embodied form, the invention provides three dimensional collapsible display construction comprising: a deformable internal frame fabricated from a material that can return to its originally defined shape when not subjected to a compressive force within a prescribed range; an outer elastic sheath surmounting said deformable internal frame member, the sheath and frame providing a display which is collapsible in the closed position for storage and which recovers to its original full size and three dimensional display configuration when not subjected to said prescribed compressive force; and a releasable retaining element for maintaining said deformable internal frame in a deformed condition when the element is in a closed position.
Accordingly, the embodied displays of the present invention utilize a deformable frame as a spine that may be surmounted with suitable outer coverings such as elastic fabric or plastic film for the skin of the three dimensional display. The inventive display may include other decorative features such as interior lighting, sound and visual effects.
The support frame may be fabricated, at least in part, from from shape memory alloy material that can return to its originally defined shape when not subjected to a prescribed range of compressive force. The outer covering preferably is flexible and elastic to provide a complementary form fit with the internal support frame of the display. A releasable retaining element such as a clip or clasp member may be used to maintain the support frame in a deformed condition for shipping and storage of the display, but upon release will permit the frame to return to its original full size and three dimensional configuration.
In other embodiments, the display may include a vibration device coupled to the amusement device to produce vibrational motion of the three dimensional figure. The sheath may be clear, translucent or opaque and provide a paintable surface. The sheath may include means for attaching other display components such as three-dimensional molded details, body features, personal effects and appendages. The three dimensional display outer covering may include a molded image of one of a human, an animal, a fictional character, a cartoon character, a comic character, or inanimate object such as Christmas Tree or ornament. The display may include rigid parts attached to the flexible sheath and/or other collapsible elements and features connected to the outer sheath. The sheath may include wind slots, air holes and the like to provide for stability of the display during varying weather conditions and to provide ease in the deforming process when the display is to be stored and not in use.
The exterior sheath may be formed from films, fabrics or webs fabricated from plastic, nylon or any other flexible, yet durable material. The sheath is preferably translucent so that it can be illuminated from within, as is known in the art.
In more detail, the internal frame may be formed from a material that changes its shape in response to an external force and returns to its original shape when the force is removed. The energy expended in deforming the frame is stored in it and can be recovered when the internal frame returns to its original shape. Generally, the amount of the shape change is directly related to the amount of force exerted. If too large a force is applied, however, the frame will permanently deform and not return to its original shape.
There are several types of configurations that are suitable for the deformed internal frame. One suitable frame is formed by wire wound into a cylindrical or conical shape. The SMA is coiled with space between successive coils; when a deforming force is applied the coils are pushed closer together. A third type of frame configuration is designed so the applied force twists the coil into a tighter spiral. Common examples of SMAs are found in clipboards and butterfly hair clips.
Other configuration examples for components of the internal frame are shapes like a shallow arch; open-core cylinders of solid, elastic material.
As previously described the SMA may be fabricated from a wide variety of metal alloys having suitable memory characteristics. One example is memory wire formed by stretching (at room temperature) and subsequently heat treated and shaped (at a range of 280-350 degrees C.) and then cooled to ambient temperature. Memory wire is composed of the following iron alloy:
Carbon (C)
0.59% by weight
Silicon (Si)
0.23% by weight
Manganese (Mn)
0.62% by weight
Phosphorous (P)
0.019% by weight
Sulfur (S)
0.004% by weight
Nickle (Ni)
0.01% by weight
Chromium (Cr)
0.021% by weight
Copper (Cu)
0.01% by weight
Ferrous alloys are the most commonly used SMA materials. The most popular alloys include high-carbon wire, oil tempered low-carbon, chrome silicon, chrome vanadium, and stainless steel.
Other metals that are sometimes used to make SMAs are beryllium copper allow, phosphor bronze, and titanium. Rubber or urethane may be used for cylindrical, non-coil SMAs. Ceramic material has been developed for coiled SMAs in very high-temperature environments. One-directional glass fiber composite materials are being tested for possible use in SMA.
The deformable frame components may be formed utilizing the following processing techniques:
Coiling
Cold winding. Wire up to 0.75 inch (18 mm) in diameter can be coiled at room temperature using one of two basic techniques. One consists of winding the wire around a shaft called an arbor or mandrel. This may be done on a dedicated SMA-winding machine, a lathe, an electric hand drill with the mandrel secured in the chuck, or a winding machine operated by hand cranking. A guiding mechanism, such as the lead screw on a lathe, must be used to align the wire into the desired pitch (distance between successive coils) as it wraps around the mandrel.
Alternatively, the wire may be coiled without a mandrel. This is generally done with a central navigation computer (CNC) machine.
For extension or torsion SMA, the ends are bent into the desired loops, hooks, or straight sections after the coiling operation is completed.
Hot winding. Thicker wire or bar stock can be coiled into springs if the metal is heated to make it flexible. Standard industrial coiling machines can handle steel bar up to 3 inches (77 mm) in diameter, and custom SMAs have reportedly been made from bars as much as 6 inches (150 mm) thick. The steel is coiled around a mandrel while red hot. Then it is immediately removed from the coiling machine and plunged into oil to cool it quickly and harden it. At this stage, the steel is too brittle to function as a SMA, and it must subsequently be tempered.
Heat treating. Whether the steel has been coiled hot or cold, the process has created stress within the material. To relieve this stress and allow the SMA to maintain its characteristic resilience, the SMA must be tempered by heat treating it. The SMA is heated in an even, held at the appropriate temperature for a predetermined time, and then allowed to cool slowly. For example, a SMA made of music wire is heated to 500 degrees F. (260 degrees C.) for one hour.
Grinding. If the design calls for flat ends on the deformable frame, the ends are ground at this stage of the manufacturing process. The frame is mounted in a jig to ensure the correct orientation during grinding, and it is held against a rotating abrasive wheel until the desired degree of flatness is obtain. When highly automated equipment is used, the frame is held in a sleeve while both ends are ground simultaneously, first be coarse wheels and then by finer wheels. An appropriate fluid (water or an oil-based substance) may be used to cool the frame, lubricate the grinding wheel, and carry away particles during the grinding.
Shot peening. This process strengthens the steel to resist metal fatigue and cracking during its lifetime of repeated flexings. The entire surface of the SMA is exposed to a barrage of tiny steel balls that hammer it smooth and compress the steel that lies just below the surface.
Setting. To permanently fix the desired length and pitch of the SMA, it is fully compressed so that all coils touch each other. Some manufacturers repeat this process several times.
Coating. To prevent corrosion, the entire surface of the SMA is protected by painting it, dipping it in liquid rubber, or plating it with another metal such as zinc or chromium. One process, called mechanical plating, involves tumbling the SMA in a container with metallic powder, water, accelerant chemicals, and ting glass beads that pound the metallic powder onto the SMA surface.
FIG. 1 is a front perspective view of one embodied form of the present invention illustrating the deformable internal frame having a generally spiral configuration;
FIG. 2 is a perspective view of a display incorporating the deformable frame as shown in FIG. 1 and further illustrating the display having an exterior sheath surmounting the deformable frame;
FIG. 3 is a front perspective view of one embodied form of the present invention illustrating the deformable internal frame having a generally rectangular shape;
FIG. 4 is a perspective view of a display incorporating the deformable frame as shown in FIG. 3 and further illustrating the display having an exterior sheath surmounting the deformable frame;
FIG. 5 is a front perspective view of one embodied form of the present invention illustrating the deformable internal frame having a generally combination of spiral and circular configurations;
FIG. 6 is a perspective view of a display incorporating the deformable frame as shown in FIG. 5 and further illustrating the display having an exterior sheath surmounting the deformable frame;
FIG. 7 is a front perspective view of one embodied form of the present invention illustrating the deformable internal frame having a generally contoured configuration incorporating spiral and multiple configurations;
FIG. 8 is a perspective view of a display incorporating the deformable frame as shown in FIG. 7 and further illustrating the display having an exterior sheath surmounting the deformable frame;
FIG. 9 is a front perspective view of one embodied form of the present invention illustrating the deformable internal frame having a generally contoured configuration incorporating spiral and multiple configurations; and
FIG. 10 is a perspective view of a display incorporating the deformable frame as shown in FIG. 9 and further illustrating the display having an exterior sheath surmounting the deformable frame.
The fabric skin may be composed of nylon and a mixture of spandex, which provides the elasticity and form fitting surmounting the internal frame.
Suitable fabric coverings may come in a variety of fibers and fiber combinations. Commonly used fibers include cotton, wool, nylon, acrylic, polyester, olefin, and spandex. Occasionally, metallic fibers such as mylar coated gold, silver and other reflective metals may be blended for visual effect, but this adds to the cost.
Synthetic fibers, particularly nylon, are strong and make an excellent choice for displays subject to hard wear. Portions of the coverings may also be reinforced at select locations with this durable fiber. Acrylic fibers are also suitable as are Olefin fibers.
The sheath may be knitted, giving the covering stretch and the ability to conform to the internal frame. Generally, a plain knit stitch can be used in the portion of the cover and a rib stitch is used where stretch is needed. The rib stitch is very stretchy, with the ability to return to shape.
The internal frame may be secured to the outer sheath by fasteners such as zipper snaps, clamps, hook and loop-type strips sold under the trademark VELCRO strips or other known means. The fasteners will be designed to mate with and be secured to corresponding receptacles or mating hook and loop-type strips mounted on the cover.
The frame may also be provided with flexible hinges so that it can be folded into a more compact configuration when the display device is disassembled for shipment or storage.
Internal light fixtures for illuminating the assembled display from within the cover may be associated with the internal frame. The light fixtures may include a socket mounted on the frame and electric light strings operating with the socket. Power maybe supplied to the bulb by a conventional power supply using a conventional electrical cord. When power is supplied to the bulb, it attractively and safely illuminates the cover from within. The bulb may be turned on in a conventional fashion by, for example, operating a switch incorporated into the light fixture, or by merely connecting the electrical cord to the power supply.
In other embodiments, the display may include a vibration device coupled to the amusement device to produce vibrational motion of the three dimensional figure. The sheath preferably provides a paintable surface. The sheath may include a molded image having three-dimensional molded details. The three-dimensional details may include at least one of body features, personal effects and appendages. The rubberized sheath provides a flexible body, which holds its shape when released.
Flexible sheath may include a silicon-based rubber, such as, for example, KRATON. In a preferred embodiment, flexible sheath includes an injection moldable silicon based rubber. Other flexible materials may be employed which provide flexibility while maintaining three-dimensional details of the display.
The outer sheath may be composed of formed from a plurality of pieces, which may be combined of a plurality of parts. For example, a head may include a rigid moldable plastic piece such as polyvinyl chloride (PVC) or other rigid plastic material. A rigid head may provide structural support or permit different colors or features. For example, a rigid plastic part maybe carried or attached as shown in various FIGS. 4-10 .
The display include a human or animal likeness, a mythical character or superhero or any other famous or infamous character, etc. In preferred embodiments, the display may include a rock star, model, sports figure, cartoon character, a monster, an actor/actress or the like. The display may be dressed up, painted or otherwise detailed in the likeness of a subject character.
Other features may also be added to the display. For example, real or fake hair or a heart may be added to head, or a tool, instrument, sports apparatus, microphone or other apparatus maybe placed in the hand of appendage.
Having described preferred embodiments for my invention (which are intended to be illustrative and not limiting), it is noted that modifications and variations can be made by persons skilled in the art in light of the above teachings. It is therefore to be understood that changes may be made in the particular embodiments of the invention disclosed which are within the scope and spirit of the invention as outlined by the appended claims. Having thus described the invention with the details and particularity required by the patent laws, what is claimed and desired protected by Letters Patent is set forth in the appended claims.
These and other objects, features and advantages of the present invention will become apparent from the following detailed description of illustrative embodiments thereof, which is to be read in connection with the accompanying drawings.
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An improved three dimensional display such as a Holiday decoration having collapsible constructions having a shape memory internal frame. In one embodied form, the unique display includes a collapsible internal frame formed, in part, from metal wire imparted with suitable memory characteristics. Such metals are referred to as “shape memory alloys” (SMAs) because much metals “remember” their original shapes. Accordingly, the present invention uses a deformable internal metal frame supporting an outer sheath formed from suitable materials such as fabric, or plastic film for the skin of the inventive three dimensional displays.
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FIELD OF THE INVENTION
This invention relates to a semiconductor test system for testing semiconductor devices, and more particularly, to a semiconductor test system having a glitch detection means for detecting glitches in an output signal of a semiconductor device under test to accurately evaluate the performance of the device under test.
BACKGROUND OF THE INVENTION
In testing semiconductor devices such as ICs and LSIs by a semiconductor test system, such as an IC tester, a semiconductor IC device to be tested is provided with test signals or test patterns produced by an IC tester at its appropriate pins at predetermined test timings. The IC tester receives output signals from the IC device under test in response to the test signals. The output signals are strobed or sampled by strobe signals with predetermined timings to be compared with expected data to determine whether the IC device functions correctly.
Traditionally, timings of the test signals and strobe signals are defined relative to a tester rate or a tester cycle of the semiconductor test system. Such a test system is sometimes called a cycle based test system. Another type of test system is called an event based test system wherein the desired test signals and strobe signals are produced by event data from an event memory directly on a per pin basis. The present invention is applicable to both cycle based test system and the event based test system.
An example of configuration of a traditional cycle based test system is shown in a block diagram of FIG. 1 A. In this example, a test processor 11 is a dedicated processor provided within the semiconductor test system for controlling the operation of the test system through a tester bus. Based on pattern data from the test processor 11 , a pattern generator 12 provides timing data and waveform data to a timing generator 13 and a wave formatter 14 , respectively. A test pattern is produced by the wave formatter 14 with use of the waveform data from the pattern generator 12 and the timing data from the timing generator 13 . The test pattern is supplied to a device under test (DUT) 19 through a driver 15 in a pin electronics 20 .
A response signal from the DUT 19 resulted from the test pattern is converted to a logic signal by an analog comparator 16 in the pin electronics 20 with reference to a predetermined threshold voltage level. The logic signal is compared with expected value data from the pattern generator 12 by a logic comparator 17 . The result of the logic comparison is stored in a failure memory 18 corresponding to the address of the DUT 19 . As noted above, the driver 15 , the analog comparator 16 as well as switches (not shown) for changing pins of the device under test, are provided in the pin electronics 20 .
An example of configuration of an event based test system is shown in a block diagram of FIG. 1 B. In an event based test system, notion of events is employed where events are any changes of the logic state in signals to be used for testing a semiconductor device under test. For example, such changes are rising and falling edges of test signals or timing edges of strobe signals. The timings of the events are defined with respect to a time difference from a reference time point. Typically, such a reference time point is a timing of the previous event. Alternatively, such a reference time point is a fixed start time common to all of the events.
In an event based test system, since the timing data in a timing memory (event memory) does not need to include complicated information regarding waveform, vector, delay and etc. at each and every test cycle, the description of the timing data can be dramatically simplified. In the event based test system, as noted above, typically, the timing (event) data for each event stored in an event memory is expressed by a time difference between the current event and the last event. Since such a time difference between the adjacent events (delta time) is small, unlike a time difference from a fixed start point (absolute time), a size of the data in the memory can also be small, resulting in the reduction of the memory capacity.
In the example of FIG. 1B, the event based test system includes a host computer 42 and a bus interface 43 both are connected to a system bus 44 , an internal bus 45 , an address control logic 48 , a failure memory 47 , an event memory consists of an event count memory 50 and an event vernier memory 51 , an event summing and scaling logic 52 , an event generator 24 , and a pin electronics 26 . The event based test system evaluates a semiconductor device under test (DUT) 28 connected to the pin electronics 26 .
An example of the host computer 42 is a work station having a UNIX, Window NT or Linux operating system therein. The host computer 42 functions as a user interface to enable a user to instruct the start and stop operation of the test, to load a test program and other test conditions, or to perform test result analysis in the host computer. The host computer 42 interfaces with a hardware test system through the system bus 44 and the bus interface 43 . Although not shown, the host computer 42 is preferably connected to a communication network to send or receive test information from other test systems or computer networks.
The internal bus 45 is a bus in the hardware test system and is commonly connected to most of the functional blocks such as the address control logic 48 , failure memory 47 , event summing and scaling logic 52 , and event generator 24 . An example of address control logic 48 is a tester processor which is exclusive to the hardware test system and is not accessible by a user. The address control logic 48 provides instructions to other functional blocks in the test system based on the test program and conditions from the host computer 42 . The failure memory 47 stores test results, such as failure information of the DUT 28 , in the addresses defined by the address control logic 48 . The information stored in the failure memory 47 is used in the failure analysis stage of the device under test.
The address control logic 48 provides address data to the event count memory 50 and the event vernier memory 51 as shown in FIG. 1 B. In an actual test system, a plurality of sets of event count memory and event vernier memory will be provided, each set of which corresponds to a test pin of the test system. The event count and vernier memories store the timing data for each event of the test signals and strobe signals. The event count memory 50 stores the timing data which is an integer multiple of the reference clock (integral part), and the event vernier memory 51 stores timing data which is a fraction of the reference clock (fractional part). In the preferred embodiment of the present invention, the timing data for each event is expressed by a time difference (delay time or delta time) from the previous event.
The event summing and scaling logic 52 is to produce data showing overall timing of each event based on the delta timing data from the event count memory 50 and event vernier memory 51 . Basically, such overall timing data is produced by summing the integer multiple data and the fractional data. During the process of summing the timing data, a carry over operation of the fractional data (offset to the integer data) is also conducted in the event summing and scaling logic 52 . Further during the process of producing the overall timing, timing data may be modified by a scaling factor so that the overall timing be modified accordingly.
The event generator 24 is to actually generate the events based on the overall timing data from the event summing and scaling logic 52 . The events (test signals and strobe signals) thus generated are provided to the DUT 28 through the pin electronics 26 . Basically, the pin electronics 26 is formed of a large number of components, each of which includes a driver and a comparator as well as switches to establish input and output relationships with respect to the DUT 28 .
FIG. 2 is a block diagram showing a more detailed structure in the pin electronics 26 having a driver 35 and an analog comparator 36 . The circuit configuration and operation of the pin electronics 20 in the cycle based test system of FIG. 1A is the same as this one. The event generator 24 produces drive events which are provided to an input pin of the DUT 28 as a test signal (test pattern) through the driver 35 . The event generator 24 further produces a sampling event which is provided to the analog comparator 36 as a strobe signal for sampling an output signal of the DUT 28 . The output signal of the analog comparator 36 is compared with the expected data from the event generator 24 by a pattern comparator 38 . If there is a mismatch between the two, a failure signal is sent to the failure memory 47 in FIG. 1 B.
FIG. 3A shows an example of circuit diagram of a semiconductor device to be tested, and FIGS. 3B-3D show waveforms involved in the circuit diagram of FIG. 3 A. When a signal of FIG. 3B is provided to an input I 1 and a clock of FIG. 3C is provided to an input I 2 , the device of FIG. 3A produces an output signal of FIG. 3 D. As noted above with reference to FIG. 2, the output signal of FIG. 3D is sampled at strobe points to see whether it matches the expected output signal.
This situation is shown in FIGS. 4A-4D. The input, clock and output signals of the device under test are shown in FIGS. 4A-4C, respectively. The output signal of FIG. 4C is sampled by strobe signals of FIG. 4D at the timings shown by arrows therein. If the output signal matches the expected (simulated) output signal at all strobe points, the device under test is considered satisfactory and pass the current test pattern. In an actual device test, strobe timings are usually set to points immediately after the transition of the simulated output signal as in the example of FIG. 4 D.
FIGS. 5A-5C show the situation where a faulty device produces a different output signal when receiving the same test pattern in the foregoing examples. FIG. 5A shows a simulated (expected) output signal while FIG. 5B shows an actual output signal from the device under test. The output signal of FIG. 5B is faulty because it includes glitches at shaded portions in the waveform. However, by the strobe timings of FIG. 5C, the test produces a pass result since all test points are correct. The faulty is not discovered unless a manufacturer modify the test program to detect the glitches in the output signal or until it is applied to a customer application. This process is costly to both the device manufacturer and the customer.
SUMMARY OF THE INVENTION
Therefore, it is an object of the present invention to provide a semiconductor test system having a glitch detection means for detecting a glitch in an output signal of a semiconductor device under test to accurately evaluate the output signal of the semiconductor device under test.
It is another object of the present invention to provide a semiconductor test system having a glitch detection unit which includes an edge counter for counting the number of edges in the output signal from the semiconductor device under test to compare a correct number of edges, thereby detecting a glitch in the output signal.
It is a further object of the present invention to provide a semiconductor test system having a glitch detection means for detecting a glitch in the output signal from the semiconductor device under test by using a large number of strobes within a cycle of the output signal.
It is a further object of the present invention to provide a semiconductor test system having a glitch detection means for detecting a glitch in the output signal from the semiconductor device under test by using a continuous strobe signal which continuously changes a phase (timing) within a cycle of the output signal.
The present invention is a semiconductor test system having a glitch detection means for detecting glitches in the output signal from the device under test to accurately evaluate the function and signal quality of the device under test. The glitch detection means includes an edge counter which counts the number of edges of the output signal which is compared with the number of edges in the expected output signal. If the number of edges is greater than that of the expected output signal, then it is determined that the output signal from the device under test contains a glitch therein. In another aspect, the glitch detection means includes means for generating a large number of strobes within a cycle of the output signal of the device under test or generating a continuous strobe whose timing (phase) continuously changes within a cycle of the output signal.
In the present invention, the semiconductor test system for testing a semiconductor device includes an event memory for storing event data of events which are any changes in intended signals to be generated for testing a semiconductor device under test (DUT), an event generator for producing the intended signals which are test patterns, strobe signals and expected patterns based on the event data from the event memory, a pin electronics provided between the event generator and the DUT for transmitting the test pattern from the event generator to the DUT and receiving an output signal of the DUT and sampling the output signal by timings of the strobe signals from the event generator, a pattern comparator for comparing sampled output data from the pin electronics with the expected patterns and producing a failure signal when there is a mismatch therebetween, and a glitch detection unit for receiving the output signal from the DUT and detecting a glitch in the output signal by counting a number of edges in the output signal and comparing the count number with an expected number of edges.
In another aspect of the present invention, the glitch in the output signal of the device under test is detected by using a large number of strobe signals within a cycle of the output signal. In a further aspect, the glitch in the output signal of the device under test is detected by using a continuous strobe whose timing (phase) continuously changes within a cycle of the output signal.
According to the present invention, the semiconductor test system has the glitch detection unit for effectively detecting glitches in the output signal from the device under test to accurately evaluate the device under test. The glitch detection unit in the first embodiment allows the test system to detect unexpected output transitions in the device under test while adding only a small amount of extra hardware to the test system. The glitch detection unit also enhances failure detection accuracy without requiring extensive test pattern generation or increasing a device test time. In the second embodiment, glitches can be accurately detected by either the multiple-strobe signals or the continuous strobe signals of the present invention. The second embodiment of the present invention is effective in detecting glitches in the output signal of the device under test without adding any hardware to the test system.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a schematic block diagram showing a basic structure of an event based test system, and FIG. 1B is a schematic block diagram showing a basic structure of a cycle based test system, wherein the present invention can be applicable to both types of test system.
FIG. 2 is a block diagram showing a more detailed structure concerning the pin electronics of FIGS. 1A and 1B and associated drive events (test pattern) and sampling event (strobe signal) for testing a semiconductor device.
FIG. 3A is a circuit diagram showing an example of semiconductor circuit under test, and FIGS. 3B-3D are timing charts showing waveforms of input and output signals of the device under test of FIG. 3 A.
FIGS. 4A-4C are timing charts showing waveforms of input and output signals of the device under test of FIG. 3A,
FIG. 4D is a timing chart showing an example of timings of strobe signals for sampling the output signal of the device under test shown in FIG. 4 C.
FIGS. 5A-5C are timing charts showing a relationship among an expected output signal, an actual output signal of the device under test having a glitch therein, and an example of timings of the strobe signals.
FIG. 6A is a circuit diagram showing an example of semiconductor circuit under test, and FIGS. 6B and 6C are timing charts showing waveforms of input and output signals of the device under test of FIG. 6A, and FIG. 6D is a timing chart showing the timings of strobe signals.
FIG. 7 is a block diagram showing an example of configuration of a glitch detection unit of the present invention to be used a semiconductor test system.
FIG. 8 is a block diagram showing an example of more detailed circuit configuration in the glitch detection unit of the present invention.
FIG. 9 is a circuit diagram showing an example of configuration in an edge counter in the glitch detection unit of FIG. 8 in accordance with the present invention.
FIGS. 10A-10C are timing charts showing a relationship among an expected output signal, an actual output signal of the device under test having a glitch therein, and timings of the multiple strobe signals in the present invention.
FIGS. 11A-11C are timing charts showing a relationship among an expected output signal, an actual output signal of the device under test having a glitch therein, and timings of the continuous strobe signal in the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention is a semiconductor test system having a glitch detection means for detecting glitches in the output from the device under test to accurately evaluate the function and signal quality of the device under test. In the first aspect, the glitch detection means is a glitch detection unit (circuit) having an edge counter for counting the number of edges of the output signal which is compared with the number of edges in the expected output signal. If the number of edges is greater than the expected output signal, then it is determined that the output signal from the device under test contains a glitch therein. In another aspect, the glitch detection means includes means for generating a large number of strobes within a cycle of the output signal of the device under test or generating a continuous strobe whose timing (phase) continuously changes within a cycle of the output signal.
Assuming a situation where a circuit diagram such as shown in FIG. 6A is tested by a semiconductor test system by applying input test signals of FIG. 6 B. As also shown in FIG. 6B, the expected (simulated) output signal in this case is “0”. In this example, an actual output signal of the device under test is correct by showing “0” as shown in the left of FIG. 6 C. However, in the case where the output signal of the circuit diagram under test changes to a high level “1” without changes in the input signals as shown in the right of FIG. 6C, this device is faulty. The strobe point T 1 in FIG. 6D cannot detect this abnormal change, i.e., a glitch, in the output signal while strobe point T 2 is able to detect this error in the output signal.
In the first aspect of the present invention, a glitch detection unit (circuit) is incorporated in the semiconductor test system. An example of configuration of a glitch detection unit to be used in the semiconductor test system is shown in FIG. 7 . In this example, a glitch detection unit 53 is connected between the pin electronics 26 to receive an output signal of the device under test and the event generator 24 to receive the expected (simulated) output signal. When a glitch is detected in the output signal of the device under test, the glitch detection unit 53 generates a detection signal.
The glitch detection unit 53 includes a logic comparator 55 , an edge count unit 56 and an edge count unit 58 . The edge count unit 58 counts the number of edges in the output signal from the device under test. The edge count unit 56 counts the number of edges in the expected (simulated) output signal from the event generator (pattern generator) 24 . The numbers of edges counted by the edge count units 58 and 56 are compared by the logic comparator 55 . If the number of edges counted by the edge count unit 58 is greater than that of the edge count unit 56 , it means there is a glitch in the output signal of the device under test. Thus, the logic comparator 55 produces a glitch detection signal which is provided to, for example, the host computer of the test system. In the arrangement of FIG. 7, in the case where the test system can directly produce the number of edges associated with the expected output signal, the edge count unit 56 is unnecessary.
An example of more detailed circuit configuration in the glitch detection unit 53 is shown in FIG. 8 which is basically the combination of the edge count unit 58 of FIG. 7 and the logic comparator 55 . The edge count unit 58 includes an analog comparators 62 and 64 , buffers 63 and 65 , edge counters 67 and 68 , a multiplexer 71 , and an input signal decoder 72 . The edge count unit 58 counts the number of edges of an input signal (output signal of the device under test). Although not shown here, the edge count unit 56 of FIG. 7 for counting the number of edges of the expected signal may be included in here depending on the arrangement of the test system as noted above. The edge count unit 56 has the same structure as that of the edge count unit 58 .
The analog comparator 62 is configured, for example as a Schmitt trigger circuit, and is provided with a threshold voltage V OH to determine logic “1” in an input signal (output signal of the device under test). The output of the analog comparator 62 is provided to the edge counter 67 . Similarly, the analog comparator 64 is configured, for example as a Schmitt trigger circuit, and is provided with a threshold voltage V OI to determine logic “0” in the input signal. The output of the analog comparator 64 is provided to the edge counter 68 .
Thus, the edge counter 67 counts the number of rising edges in the input signal and the edge counter 68 counts the number of falling edges in the input signal. The multiplexer 71 selects the count data in one of the edge counter 67 or 68 and provides the selected count data to the logic comparator 55 to be compared with the expected number of edges. The input signal decoder 72 is to determine whether the value of the input signal is “0”, “1” or “Z”. This information is sent to the failure memory such as shown in FIGS. 1 and 2 when the logic comparator 55 indicates that the output signal of the DUT includes a glitch. The data in the failure memory is used in a failure analysis stage after the test.
FIG. 9 shows an example of configuration of the edge counter 67 or 68 in FIG. 8 . In this example, the edge counter is implemented using a ripple counter architecture. This architecture allows a counter to detect high frequency glitches with a minimum logic area implementation. Other benefit of using a ripple counter is low loading on the input signal (device output signal). The example of FIG. 9 is a 32-bit ripple counter where 32 edge triggered flip-flops or toggle flip-flops are connected in series. All outputs of the flip-flops are wired-OR connected with each other.
Referring back to the example of FIG. 5, the glitch detection unit 53 of the present invention achieves its objective as follows. For a known good device, the number of rising edges on the device output signal is two. After executing the test pattern, the test system reads the counted data in the edge counter 67 and compare the results with the expected data. In this example, the count in the edge counter 67 will show four edges, i.e, existence of glitch, leading the user to further investigation.
As in the foregoing, the glitch detection unit of the present invention allows the test system to detect unexpected output transitions in the device under test while adding only a small amount of extra hardware to the test system. The glitch detection unit also enhances failure detection accuracy without requiring extensive test pattern generation or increasing a device test time.
The second embodiment of the present invention is shown in the timing charts of FIGS. 10A-10C and FIGS. 11A-11C to detect glitches. The first approach is to use many strobes within a cycle of the device output as shown in FIGS. 10A-10C. In this example, FIG. 10A shows an expected (simulated) output signal, FIG. 10B shows an actual output signal of the device under test having a glitch therein, and FIG. 10C shows an example of timings in the multiple strobe signals in accordance with the present invention. The user can specify the timings and resolution (time difference between two adjacent strobes) of the strobes when setting the test conditions.
The second approach is to use continuous strobes within a cycle of the device output as shown in FIGS. 11A-11C. In this example, FIG. 11A shows an expected (simulated) output signal, FIG. 11B shows an actual output signal of the device under test having a glitch therein, and FIG. 10C shows an example of continuous strobe in accordance with the present invention. The continuous strobe is generated by continuously increasing a time difference from a previous strobe point by so programming the event timing data in the event memory or by the operation of the event generator. The user can specify an area within a cycle of the device output signal for continuously strobing the output signal. The continuous strobe may be activated for a specified time length such as between E 1 and E 2 or between E 3 and E 4 of FIG. 11 C.
In the second embodiment, glitches can be accurately detected by the multiple-strobe signals or the continuous strobe signals of the present invention. The second embodiment of the present invention is effective in detecting glitches in the output signal of the device under test without adding any hardware to the test system.
According to the present invention, the glitch detection unit in the first embodiment allows the test system to detect unexpected output transitions in the device under test while adding only a small amount of extra hardware to the test system. The glitch detection unit also enhances failure detection accuracy without requiring extensive test pattern generation or increasing a device test time. In the second embodiment, glitches can be accurately detected by the multiple-strobe signals or the continuous strobe signals of the present invention. The second embodiment of the present invention is effective in detecting glitches in the output signal of the device under test without adding any hardware to the test system.
Although only a preferred embodiment is specifically illustrated and described herein, it will be appreciated that many modifications and variations of the present invention are possible in light of the above teachings and within the purview of the appended claims without departing the spirit and intended scope of the invention.
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A semiconductor test system has a glitch detection function for detecting glitches in an output signal from a device under test to accurately evaluate the device under test (DUT) . The semiconductor test system includes an event memory for storing event data, an event generator for producing test patterns, strobe signals and expected patterns based on the event data from the event memory, a pin electronics for transmitting the test pattern from the event generator to the DUT and receiving an output signal of the DUT and sampling the output signal by timings of the strobe signals, a pattern comparator for comparing sampled output data with the expected patterns, and a glitch detection unit for receiving the output signal from the DUT and detecting a glitch in the output signal by counting a number of edges in the output signal and comparing an expected number of edges.
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This application claims the benefit of priority under 35 U.S.C. §119 of U.S. Provisional Application Ser. No. 61/881,671 filed on Sep. 24, 2013 the content of which is relied upon and incorporated herein by reference in its entirety.
FIELD
The present disclosure relates to hyperspectral imaging, and in particular relates to hyperspectral detector systems and methods that use context-image fusion.
The entire disclosure of any publication or patent document mentioned herein is incorporated by reference.
BACKGROUND
Hyperspectral imaging involves imaging multiple (e.g., dozens or hundreds of) narrow spectral bands over a spectral range to produce a composite image wherein each pixel in the scene being captured includes contiguous spectral data of the scene. An aspect of hyperspectral imaging combines a conventional two-dimensional (2D) spatial image with a third dimension of contiguous spectral bands, essentially performing spectrometry on each individual pixel of the 2D spatial image.
Conventional hyperspectral imaging involves generating a hyper-cube of data for the scene being imaged. A hyper-cube is in essence a three-dimensional (3D) image, where two of the dimensions are spatial and one dimension is contiguous spectral data. Depending on the device used to generate the data, the acquisition time for a single hyper-cube image from most hyperspectral systems can be on the order of tens of seconds before useful context-sensitive information can be extracted.
Due to the 3D nature of the data, hyper-cubes can be quite large, with their size depending on the spatial and spectral resolution of the image. While this amount of data collection is necessary for many hyperspectral applications, it is not necessary for all of them. In spectral detection applications, more often than not, the vast majority of the data collected is not needed.
One type of hyperspectral imaging system looks for specific pre-determined spectral signatures in a given area and is called a hyperspectral detector or HSD. In essence, HSDs are “Go/No-Go” sensors that verify the presence or absence of the particular spectral signatures that cannot be readily detected by visual methods or other means. It is often preferred that the information from the HSD be available in real-time so that users can take action in real-time rather than having to wait for the computation to be completed. Furthermore, for mobile or hand-held HSDs, computing power of the HSD may be limited.
SUMMARY
An aspect of the disclosure is a method of performing hyperspectral detection of a scene. The method includes: capturing a digital context image of at least a portion of the scene over a field of regard; capturing a spectral image of the scene over an instantaneous field of view that falls within the field of regard, and wherein the instantaneous field of view is less than half of the field of regard; fusing the context image and the spectral image to form a fused image; panning the spectral image over the scene and within the field of regard to capture one or more spectral signatures within the scene; and comparing the one or more spectral signatures to one or more reference spectral signatures and marking one or more locations of the one or more spectral signatures within the context image.
Another aspect of the disclosure is a method of performing hyperspectral detection of a scene. The method includes capturing a digital context image of at least a portion of the scene over a field of regard; capturing a spectral image of the scene over an instantaneous field of view with a single column of pixels of a first sensor, wherein the instantaneous field of view falls within the field of regard; fusing the context image and the spectral image to form a fused image; panning the spectral image over the scene to capture one or more spectral signatures within the scene; comparing the one or more spectral signatures to one or more reference spectral signatures and marking one or more locations of the one or more spectral signatures within the context image; and displaying on a display in real-time the fused image and the one or more marked locations.
Another aspect of the disclosure is a hyperspectral detection system for spectrally analyzing a scene. The system includes a context camera operably arranged to capture a digital context image of at least a portion of the scene over a field of regard. The system also includes an imaging spectrometer operably arranged to capture a spectral image of the scene over an instantaneous field of view that falls within the field of regard and that is less than half of the field of regard. The system also includes means for panning the spectral image over the scene and within the field of regard to capture one or more spectral signatures within the scene. The system further includes a processor that receives and fuses the context image and the spectral image to form a fused image. The processor is configured to compare the one or more spectral signatures to one or more reference spectral signatures and to mark one or more locations of the one or more spectral signatures within the context image.
Additional features and advantages are set forth in the Detailed Description that follows, and in part will be readily apparent to those skilled in the art from the description or recognized by practicing the embodiments as described in the written description and claims hereof, as well as the appended drawings. It is to be understood that both the foregoing general description and the following Detailed Description are merely exemplary, and are intended to provide an overview or framework to understand the nature and character of the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings are included to provide a further understanding and are incorporated in and constitute a part of this specification. The drawings illustrate one or more embodiment(s), and together with the Detailed Description serve to explain principles and operation of the various embodiments. As such, the disclosure will become more fully understood from the following Detailed Description, taken in conjunction with the accompanying Figures, in which:
FIG. 1 is a schematic diagram of an example hyperspectral detection system according to the disclosure;
FIG. 2 is a front-on view of an example scene to be analyzed by the hyperspectral detector system of FIG. 1 ;
FIG. 3A is a front-on view of an example hyperspectral detection system that shows the context camera and the imaging spectrometer supported by a support member;
FIG. 3B shows the example hyperspectral detection system supported by a support device shown as a tripod by way of example;
FIGS. 4A through 4C are similar to FIG. 1 and show an example of how the hyperspectral detector system disclosed herein can be used to analyze the scene of FIG. 2 ;
FIGS. 5A through 5C correspond to FIGS. 4A through 4C , respectively, and show the scene of FIG. 2 as viewed by the hyperspectral detection system as the scene is panned;
FIG. 6 illustrates an example embodiment of the hyperspectral detection system wherein the imaging lenses for the context camera and the imaging spectrometer are replaced with a single lens;
FIGS. 7A through 7C are side, front and back views of an example hand-held hyperspectral detection system;
FIGS. 8A and 8B are front-elevated and back-elevated views, respectively, of an example handheld hyperspectral detection system that employs a smart phone; and
FIG. 9 is a close-up view of an example context camera that includes a spectrally dispersive element that allows the context camera to also serve as the imaging spectrometer.
DETAILED DESCRIPTION
Reference is now made in detail to various embodiments of the disclosure, examples of which are illustrated in the accompanying drawings. Whenever possible, the same or like reference numbers and symbols are used throughout the drawings to refer to the same or like parts. The drawings are not necessarily to scale, and one skilled in the art will recognize where the drawings have been simplified to illustrate the key aspects of the disclosure.
The claims as set forth below are incorporated into and constitute part of this Detailed Description.
The entire disclosure of any publication or patent document mentioned herein is incorporated by reference.
Cartesian coordinates are shown in some of the Figures for the sake of reference and are not intended to be limiting as to direction or orientation.
FIG. 1 is a schematic diagram of an example hyperspectral detection (HSD) system 10 according to the disclosure. The HSD system 10 is shown arranged relative to a scene 12 to be spectrally analyzed, which is discussed in greater detail below. Cartesian coordinates are shown for the sake of reference. FIG. 2 is a front-on view of an example scene 12 , i.e., looking in the z-direction.
The HSD system 10 includes a context camera 20 that includes a housing 22 that operably supports a context-camera lens 24 and an image sensor 26 . In an example, context camera 20 is a conventional visible-wavelength digital camera, while in another example the context camera is an infrared (IR)-wavelength camera or a combination of a visible (VIS) and near-IR (NIR) camera (e.g., VIS and/or near-IR (NIR) and/or short-wavelength IR (SWIR) and/or mid-wavelength IR (MWIR) and/or long-wavelength IR (LWIR)). In an example, lens 24 has zoom capability. In an example embodiment, context camera 20 is image-stabilized using one or more image-stabilization techniques known in the art. Also in an example embodiment, lens 24 includes autofocusing capability using one or more autofocusing techniques known in the art.
In an example, image sensor 26 comprises an array of pixels 27 (see corresponding close-up inset) wherein the pixel array has a size of equal to or greater than 1,280×1,024 pixels. In an example, pixels 27 have a width W 27 in the range from 3 μm to 5 μm. In an example, context camera 20 is a cell-phone camera, a tablet camera or a smartphone camera.
The context camera 20 has a field of view that is referred to herein as a “field of regard” FoR. The context camera 20 captures a digital context image of a portion of scene 12 over the field of regard FoR and generates in response a digital context-image signal SC. The digital context image is a generally recognizable 2D spatial image that provides spatial (visual) context of at least a portion of scene 12 .
The HSD system 10 also includes an imaging spectrometer 40 that in an example includes a housing 42 that operably supports an imaging lens 44 and an image sensor 46 having pixels 47 (see corresponding close-up inset). In an example, pixels 47 have a width W 47 in the range from 10 μm to 25 μm (e.g., from about 2× to about 8× the size of pixels 27 ). In an example, sensor 46 has multiple rows and columns of pixels 27 that allows for spectral imaging over a portion (i.e., a sub-region) of the digital context image. In an example, imaging lens 44 has zoom capability. In an example, imaging spectrometer 40 is dispersion-based. In an example, sensor 46 is capable of analyzing 512 spatial pixels 47×80 spectral pixels, with a size of 15 microns/pixel, and a spectral range of 0.9 μm to 1.7 μm at 10 nm (spectral)/pixel. In an example embodiment, imaging spectrometer 40 is compact, e.g., has a volume of less than about 12 cubic inches, to facilitate portability of HSD system 10 . In an example embodiment, imaging spectrometer 40 is image-stabilized using one or more image-stabilization techniques known in the art. Also in an example embodiment, lens 44 includes autofocusing capability using one or more autofocusing techniques known in the art.
The imaging spectrometer 40 has an instantaneous field of view iFoV that is substantially narrower than a field of regard FoR of context camera 20 . FIG. 1 shows a width W S of the spectrometer instantaneous field of view iFOV in scene 12 , along with the corresponding width W′ S of the corresponding spectrometer (spectral) image formed at image sensor 46 . FIG. 1 also shows a width W R of the field of regard FoR in scene 12 , as well as the corresponding width W′ R of the corresponding context-camera image formed at image sensor 26 . The widths W S and W′ S are related by the magnification M 44 of imaging lens 44 , i.e., W′ S =M 44 ·W S . Likewise, the widths W R and W′ R are related by the magnification M 24 of imaging lens 24 , i.e., W′ R =M 24 ·W R . In the case where M 44 =M 24 , it follows that W′ S /W′ R =W S /W R .
The imaging spectrometer 40 captures a digital spectral image of a narrow portion of scene 12 over the instantaneous field of view iFoV and generates in response a digital spectral-image signal SS that includes one spatial dimension (e.g., a column of pixels) and one spectral dimension (i.e., the spectral data for each pixel in the column of pixels). In example embodiments, imaging spectrometer 40 operates over one or more of the visible and IR wavelengths, e.g., one or more of VIS, NIR, SWIR, MWIR and LWIR.
The instantaneous field of view iFoV is substantially narrower than field of regard FoR. In an example, the instantaneous field of view iFoV is less than half of the field of regard FoR. The width W′ S of the spectral image is define by the number N C47 of columns of pixels 47 multiplied by the width W 47 of a single pixel 47 of sensor 46 , i.e., W′ S =(N C47 )·(W 47 ). The minimum width of W′ S is when N C47 =1, i.e., W′ S =W 47 . Likewise, the width W′ R of the context image is defined by the number N C27 of columns of pixels 27 multiplied by the width W 27 of a single pixel 27 of sensor 26 , i.e., W′ R =(N C27 )·(W 27 ). Note that the minimum value of the ratio W′ S /W′ R (and thus the minimum value of W S /W R ) is W 47 /W R .
In various examples, W 47 /W′ R ≦[W′ S /W′ R ]<0.5 or W 47 /W′ R ≦[W′ S /W′ R ]<0.25 or W 47 /W′ R ≦[W′ S /W′ R ]<0.15 or W 47 /W′ R ≦[W′ S /W′ R ]<0.10 or W 47 /W′ R ≦[W′ S /W′ R ]<0.5 or W 47 /W R ≦[W′ S /W′ R ]<0.1 or W 47 /W′ R ≦[W′ S /W′ R ]<0.05 or W 47 /W′ R ≦[W′ S /W′ R ]<0.1. In an example embodiment, instantaneous field of view iFoV is defined by a single column of pixels 47 of image sensor 46 , so that W′ S /W′ R =W 47 /W′ R . In other example embodiments, instantaneous field of view iFoV is defined by a portion of the available row and column pixels 47 of image sensor 46 .
FIG. 3A is a front-on view of an example configuration of HSD system 10 wherein context camera 20 and imaging spectrometer 40 are operably supported by a support member 50 so that each can rotate about respective axes A1 and A2 shown oriented in the y-direction. Also in an example, support member 50 is rotatable about an axis A3 oriented in the same direction as axes A1 and A2. In an example, support member 50 is attached to or includes a post 52 to facilitate rotation about axis A3. In an example, post 52 is sized and otherwise configured to be hand-held (e.g., to have a hand grip) so that that HSD system 10 can be hand-held by a user (see FIGS. 7A through 7C , introduced and discussed below). Thus, in an example, post 52 defines a handle.
In another example illustrated in FIG. 3B , post 52 is used to mount HSD system 10 to a support device 54 , such as a gimbaled device or a tripod (as shown). In an example, post 52 includes a switch 53 that can be used to activate HSD system 10 , e.g., to capture a context image 100 and/or a spectral image 110 (see FIG. 5A ), to provide input to a computer, etc.
The support device 54 serves to facilitate the relative alignment of context camera 20 and imaging spectrometer 40 so that select pixels of context-camera image sensor 26 are co-located with pixels 47 of imaging-spectrometer sensor 46 .
With reference again to FIG. 1 , HSD system 10 also includes a computer 60 operably connected to context camera 20 and imaging spectrometer 40 . The computer 60 is configured to receive context-image signals SC and spectral-image signals SS and to process these signals (and, when needed, to fuse spectral image 110 with context image 100 ) to perform context-based hyperspectral detection, as described in greater detail below. The HSD system 10 also includes a display 70 operably connected to computer 60 . The display 70 can be used to display context image 100 , spectral image 110 or both images to together when viewing at least a portion of scene 12 , as discussed below. In an example, display 70 has touch-screen capability that can be used to control computer 60 .
The computer 60 includes a processor 62 and a memory unit (“memory”) 64 . In an example, memory 64 includes stored spectral data (reference spectral data) to which the measured spectra can be compared.
The computer 60 is configured to execute instructions stored in firmware and/or software to process spectral-image signals SS and context-image signals SC. The computer 60 is programmable to perform the functions described herein, including the operation of HSD system 10 and the aforementioned signal processing of spectral-image signals SS and context-image signals SC. As used herein, the term “computer” is not limited to just those integrated circuits referred to in the art as computers but broadly refers to computers, processors, microcontrollers, microcomputers, programmable logic controllers, application-specific integrated circuits and other programmable circuits, and these terms are used interchangeably herein.
Software in the form of instructions embodied in a computer-readable medium may implement or aid in the performance of the operations of HSD system 10 disclosed herein, including the aforementioned signal processing. The software may be operably installed in computer 60 and in particular in processor 62 and memory 64 . Software functionalities may involve programming, including executable code, and such functionalities may be used to implement the methods disclosed herein. Such software code is executable by the general-purpose computer, e.g., by processor 62 .
In an example, the software causes processor 62 to fuse or otherwise combine a 2D context image 100 with a 1D spectral image 110 . In particular, the pixels of context-camera image sensor 26 and imaging-spectrometer sensor 46 can be given respective grid coordinates that the software can use to process context image 100 and spectral image 110 . For example, the pixels of context-camera image sensor 26 can be given grid coordinates C1H through C1280H by (x) C1V through C1,024V, and the imaging-spectrometer sensor 46 can be given coordinates S1V through S512V (where V=vertical, H=horizontal). The imaging spectrometer 40 and context camera 20 are aligned so that the context-camera image-sensor pixels C1V×C640H and C2V×C640H are co-located with spectrometer pixel row S1V, and C1023V×C640H and C1024V×C640H are co-located with spectrometer pixel row S512V.
In operation, the code and possibly the associated data records are stored within a general-purpose computer platform within processor 62 and/or in memory 64 . At other times, however, the software may be stored at other locations and/or transported for loading into the appropriate general-purpose computer systems. Hence, the embodiments discussed herein can involve one or more software products in the form of one or more modules of code carried by at least one machine-readable medium. Execution of such code by processor 62 of computer 60 enables the platform to implement the catalog and/or software downloading functions in essentially the manner performed in the embodiments discussed and illustrated herein.
The computer 60 and/or processor 62 may each employ a computer-readable medium or machine-readable medium (e.g., memory 64 ), which refers to any medium that participates in providing instructions to the processor for execution, including, for example, determining the spectral content of select items in scene 12 , as discussed in greater detail below. The memory 64 constitutes a computer-readable medium. Such a medium may take many forms, including but not limited to non-volatile media, volatile media and transmission media. Non-volatile media include, for example, optical or magnetic disks, such as any of the storage devices in any computer(s) operating as one of the server platforms discussed above. Volatile media include dynamic memory, such as the main memory of such a computer platform. Physical transmission media include coaxial cables, copper wire and fiber optics, including the wires that comprise a bus within a computer system.
In an example, computer 60 includes input means (e.g., the aforementioned touch-screen capability for display 70 ) such as a keyboard, buttons, etc. (see buttons 210 , FIG. 7C , which is introduced and discussed below) that allow a user to provide input to the computer. Example inputs to HSD system 10 via computer 60 include software control settings such as image acquisition speed or shutter speed, selection of spectral data stored in memory 64 (e.g., selection from a spectral library), on/off selection for recording a context image and/or a spectral image, and on/off selection for illumination (not shown).
In an example embodiment, HSD system 10 includes a power supply 80 , such as a battery pack, so that the HSD system can be portable.
Examples of how spectral-image signals SS and context-image signals SC are processed are described in greater detail below. The HSD system 10 is operable to capture still images as well as video images.
The HSD system 10 can have other components that are not shown that provide additional functionality and information, such as GPS coordinates, geographic-information-system (GIS) data, compass heading, inclinometer heading, etc. As noted above, these devices/functions may also reside in computer 60 or other parts of HSD system 10 .
In an example, computer 60 is contained in context camera 20 , e.g., as processor 62 and memory 64 therein. For example, in the case where context camera 20 comprises a smartphone camera or a tablet camera, computer 60 can include the smartphone computing elements and the functionality of these devices, such as those mentioned immediately above (see FIG. 9 , introduced and discussed below).
In conventional HSD systems, the spectral image data is captured by a stationary sensor platform that systematically step-scans a small instantaneous field of view (iFoV) (e.g., a single column of pixels) over the much wider field of regard (FoR). The duration of the scan can be from one to tens of seconds, depending on the particular application, the conditions, and the nature of the scene being analyzed. The spectrometer sensor and the scene must remain stationary and undisturbed relative to each other for the duration of the scan to capture coherent, accurate spatial context information, which is usually not available until the scan is complete.
The HSD system 10 operates in a simpler and more efficient manner. Rather than collecting all the spectral data for each pixel 47 of imaging-spectrometer sensor 46 for scene 12 , spectral data is collected for only a small region of the scene, e.g., a single column of pixels 47 or a small number of columns of pixels 47 , wherein, in an example, the number of pixel columns is defined by the user. The spectral data for the small region of scene 12 is then displayed as a spectral image 110 in real-time along with context image 100 , i.e., the spectral image is fused with the context image and displayed on display 70 .
FIGS. 4A through 4C are similar to FIG. 1 and show an example of how HSD system 10 can be used to analyze scene 12 . FIG. 4A shows context-camera field of regard FoR being directed to the “+x” end of scene 12 . In this position, context camera 20 captures a context image of an end portion of scene 12 . The imaging spectrometer is arranged (e.g., rotated) so that its instantaneous field of view iFoV is roughly in the center of field of regard FoR at the location of scene 12 . Other positions of instantaneous field of view iFoV are possible, and a center position is shown as one convenient example position.
FIGS. 4B and 4C show context camera 20 and imaging spectrometer 40 being scanned together over scene 12 , with FIG. 4B showing the center of the scene being analyzed, and FIG. 4C showing the “−x” end of the scene being analyzed. Note that by scanning context camera 20 and imaging spectrometer 40 together, instantaneous field of view iFoV maintains its position within field of regard FoR. However, context camera 20 and imaging spectrometer 40 need not be scanned together in this manner. In an example, the relative position of instantaneous field of view iFoV can change within field of regard FoR, e.g., by moving (rotating) imaging spectrometer 40 at a different rate than context camera 20 . In another example, context camera 20 can be fixed and imaging spectrometer 40 moved (e.g., rotated) to scan over some or all of field of regard FoR.
In examples, the scanning of scene 12 by context camera 20 and imaging spectrometer 40 can be performed manually or automatically, e.g., under the control of computer 60 . Because context camera 20 is used, it is not necessary to wait for imaging spectrometer 40 to complete an entire scan of field of regard FoR before presenting useable data (spectral recognition fused with spatial context) to the user, e.g., via display 70 . Because the feedback is in real-time (e.g., >15 frames/second), the user has the ability to position instantaneous field of view iFoV anywhere within field of regard FoR, and can also change the position of the field of regard relative to scene 12 . The user can start and stop anywhere in scene 12 and can instantly reposition anywhere within the scene, including looking into “blind-spots” or otherwise inaccessible areas.
FIGS. 5A through 5C correspond to FIGS. 4A through 4C , respectively, and show scene 12 as viewed by HSD system 10 . FIGS. 5A through 5C each includes a context-camera image 100 defined by field of regard FoR and the corresponding spectral image 110 in the form of a vertical stripe superimposed with the corresponding context-camera image. The spectral image 110 is stippled for clarity and represents the hyperspectrally sensitive portion of scene 12 . The combination of context image 100 and spectral image 110 defines a fused image 114 .
FIG. 5A shows fused image 114 at the +x side of scene 12 . This represents the initial position of HSD system 10 for scanning and analyzing scene 12 . FIG. 5A also shows the width W′ R of context image 100 and the width W′ S of spectral image 110 . Note how in FIG. 5A context image 100 covers only an end portion of scene 12 , and how spectral image 110 only covers a portion of context image 100 at the left edge of the scene.
In an example of the operation of HSD system 10 , the system is powered up and initialized. This can include initializing context camera 20 , including initiating automated adjustment of the focus and light intensity levels. The initialization process can also include initializing imaging spectrometer 40 , including initiating the automated adjustment of focus and light intensity levels and performing a spectral calibration.
Once the initialization is completed, the user can direct HSD system 10 toward a select portion (e.g., a target area) of scene 12 . The user can then position spectral image 110 within context image 100 , i.e., within field of regard FoR, to define the configuration of fused image 114 . As noted above, FIG. 5A represents an example initial position of context image 100 and spectral image 110 for fused image 114 relative to scene 12 .
At this point, the user activates imaging spectrometer 40 (e.g., via switch 53 ) and moves context camera 20 and the imaging spectrometer (e.g., in synchrony) to pan scene 12 to identify spectral signatures of interest, e.g., by comparing detected spectra to reference spectra stored in memory 64 . The movement (scanning) of fused image 114 is indicated by arrows AR1 and AR2 that show the movement of context image 100 and spectral image 110 .
FIG. 5B shows context image 100 and spectral image 110 after having scanned over the left-half of scene 12 so that the context image and the spectral image are about centered in the scene. A tag 120 has been placed on a lamp 13 , which contains an incandescent bulb (not shown) that burns hot and thus has a strong spectral signal over the IR spectrum that matches a stored spectral signature in the spectral library maintained in memory 64 . The tag 120 serves to mark the position of the spectral signature within context image 100 .
If a spectral signature of interest (i.e., a spectral match) is found during the scanning of fused image 114 , then the corresponding area of context image 100 is identified as a region of interest RoI, as shown as a dotted-line box in FIG. 5B . For example, the corresponding context-image pixels 27 are highlighted and the spatial, color and intensity geometry of the surrounding context-image pixels are highlighted e.g., to define region of interest RoI on context-camera display 70 . The region of interest RoI can be tracked while it remains within field of regard FoR.
As context camera 20 and imaging spectrometer 40 continue to move and scan fused image 114 over scene 12 , tag 120 remains in place. Moreover, context image 100 is updated with new tags to mark new spectral matches as they are identified. FIG. 5C shows fused image 114 at the right side of scene 12 after having scanned the scene. Two new spectral signatures associated with a tea cup 14 and a teapot 16 are each identified and marked with respective tags 120 . Note that the two new tags 120 are black diamonds, which represent a different spectral signature than the star tag 120 that identifies the spectral signature associated with lamp 13 .
In an example embodiment, spectral matches are continuously tracked and the associated pixels 27 of context image 100 highlighted while they remain within field of regard FoR. For example, a spectral-match tag 120 at lamp 13 can be used to indicate a spectrally matching fingerprint on the lamp.
The result of the scan of scene 12 as performed by HSD system 10 is spectral identification information (and optionally geometry-tracking information) about the scene. The information can be embodied in one or more still images or in a video image.
At this point, the user can display a still version or video version of fused image 114 complete with spectral tags 120 and optionally with geometry tags 122 . The user also can relocate within scene 12 from a different perspective, angle or distance, can return to earlier scanned portions of the scene to rescan and/or can relocate to another scene within field of regard FoR.
The type of scanning performed by HSD system 10 is not the same as, and nor should it be confused with, the so-called “push-broom” hyperspectral imaging method. The push-broom method generates a continuous 2D spatial×1D spectral hyper-cube of the scene line by line (similar to a strip-chart) by scanning in one direction across the scene. While the scanning method disclosed herein requires moving context camera 20 and imaging spectrometer 40 relative to scene 12 to spatially and contextually locate a spectrally matching region within the scene, it is not necessary to move across the entire scene, nor in any pre-determined fashion, to acquire and display contextually useful data to the user.
As noted above, conventional hyperspectral imaging performs spectral analysis on each and every pixel of the imaging spectrometer within a given 2D image. A 3D hyper-cube of data is generated for each image, with two spatial dimensions and one spectral dimension. As an example of conventional hyperspectral imaging, for a moderate-resolution image, there could be 640×480 spatial increments (pixels) and 100 spectral increments (bands), for a total of 30,720,000 data points. After capture and storage of that data cube (approximately 20 seconds @ 30 camera frames/second), contextual analysis of the scene by the user can begin.
The HSD system 10 and associated methods disclosed herein obviate the need for generating the second (horizontal) spatial dimension to access contextually usable data. Using the above hyper-cube resolution as a baseline, the elimination of the generation of the second spatial dimension has at least the following advantages. First, it reduces the number of data points required for contextual analysis from 30,720,000 to 48,000, which is a 640× improvement. Second, it reduces the time required for the user to gain access to contextually useful information from >20 seconds to <0.03 seconds, which represents a 600× improvement. Third, it reduces the complexity and increases the compactness of HSD system 10 , to the point where the HSD system can be hand-held.
FIG. 6 illustrates an example embodiment of HSD system 10 wherein imaging lenses 24 and 44 for context camera 20 and imaging spectrometer 40 , respectively, are replaced with a single lens 144 that is used for both the context camera and the imaging spectrometer. This allows for context image 100 and spectral image 110 to be captured using a common (i.e., the same) lens. In the example shown, a dichroic mirror 146 and a regular mirror 148 are employed to direct light from scene 12 to imaging spectrometer 40 . In another example embodiment, additional optical components 149 in the form of lenses, one or more aperture stops, etc., are positioned between lens 144 and either context camera 20 or imaging spectrometer 40 (as shown, by way of example) to correct for imaging at the different wavelengths and to otherwise define the imaging optics for the context camera or the imaging spectrometer. The embodiment of FIG. 6 allows for a single light-collection optical system in the form of lens 144 , which simplifies HSD system 10 . In an example, lens 144 has zoom capability. In an example, lens 144 is image-stabilized using one or more image-stabilization techniques known in the art. Also in an example embodiment, lens 144 includes autofocusing capability using one or more autofocusing techniques known in the art.
FIG. 6 also illustrates an example embodiment of HSD system 10 that includes an illumination source 160 for illuminating at least a portion of scene 12 with illumination light 162 . The light 162 may be selected to have wavelengths specifically intended for use by imaging spectrometer 40 or by context camera 20 , or both.
If active illumination by illumination source 160 is necessary or desirable, only the narrow region being spectrally scanned needs to be stably illuminated, and only for the duration of a camera frame. The entire scene 12 need not be illuminated for the entire scan of the scene. This results in a significant gain in illumination intensity (based on area reduction and/or pulse duration) for the same illumination source, resulting in a corresponding increase in the signal-to-noise ratio and system sensitivity.
The HSD systems and methods disclosed herein have a number of advantages over prior art HSD systems and methods. Because of the simplified data collection and processing, the HSD system can be portable and can be configured as a hand-held device. Further, the system user has the flexibility to rapidly and easily scan any portion or sub-portion of a scene that they want to analyze at their discretion, in real-time. Because of the context feedback provided by context image 100 , the user has the ability to make immediate adjustments to the spatial scan parameters on-the-fly during a scan.
By eliminating the need to generate a complete spectral scan for every pixel in the 2D context image 100 , by spectrally scanning only a very narrow portion of the 2D context image and by seeking only a good spectral match to stored spectral signature(s), the acquisition speed, analysis, and presentation of context-sensitive information occurs in real-time (>15 frames per second).
Because context image 100 provides the spatial context information of scene 12 being analyzed, it is not necessary to have equally high spatial resolution for spectral image 110 . This allows for larger pixels to be used for sensor 46 of imaging spectrometer 40 , with a corresponding improvement in the signal-to-noise ratio and decrease in hardware costs, thereby making HSD system 10 more sensitive in the spectral domain and more cost effective.
FIGS. 7A through 7C show a side view, a front-on view and a back view, respectively, of an example hand-held HSD system 10 . The hand-held HSD system 10 includes a housing 200 having a front end 202 , a back end 204 , and a handle 52 attached to the housing. The housing 200 includes an interior 206 configured to contain the main elements of HSD system 10 as described above. The context camera 20 and imaging spectrometer 40 optically communicate through housing front end 202 . In addition, optional illumination source 160 also communicates through housing front end 202 . The housing back end 204 includes display 70 as well as various buttons 210 that provide input to HSD system 10 , turn the system on and off, direct/rotate context camera 20 and imaging spectrometer 40 , etc. The handle 52 allows a user to hold HSD system 10 and point it at scene 12 while conveniently viewing fused image 114 on display 70 .
FIGS. 8A and 8B are front-elevated and rear-elevated views, respectively, of another example hand-held HSD system 10 . The hand-held HSD system 10 utilizes a smart phone 250 whose digital camera serves as context camera 20 and whose display serves as display 70 . The smart phone 250 is supported by support member 50 , which is attached to the back end of imaging spectrometer 40 supported by handle 52 . FIGS. 8A and 8B show a context-camera optical axis AC and an imaging-spectrometer optical axis AS. In an example, computing components (not shown) of smart phone 250 are used as computer 60 .
FIG. 9 is a close-up view of context camera 20 illustrating an embodiment wherein context-camera image sensor 26 , which is made up of pixels 27 , can also collect spectral data, thereby eliminating the need for a separate imaging spectrometer. In the embodiment of FIG. 9 , context camera 20 includes a spectrally dispersive element 270 adjacent to image sensor 26 . The spectrally dispersive element 270 serves to disperse light 280 from scene 12 over a range of pixels 27 S and is used to define the spectral data, while the remaining pixels 27 C are used for context camera 20 in the usual fashion. The context-camera image 100 will be missing context data from those pixels 27 S used to capture spectral data. Thus, in the embodiment of FIG. 9 , context camera 20 includes a built-in imaging spectrometer 40 .
It will be apparent to those skilled in the art that various modifications to the preferred embodiments of the disclosure as described herein can be made without departing from the spirit or scope of the disclosure as defined in the appended claims. Thus, the disclosure covers the modifications and variations, provided they come within the scope of the appended claims and the equivalents thereto.
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The hyperspectral detector systems and methods disclosed herein include capturing a context image and a single-column spectral image that falls within the context image. The context and spectral images are then combined to form a fused image. Using the fused image, the spectral image is panned over the scene and within the context image to capture spectral signatures within the scene. The spectral signatures are compared to reference spectral signatures, and the locations of the one or more spectral signatures within the context image are marked. The systems and methods obviate the need to store and process large amounts of spectral data and allow for real-time display of the fused context image and spectral image, along with the marked locations of matched spectral signatures.
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FIELD OF THE INVENTION
[0001] The present invention relates to a process for organizing multimedia data that calls on an ontology, i.e. a structured set of concepts representing knowledge.
[0002] The invention has household applications in organizing multimedia data, and in particular digital photo data. It also has applications in customizing the organization of shared multimedia data. The invention's applications extend to providing public access to multimedia content on demand.
[0003] The multimedia data integrated into this organization system can include image-related data, sequences of images, sound, text, or any combination of these datasets.
BACKGROUND OF THE INVENTION
[0004] The wide range of multimedia data capture and reproduction equipment now available has generated a significant increase in the volume of data that users have access to and that they can share using this equipment. In particular, the increase in the memory capacities of digital cameras has generated an increase in the number of photographs taken during any given event.
[0005] The large volume of data liable to be presented prompts us to sort through and organize this data. The sort-through employed may depend not only on the person the multimedia data is intended for but also on the media via which the data is to be presented.
[0006] To illustrate this point, digital photograph data can be organized to create a slideshow or an album of printed proofs. Several albums related to the same event may include different photographs depending on the people they were intended for.
[0007] The same is true for video clip data, sound data, text data or any combination of multimedia data.
[0008] While the final presentation may be pleasing, users often find it tedious having to go through the data sorting, classification and organization steps.
[0009] Documents (1) and (2) whose references are specified at the end of the description describe various image creation and album creation techniques.
SUMMARY OF THE INVENTION
[0010] The creation of different presentations for different people and for different presentation media is generally a tedious task, regardless of the method used to classify or index the multimedia data and regardless of the tools users are able to use to create an individual data presentation.
[0011] An example that will be used as an illustration throughout this description is the presentation of marriage photos. The choice of photographs to be selected for a presentation should ideally depend on the person the presentation is intended for, i.e. the happy couple, the parents, friends, witnesses etc., as well as on the presentation media, i.e. slideshow, photo album, a fun object, a 3D object, etc.
[0012] The object of the invention is to provide a method that makes it far easier to organize digital data, at least in a certain number of given contexts.
[0013] It is also an object of the invention to provide a user with different means of organizing the same multimedia dataset for different target people, and with far less effort to put in.
[0014] To achieve these goals, the object of the invention is a process for organizing multimedia data in which the multimedia data is represented by contingent individuals of an instantiated ontology that among other things includes generic individuals and semantic links between individuals.
[0015] The process can be carried out with a computer, such as a personal computer or a server, running a software.
[0016] It can still be carried out with a processor of a specific multimedia device, such as a camera, or a digital photo-frame.
[0017] The process can also be performed on a device with an application specific integrated circuit.
[0018] The method comprises:
the presentation to the user of the choice of at least one individual from the instantiated ontology, and in response to a user-prompted choice, the selection and organization of a subset of multimedia data corresponding to the contingent individuals of the instantiated ontology according to at least one selection and/or organization rule engaging the user-chosen individual and the related semantic links.
[0021] The selection is carried out automatically and does not require any additional user input.
[0022] When the multimedia data includes image date, the process can additionally comprise a step of producing a photo-album and/or a slideshow using the selected subset of data.
[0023] The term ‘individuals’ describes the basic conceptualized elements of the ontology. These individuals are divided into either generic individuals or contingent individuals.
[0024] The full set of generic individuals and the related semantic links can form one or more generic ontologies. The generic ontology is used as the basic structure for organizing the multimedia data. The multimedia data are represented by contingent individuals that through semantic links are associated with individuals in the generic ontology. The generic ontology and the generic individuals are preferably not liable to be created or modified by a user implementing the process.
[0025] The contingent individuals on the other hand are indeed liable to get associated with knowledge content by the user. Examples of contingent individuals could include pointers towards existing multimedia data or towards data liable to be captured by the user.
[0026] The term ‘pointer’ describes an address or any other piece of information that makes it possible to identify, locate or find a multimedia data. A multimedia data object is considered as being associated with an individual of the ontology whenever this individual has a pointer to this multimedia data object.
[0027] The group formed by the generic ontology and the contingent individuals associated to it by means of semantic links is termed ‘instantiated ontology.
[0028] The instantiated ontology is used in association with one or preferably several selection and organization rules. The association of rules and instantiated ontology forms an organization system that is geared to multimedia data designed to be presented, and especially photographs.
[0029] Thanks to the invention the data, and especially the digital photos can be organized without labeling the photos and without a semantic content analysis.
[0030] The selection and organization of the presentation-focused multimedia data essentially depends on one or more individuals selected by the user. The panel of individuals offered to the user can include generic individuals, contingent individuals, or combinations of the two.
[0031] In a preferred implementation of the invention, the panel of choices offered to the user includes generic individuals.
[0032] The organization rule or organization ruleset can be immutable and unique. It is also possible to allow for several rulesets liable to be selected either directly by the user or according to the form of the presentation the user requires. To illustrate this point, it is possible to have a ruleset that applies when the data organization is aimed at producing a photo album and another ruleset for when the data organization is aimed at producing a video clip or a slideshow.
[0033] In a simplified implementation of the method, a single parametric or non-parametric rule can be used. This kind of rule would for example consist of selecting multimedia data associated with individuals from the ontology presenting a direct semantic link with the individual selected by the user.
[0034] It is possible to redistribute generic individuals into classes of individuals sharing common characteristics, in which case the section rules can also involve classes.
[0035] In this way, a rule in a ruleset can be selected according to the individual or individuals selected by the user or according to the class group of the user-selected individual or individuals, in which case the number of rules can for example be equal to the number of generic individuals in the ontology. One rule can, for example, be associated to each generic individual and/or to each class of individuals.
[0036] The process according to the invention is liable to be implemented based on an instantiated ontology given to the user. However, the method can also advantageously include a preliminary step involving the assisted creation of the instantiated ontology based on a generic ontology. In this scenario, the user need only be provided with one ontology or several generic ontologies.
[0037] The assisted creation offered to the user may involve providing suitable means of sorting. This would for example include configuring a data capture equipment interface according to a user-selected generic ontology, in which case the configuration step would offer the user a specific multimedia data sorting option.
[0038] To illustrate this point, when the user chooses a generic ontology, a display icon and/or control key can be associated with each generic individual in the ontology. If a PC equipped with a mouse is used as the interface, then the sort-through can be performed via drag-and-drop between icons representing the multimedia data and icons representing the individuals in the generic ontology.
[0039] The user-directed sort-through results in the creation of semantic links. The process in fact comprises the creation of semantic links between contingent individuals associated with the multimedia data and generic individuals in the selected ontology representing sort categories into which the user assigns the multimedia data. Semantic links are therefore created as a function of the user-performed sort-through.
[0040] Other characteristics and advantages of the invention will appear in the following description, which refers to the figures of the appended drawings. This description is given purely as an illustration and is not an exhaustive example.
BRIEF DESCRIPTION OF THE DRAWINGS
[0041] FIG. 1 is a simplistic diagrammatic illustration of a type of instantiated ontology liable to be used to implement a process according to the invention.
[0042] FIG. 2 is a flow chart showing the main steps of a multimedia data organization process implementing the invention.
DETAILED DESCRIPTION OF THE INVENTION
[0043] FIG. 1 is a simplistic diagrammatic illustration of an instantiated ontology 10 including a generic ontology 12 and a certain number of contingent individuals 14 .
[0044] The generic ontology comprises two classes of individuals 16 a and 16 b , each of which includes a certain number of generic individuals 18 .
[0045] For illustrative purposes, the description of the figures covers a generic ontology designed for organizing digital data relating to a marriage.
[0046] Hence, the first class of individuals 16 a comprises individuals related to episodes occurring during a marriage. The episodes illustrated correspond to the exchange of vows EV during a civil or religious marriage ceremony, to a toast T, and to a wedding reception WR.
[0047] There is a generic individual in the ontology for each different episode.
[0048] In the class of individuals 16 b , the individuals represent the typical roles in a marriage ceremony. For illustrative purposes, the figure features bridegroom B, witness T and a friend F.
[0049] The generic ontology also contains a certain number of generic semantic links. The semantic link “is followed by” is indicated by a reference s and links together individuals in the class of episodes 16 a . The generic ontology thus contains the knowledge that the wedding vows are followed by a toast that in turn is followed by a wedding reception.
[0050] In the same way, the generic semantic link “is important for”, which is indicated with a reference i, links individuals in the class of episodes 16 a together with individuals in the class of wedding ceremony roles 16 b as well as individuals within the wedding roles class. Thus, in the example illustrated, the generic ontology contains the knowledge that the exchange of vows and the wedding ceremony are key moments for the bridegroom, that the exchange of vows and the toast are key moments for the witness, and so on.
[0051] The contingent individuals 14 are or include pointers or addresses or identifiers of multimedia data. To simplify the description, pointers, addresses and identifiers are treated as the multimedia data they represent. Hence, in the rest of the text we will voluntarily stretch the meaning of the words and refer to contingent individuals as “multimedia data”.
[0052] In the example illustrated, the multimedia data includes digital photo files 14 a , 14 b , 14 c and 14 d and text files 14 e and 14 f liable to contain text previously entered by a user.
[0053] Multimedia data 14 are linked to the generic individuals of generic ontology 12 by the semantic links “is represented by” identified with the reference r. Hence, the exchange of vows is represented by the set of photos 14 a whereas the bridegroom is represented by a set of photographs 14 d . Semantic links r are in turn designated “contingent semantic links”.
[0054] Although not included in the figure for the obvious purpose of keeping it clear, it cannot be excluded that the same photograph, and by extension the same contingent individual 14 may have semantic links connecting it to different generic individuals in the generic ontology.
[0055] FIG. 2 illustrates another option for implementing the invention. We begin by describing a preliminary sort-through step 100 . This step is not strictly speaking an integral part of the organization method itself, and is not necessarily implemented by the same user as the user looking to organize data in order to present it. The sort-through step corresponds to the creation of an instantiated ontology. The method can, however, be implemented using an existing instantiated ontology.
[0056] A first step 101 in the preliminary phase comprises the selection of a generic ontology. In the example illustrated, this generic ontology is a marriage-related ontology. Similarly, other generic ontologies can be provided to handle other events such as a birthday, a holiday, etc. In each case, the generic individuals can correspond to events, places, people, situations, and more generally any foreseeable subject typically encountered in the target context and which is liable to have multimedia data relating to it.
[0057] Once the generic ontology has been selected, a sorting interface can be automatically configured in a step 102 designed to best adapt the generic ontology to the sort-through process. In the example illustrated, a screen display can be configured to make an icon 118 correspond to each respective generic individual in the ontology. Only a limited number of icons are shown in the figure. Following the same process, it would be possible to assign a control key to each of the generic individuals in the generic ontology selected.
[0058] The user could therefore use a mouse and a drag-and-drop command to match icons 114 representing multimedia data to icons representing generic individuals. This sort-through step can also include the entering of text corresponding to the text data 14 e and 14 f in FIG. 1 . This text input step is shown by reference 103 . Similarly, data can also be entered in the form of voice commentaries or music.
[0059] The user commands are used to create contingent semantic links and thereby build an instantiated ontology in a further step 104 . The contingent semantic links are the semantic links referenced r in FIG. 1 . They link multimedia data to generic individuals in the generic ontology.
[0060] The premolar step is thus completed when the instantiated ontology has been built.
[0061] The data organization process itself, 120 , can use the instantiate ontology built through step 104 or any other instantiated ontology of the same type that comprises multimedia data.
[0062] A first step 122 comprises the selection of an instantiated ontology. This amounts to simultaneously selecting a multimedia dataset, for example a set of digital photos, and a set of knowledge relating to this dataset. The knowledge is in particular stored in the generic and contingent links linking together the individuals in the instantiated ontology.
[0063] Once the ontology has been chosen, the user is presented with another choice option 126 : the choice of one or more individuals. This choice may be preceded by screen display 124 of a certain number of icons relating to individuals in the instantiated ontology selected. This step can also take place by configuring a keyboard or any other ad hoc interface.
[0064] The choice given to the user can be restricted to generic individuals or it may also include contingent individuals. Otherwise, it may be possible to limit the individuals offered in this choice according to the number of semantic links attached to them.
[0065] The choice step involves the user selecting one or possibly more of the individuals offered for selection.
[0066] To illustrate this, the individuals available for selection may be individuals EV, C, WR, B, W and F in FIG. 1 . The individual selected by the user could, therefore, be individual C (ceremony).
[0067] Another choice 128 can be presented to the user. This is the choice of media or mode of data presentation. For example, if the multimedia data is mainly photograph-related, the user can choose whether the multimedia data is earmarked for presentation as a slideshow or as a photo album.
[0068] The selection and organization of a subset of multimedia data is then carried out via a step 130 . This step calls on a ruleset 132 that may, if necessary, be selected according to the presentation format chosen during the second choice 128 .
[0069] These rules are pre-established and they can be related to contingent or generic semantic links just as they can be related to contingent or semantic individuals. These rules determine the multimedia data that has to be selected taking into account the user's choice or choices.
[0070] A certain number of examples can be given:
(a) select all the multimedia data (contingent individuals) related to a given generic individual if the user selects this generic individual. (b) take all the multimedia data linked related to the generic individual to which a user-chosen multimedia data (contingent individual) is linked. (c) take all the multimedia data linked to an individual chosen by the user by a number of successive links below X. (d) randomly select x percent of the multimedia data linked to the individual chosen by the user and 100-x percent of the multimedia data linked to the individual by less than y consecutive “is followed by” links.
[0075] These examples highlight how the rules can be specific to generic individuals or classes of individuals. They may also be generic themselves, by considering for example a number of links.
[0076] The rules can also apply to the organization of data and how it is presented. To illustrate this point, if the user has chosen to present the data as a photo album, there can be a rule stating for example that the print format for a photo in the album shall depend on the number of semantic links linking the contingent individual representing this photograph to generic individuals. A single link would for example result in a small presentation format, two links in a middle-sized format, and more than two links in large formats.
[0077] The method according to the invention can advantageously be used to create a multimedia presentation product designed specially for the target recipient.
[0078] Staying with our example of producing a photo album, it is possible, during the choice of individual step 126 , to offer the user either a broader choice covering a set of individuals in the ontology, or else a more limited choice. For example, this choice can be limited to the individuals within a class.
[0079] Thus, focusing on the class of wedding roles 16 b in FIG. 1 , the user can choose an organization more specifically targeting the bridegroom B, the witness W or the friend F.
[0080] If, for example, the rule is to select the photos related to the individual chosen (W) by less that three successive links, the photo album will mostly contain photos of the bridegroom, the exchange of vows ceremony, and the toast. The photos are related to the witness W by links i and r only. The witness in this example would, however, only receive photos of the wedding reception WR or the friend F, which suppose at least three consecutive links, for example, from 14 T to WR, from WR to 1 T and from T to W.
[0081] Rules engaging the semantic links s “is followed by” can be used to chronologically sequence the selected photographs.
[0082] It is possible to include a set of successive conditional rules running in the order from the most restrictive rules to the least restrictive rules. Since the use of a more restrictive rule is conditioned by the fact that it can generate a sufficient number of multimedia objects given the presentation format and the number of multimedia objects that the presentation needs to contain. Users can be offered this option during step 128 .
[0083] In a multimedia content on-demand distribution system, the generic ontologies can be saved on a server managed by the on-demand distribution service provider and the user choices mentioned hereabove can be made remotely via a communication network.
CITED DOCUMENTS
[0000]
1) U.S. Pat. No. 6,636,648
2) US 2003/0147558
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A multimedia data organization process, i.e. creation, of a photo album or slideshow, said multimedia data being represented by contingent individuals ( 14 a , 14 b , 14 c , 14 d , 14 e , 14 f ) of an instantiated ontology that in addition to generic individuals (EC, C, F, M, T, A) comprises semantic links between individuals, comprising: —the presentation to the user of the choice of at least one individual from the instantiated ontology, and in response to a user-prompted choice, —the selection and organization of a subset of multimedia data corresponding to the contingent individuals of the instantiated ontology according to at least one selection and/or organization rule engaging the user-chosen individual and the related semantic links.
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BACKGROUND OF THE INVENTION
This invention relates to toilet assemblies used in waste disposal systems on passenger vehicles such as buses, trains and aircraft. A preferred embodiment of a waste disposal system for railcars is described and claimed in a co-pending application, incorporated herein by reference, Ser. No. 07/862,320 (our reference NORCAN.004A) filed on the same date as the present invention and assigned to the assignee of the present invention.
The main components of such a toilet assembly are a flush valve assembly, a toilet bowl, a spray ring, a support base and a flush control unit.
In the prior art toilet assemblies, each of these components are relatively heavy and in the case of flush valve assemblies, require numerous moving parts. For instance, these prior flush valves typically incorporate motors or pneumatically driven valves having many relatively heavy moving parts. In addition, these assemblies are prone to frequent breakdowns and constant maintenance. The prior art toilet bowls are made from relatively heavy, as well as expensive stainless steel. Likewise, the prior art support bases typically comprise vertical legs typically made from steel.
The prior art toilet assemblies have additional disadvantages besides excessive weight and complexity. One disadvantage is that the prior art spray rings are formed from stainless steel tubing. When the spray holes become clogged, which is not infrequent due to lime and calcium deposits from local water sources, a chemical cleaning of the tube is required since the spray ring may not be quickly and inexpensively replaced.
Another disadvantage is that the structural configuration of the prior art support bases expose the toilet assembly to excessive tipping forces since the prior art support bases are connected at or close to the bottom of the bowl. These tipping forces are further accentuated due to the fact that the prior art support bases are not positioned under the center of gravity of the whole toilet assembly. Rather the prior art bases are positioned under the center of gravity of the bowl and fail to take into account the additional weight of the components attached to the rear of the bowl. Furthermore, the attachment of the bowl to the prior art support base requires that additional thicknesses of material (doublers) are needed on the exterior surface of the bowl for allowing the bowls to be attached to the prior art base, thus further increasing the weight of the toilet assembly.
A further disadvantage of the prior art toilet bowl assembly is that the vertical legs of the prior art support base restrict the work space between the shroud and the front of the support base.
SUMMARY OF THE INVENTION
The present invention includes significant structural and functional improvements to the toilet bowl, the spray ring, the flush valve assembly, and the support base. The improved bowl is a composite member manufactured as a prepreg lay-up member with a nickel-plated finish coating. The composite material of the present invention eliminates the need for expensive and heavy stainless steel bowls.
The improved spray ring is a disposable plastic tube. Advantageously the bowl contains a separate lip or flange mounted peripherally around the top exterior of the bowl. The spray ring simply snaps in between this lip and the toilet bowl for ease of maintenance. The disposability eliminates the need for constant cleaning of the spray ring due to lime and calcium deposits formed from local water sources.
The preferred embodiment of the valve assembly contains no motor driven parts or gear systems. The valve assembly comprises a cylindrical vacuum chamber, a flush solenoid and a valve blade. The valve blade is selectively openable, such that the valve blade in the open position connects the bowl to an outside vacuum source located in the waste outlet tubing so that the waste contained in the bowl can be sucked out.
The vacuum chamber contains a top cap with a top vacuum port and a bottom cap with a bottom vacuum port. A piston movable vertically within the chamber is connected to the valve blade such that the rise of the piston opens the valve blade and the descent of the piston closes the valve blade. A feature of the invention is that this flush valve assembly is self-cleaning such that the valve blade automatically cleans the juxtaposed face seals each time the valve is actuated.
The flush solenoid located adjacent to the chamber, is selectively openable to connect another outside pure vacuum source to the top and bottom vacuum ports on the vacuum chamber. The opening of the flush solenoid connects the pure vacuum to the top port of the chamber causing the piston to rise and the closing of the flush solenoid connects the pure vacuum to the bottom port, causing the piston to descend.
The support base used to cradle the bowl combines the use of side members in the form of obtuse, scalene triangular legs of lightweight composite material connected to each other in the front and rear of the base. The triangulated, slanted design of the support base compensates for the center of gravity of the whole assembly, including the valve assembly and the waste line tubing located behind the bowl. In addition, the design of the base enables the weight of the toilet assembly to be distributed over a greater area than in previous devices for reducing the forces which tend to tip or rotate the bowls relative to the assembly. The bowl is connected to the support base of the present invention in a manner such that the front of the bowl approximately half way down from the top of the bowl rests on the front lateral support sheet while the rear of the bowl is secured to the rear lateral support sheet. This obviates the need for doublers, and thus contributes to its light weight. The angled configuration of the composite legs also allows for more working space between the support base and the aesthetic shroud.
The use of lightweight composite material for toilet assemblies utilized on commercial passenger vehicles are advantageous from an economical standpoint. For instance, a reduction of a few pounds on commercial aircraft can lead to substantial savings on fuel costs.
In one embodiment of the present invention, the use of composite material has lowered the overall weight of the present toilet assembly to approximately 9 lbs, as opposed to 22 lbs. for prior art toilet assemblies. This reduction in weight will lead to substantial cost savings when the invention is used on commercial aircraft.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a perspective view of the toilet assembly of the present invention;
FIG. 1a is a partial cross-section of the bowl taken along lines 1a-1a of FIG. 1;
FIG. 1b is a top perspective view of the disposable spray ring of the present invention;
FIG. 2 is an exploded view of the toilet assembly of FIG. 1;
FIG. 3 is an exploded view of the vacuum chamber of the present invention;
FIG. 3a is an enlarged partial view of the blade of FIG. 3.
FIG. 4 is an exploded view of the piston and valve blade combination of the present invention;
FIG. 4a is an enlarged cross-sectional view of the diaphragm of FIG. 4 taken along lines 4a-4a;
FIG. 5 is an exploded view of the waste outlet tubing in relation to the valve assembly of the present invention;
FIG. 6 is a perspective view of the top and bottom caps of the vacuum chamber of the present invention;
FIG. 7 is a partial cross-sectional view of the top cap taken along lines 7--7 of FIG. 6;
FIG. 8 is a top plan view of the bottom cap of the vacuum chamber of the present invention;
FIG. 9 is a partial cross-sectional view of the bottom cap taken along lines 9--9 of FIG. 8;
FIG. 10 is a schematic representation of the solenoid needle and flapper valve in relation to the vacuum ports when the flush solenoid of the present invention is in the closed position;
FIG. 11 is a schematic representation of the solenoid needle and flapper valve in relation to the vacuum ports, when the flush solenoid of the present invention is in the open position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring to FIG. 1, the present invention comprises a toilet bowl assembly 2 which is light in weight and very sturdy. The assembly 2 comprises a very lightweight toilet bowl 4 advantageously constructed out of resin-impregnated fiber composite material. In the preferred embodiment, the composite material for the bowl 4 is woven fiberglass. As shown in FIG. 2, the bowl 4 has generally a funnel-like shape with a tubular bottom rear portion 38 of reduced diameter which represents the outlet for the waste contained in the bowl 4.
Referring to FIG. 1a, the top opening of the bowl 4 is connected to a separate lip or flange 6. This flange 6 will typically be made of plastic or stainless steel. The flange is placed circumferentially around the outer rim of the bowl 4 so that the flange 6 hangs over the bowl 4. In one embodiment, the bowl 4 and flange 6 are coated with a nickel-plated coating, which provides a very durable, abrasion-resistent, non-stick surface.
A disposable spray ring 8 is located between the bowl 4 and the flange 6. Ring 8 extends around the upper rim of the bowl 4 to provide an even spray pattern for bowl cleansing. Referring to FIG. 1b, in the preferred embodiment, the spray ring 8 is formed from a length of flexible plastic polyethylene tubing having two open ends with equidistantly spaced holes 9 for the emission of water onto the interior surface of the bowl 4. The tubing conforms to the shape of the rim of the bowl 4, with the two ends connected at the back of the interior of the bowl 4 to a single piece of plastic tubing 10 via a mating T-connector member 11. The spray ring 8 is simply wedged between the flange 6 and the bowl 4 for easy maintenance, as shown in FIG. 1a. The disposability of the spray ring 8 eliminates the need for frequent cleansing of the ring 8. When calcium and lime deposits form on the interior of the ring 8 from local water sources, the ring 8 is simply removed and disposed of and a new ring installed in it's place.
Referring to FIG. 2, the back of the bowl 4 contains an opening 5 so that the tubing 10 can extend through the opening 5 and connect to a potable fresh water source (not shown), which will supply the water necessary to cleanse the bowl 4.
The end of the tubing 10 away from the mating member 11 is connected to the output fitting 13 of an anti-siphon valve 12. The anti-siphon valve 12 only permits flow of water in one direction for sanitary purposes, so that waste water from the bowl 4 will not be able to travel from the bowl 4 back through the plastic tubing 10 and into the potable fresh water source (not shown).
The anti-siphon valve 12 advantageously includes an anti-freeze mechanism having a return conduit. As shown in FIG. 2, the output fitting 13 is connected to a plastic top 14 of the anti-syphon valve 12 which accumulates surplus water. One end of a rectangular shaft 16 containing one or more water return channels is connected to the bottom of the anti-siphon valve 12 for providing a passage for the water that has accumulated in the top 14 of the anti-syphon valve 12 and for preventing excess water from freezing inside of the top 14. The rectangular shaft 16 lies on top of a support member 18 of the support base 20, which will be discussed later. As shown in FIG. 1, the distal end of the shaft 16 is attached to the flange 6 and overhangs the rim of the bowl 4 so that the accumulated water is returned to the bowl 4.
Referring back to FIG. 2, the input fitting 15 of the anti-siphon valve 12, is connected via tube 17 to the outlet port of a rinse solenoid valve 22, which is attached to the rear of the support base 20. The inlet port of the rinse solenoid valve 22 is connected to an outside potable fresh water source (not shown). The rinse solenoid valve 22 in the closed position will not allow water from the potable fresh water source to enter the spray ring 8. However, the rinse solenoid valve 22 when activated to it's open position, will allow water to pass through the tubing 17, the anti-syphon valve 12, the tubing 10 and finally into the spray ring 8. The rinse solenoid valve 22 is activated by a timer/electronic control module 24 discussed below.
The bowl 4 of the present invention is supported by a novel support base 20 comprising a front sheet 30, a rear sheet 31 and side members 26 shown in FIGS. 1 and 2. The bowl 4 is cradled by the support base 20 such that the front of the bowl 4 approximately half way down from the top of the bowl 4 rests on the front sheet 30 of the base 20 while the rear 38 of the bowl 4 is secured in between the rear sheet 3 of the base 20 and the support member 18 as shown in FIG. 1.
Referring to FIG. 2, the side members 26 of the support base 20 are generally in the shape of an obtuse, scalene triangle and formed by legs 26a, 26b, 26c and 26d made out of light weight composite material. In the preferred embodiment, the composite material for these legs is shredded glass fiber impregnated with phenolic-resin or hard anodized aluminum. The legs 26a and 26b are connected to each other by horizontal composite bars 27, while legs 26c and 26d are connected to each other by horizontal composite bars 29. The legs 26a, 26b, 26c, 26d and composite bars 27,29 define openings 28 in the side members 26 for an additional reduction in weight. The side members 26 are connected to each other in the front and back via stainless steel sheets 30, 31 for better lateral support. The front sheet 30 contains parallelogram-like openings and is larger than the rear sheet 31. The upper portion of legs 26a and 26c are connected to support bars 32, which in turn are connected to a support member 18 where the rectangular shaft 16, which was discussed earlier, is placed.
The advantages of having this particular design for the base 20 are numerous. For instance, when a shroud (not shown) eventually encases the support base 20 for aesthetic purposes, the slanted obtuse, scalene triangular shape of the side members 26 create more room between the support base 20 and the shroud. This extra room is especially advantageous when work needs to be done on the toilet assembly 2. In addition, the triangulated shape of the base 20 takes into account the center of gravity of the whole assembly 2 by compensating for the extra weight of the valve assembly 34 and the waste line tubing 36 (shown in FIG. 1) located behind the bowl 4. The shape of the base 20 also provides for a better distribution of the weight of the bowl 4 by making contact higher up on the bowl 4 as opposed to prior devices. Finally, the fact of having the bowl 4 cradled by the support base 20 as opposed to being hard mounted, obviates the need for heavy metal doublers.
Referring to FIG. 2, the bottom rear of the bowl 38 contains an exit opening 40 which is connected to a waste outlet tubing 36 by means of a flange attachment. The rear 38 of the bowl 4 is secured to the top of the rear sheet 31 of the base 20 and the bottom of the support member 18 via the flange attachment, as shown in FIG. 1.
Referring to FIG. 2, a first mating flange 42 is adhesively attached onto the rear 38 of the bowl 4. A second mating flange 43, welded to one end of a piece of straight outlet tubing 49, is screwed onto the first mating flange 42 with the top of the rear sheet 31 of the base 20 and the bottom of the support member 18 held in between as shown in FIG. 1
The intended construction of the flush valve assembly 34 is shown in FIGS. 3-8. Referring to FIG. 5, the remainder of the waste outlet tubing 36 has the distal end of tube 49 welded onto a first large flange 45, which is welded over a first small flange 46. The first large flange 45 contains an interior groove in which a first spring loaded internal face seal 47 is located. This combination of a first large flange 45, a first small flange 46 and a first internal face seal 47 is welded onto a first valve body 48. The first valve body 48 is connected to a second valve body 49. A U-shaped spacer 50 is in juxtaposition with respect to the valve bodies 48, 49. The valve blade 51, which will be discussed later, is slidable in between the opening of the spacer 50.
The distal side of the second valve body 49 is connected to a second large flange 52. The second large flange 52 contains a second internal face seal 53 located within an internal groove. Both face seals 47, 53 will make flush contact with the valve blade 51 so that no air or particles can get trapped between the valve bodies 48, 49. The face seals 47, 53 utilized are a commercially standard unit containing an external circumferential groove where a continuously wound helical spring (not shown) is located. These springs are calibrated in a conventional manner by a manufacturer such as Ball seal such that the seals 47, 53 will provide enough force onto the blade 51 to create a seal without impeding the blade's movement. The face seals provide a separate function of cleaning the surfaces of the blade 51 as the blade 51 slides up and down.
Finally, an elbow tubing 54 having one end welded onto a second small flange 55 is connected to the second big flange 52 via an internal spring ring 56. The distal end of the elbow tube 54 is connected to a drain line (not shown) which is eventually connected to an outside waste tank (not shown). These types of components allow for quick connecting and disconnecting of the flush valve assembly 34 without the use of conventional nuts and bolts. All the components utilized in the connecting of the waste outlet tubing 36 are advantageously made out of stainless steel.
Referring to FIGS. 3 and 4, the portion of the flush valve assembly 34 located on top of the waste outlet tubing 36 comprises a flush solenoid 58, a vacuum chamber 60, a piston 64 and the valve blade 51. The vacuum chamber 60 comprises a hollow cylindrical tube 59, a top cap 61 and bottom cap 62. The top and bottom caps 61, 62 are retained on the hollow tube 59 via threaded bolts extending through holes 105 and secured by complementary nuts (see FIG. 5).
The bottom cap 62 contains a slot 110 as shown in FIG. 3, so that the blade 51 can move freely in and out of the chamber 60. The slot 110 contains a shop-made rubber gasket (not shown) with sufficiently close tolerances to seal the vacuum within the chamber 60.
Furthermore, there are three openings located within the bottom cap 62. A first vacuum port 90 located in the bottom cap 62 is connected to an outside pure vacuum source (not shown but discussed later) via a metal inlet tube 88 as shown in FIGS. 3 and 6. A second opening 92 located on the bottom cap 62 is linked to a vacuum port 120 shown in FIG. 7, located in the top cap 61 via a second metal tube 94 which extends from the bottom cap 62 to the top cap 61 as shown in FIGS. 3 and 7. Finally, a third opening 96 shown in FIG. 8, located in the bottom cap 62 is linked to a vacuum port 121 shown in FIG. 9 is also located in the bottom cap 62.
The vacuum connected to tube 88 is a pure vacuum since it is connected to a vacuum blower (not shown) on a line separate from the waste tank (not shown) so that there is no chance of fine particles of waste impeding the flow of vacuum. The path taken by the vacuum within the flush valve assembly 34 is described with reference to FIGS. 3, and 6-11. In the description, the vacuum is sometimes referred to as a positive pressure source for ease of explanation. It is understood of course, that the actual flow of air will be in reverse direction. When vacuum is introduced through the tube 88 from a pure outside vacuum source, the vacuum will take the following path: The vacuum will enter the first port 90 from the tube 88 and then proceed to the second opening 92. As described in more detail hereinafter with respect to FIGS. 10 and 11, depending on whether the flush solenoid 58 is open or closed, the vacuum will either (i) bypass the second opening 92 or (ii) enter it and proceed to the vacuum port 120 located in the top cap 61 (FIG. 7). If the vacuum bypassed the second opening 92, the vacuum will then pass to and through the third opening 96 and proceed to the vacuum port 121 located in the bottom cap 62 (FIGS. 8 and 9).
As shown in FIGS. 3 and 4, a plastic piston 64 in the shape of a disc is located within the interior of the chamber 60. As shown in FIG. 4, the piston 64 contains an external circumferential groove where a commercially standard spring loaded face seal 80 is contained to seal the vacuum source either above or below the piston 64 within the chamber 60.
Referring to FIG. 4, the piston 64 is made up of top and bottom circular pieces 65, 66 which are screwed together. By way of specific example, the plastic material Ulten 2000 sold by General Electric is advantageously used as the material for the pieces 65,66 of piston 64. The center of the top piece 65 of the piston 64 contains a hole 100 affixed to a hollow air tube 68. As shown in FIG. 3, the top cap 61 contains a centrally located hole 101, through which extends the distal end of the tube 68 in sliding engagement. This distal end is exposed to outside ambient air and as described below, this tube 68 enables an interior cavity 74 of the piston 64 to be exposed to the outside ambient air.
Referring back to FIG. 4, the interior of the top piece 65 of the piston 64 contains a recess 107 located radially outward from the hole 100 for the placement of a circular diaphragm 70 which is discussed in detail below. The diaphragm 70 is kept in the recess 107 by a retainer 72. The recess 107 is connected to the hole 100 via a first recessed slot or cavity 74 located on the interior lower surface of the top piece 65 of the piston 64.
The interior upper surface of the bottom piece 66 of the piston 64 contains a second through opening 76 located adjacent to the diaphragm 70 when the top and bottom pieces 65, 66 of the piston 64 are screwed together. The center of the bottom piece 66 of the piston 64, which is in juxtaposition with the bottom hole 100, and the second opening 76 are connected via a second recessed slot 78, located on the bottom piece 66 which will create a channel or cavity within the piston 64 when mated with the first recessed slot 74 located on the interior surface of the top piece 65.
As shown in FIG. 4a, the diaphragm 70 is a flexible rubber disc having a main portion capable of moving in or out of the recess 107. The main portion of the diaphragm 70 has a substantially flat side 130 which is juxtaposed in close proximity to the recess 107 and a semi-circular opposite side 135 spaced away from the recess 107. The retainer 72 is secured to the diaphragm 70 via a circumferential groove 138 around the main portion of the diaphragm 70. The area between the main portion and the groove 138 is flexible to allow the main portion of the diaphragm 70 to either move toward or away from the recess 107. When a vacuum is created above the piston 64, the main portion of the diaphragm 70 will move toward the recess 107 and away from the second opening 76 such that the flat side 130 will be flush with ceiling of the recess 107 and the semi-circular side 135 will be distanced from the opening 76. This permits ambient air to flow through tube 68 from outside the top cap 61 to the second opening 76 and into the bottom portion of the chamber 60.
When a vacuum is created above the piston 64, the main portion of the diaphragm 70 will move away from the recess 107 and toward the opening 76 such that the flat side 130 will be distanced from the ceiling of the recess 107 and the semi-circular side 135 will be flush against the opening 76. When the diaphragm 70 blocks the opening 76, ambient air cannot escape from the tube 68 and the cavity 74 to the bottom of the chamber 60 below the piston 64. Otherwise, the vacuum created beneath the piston 64 would suck the ambient air from outside the chamber 60 through the tube 68 and the opening 76. Thus, the diaphragm 70 closes off the opening 76 as discussed previously to create a suction causing the piston 64 to descend.
Referring to FIG. 4, a flexible valve blade 51 made out of stainless steel is connected to the bottom 66 of the piston 64 via a gasket 82, creating a unitary body. When the piston 64 rises, the blade 51 rises also.
The blade 51 contains a circular port 84 which will coincide with the interior bores of the waste line tubing 36 when the blade 51 is raised as shown in FIG. 5. The blade 51 is slidably retained within the opening of the spacer 50 as discussed earlier. The outside diameter of the blade 51 is less than the inside diameter of the spacer 50. The spacer 50 and the blade 51 have approximately the same thickness.
A significant feature of the invention is that the flush valve assembly 34 is a self-cleaning unit. Referring to FIG. 3a, the blade 51 contains notches 86 on both ends of its bottom edge 87 which automatically cleans the face seals 47, 53 each time the valve assembly 34 is actuated. As noted above, the face seals 47,53 reciprocally clean the surfaces of the valve blade 51 each time the valve blade 51 is actuated.
Referring back to FIG. 3, a flush solenoid 58 is connected to the chamber 60 via an opening 111 on the bottom cap 62. In the preferred embodiment, the solenoid 58 comprises a cylindrical shell having a needle element 98 and a circular flapper valve 140, shown schematically in FIGS. 10 and 11. The solenoid 58 is actuated by the control module 24 which is discussed later.
Referring to the schematic FIGS. 10 and 11, the vacuum path, in relation to the openings 90, 92, 96 located in the bottom cap 62 of the chamber 60, has been simplified. When the solenoid 58 is in the closed position as shown in FIG. 10, the solenoid needle 98 blocks off the second opening 92 so that the vacuum source of the first port 90 is connected only to the third opening 96 which will create a vacuum in the bottom portion of the chamber 60 through the port 121 located in the bottom cap 62. This will cause the piston 64 to either move down in the chamber 60 or, if the piston 64 is already at the bottom of the chamber 60, the piston 64 will remain so. When the solenoid 58 is in the open position as shown in FIG. 11, the needle 98 will move up causing the flapper valve 140 to pivot or tilt due to the air movement and block the third opening 96. Now the vacuum from the first port 90 is only connected to the second opening 92 which is linked to the port 120 located on the top cap 61 (FIG. 7). This will create a vacuum in the top of the chamber 60 causing the piston 64 to move upwardly.
It will thus be seen that the novel flush valve assembly 34 of the present invention is of relatively simple construction with relatively few parts. For instance, the lowering of the piston 64 to the bottom of the chamber 60 is achieved by the diaphragm and the air contained in the tube 94. Another feature of the invention is that during the descent of the piston 64, the ambient air that was contained in the tube 94 will bleed into the top portion of the chamber 60 above the piston 64, to eliminate the vacuum that was created there earlier, allowing the piston 64 to rapidly descend down in the chamber 60. Likewise, during the rise of the piston 64, the tube 68 enables the area beneath the piston 64 to fill with ambient air so that the force of the vacuum that is created above the piston 64 will not be impeded by a counteracting vacuum force located beneath the piston 64.
Referring back to FIG. 2, located in between legs 26a and 26b of the support base 20 is a timing mechanism/control module 24 of the type well known in the prior art. The timing mechanism/control module 24 establishes when the solenoids 22, 58 should open and close. The control module/timing mechanism 24 control the operation of the toilet assembly 2 through sequenced micro-switches.
In operation, when the user depresses the flush button located on the lavatory module (not shown), a signal will be sent to the electronic control unit 24 to activate the outside vacuum source while simultaneously initiating the toilet flush cycle.
The control unit 24 will then alert the rinse solenoid 22 to actuate into the open position. This will allow water from the potable fresh water source (not shown) to proceed through the plastic tubing 17, through the anti-siphon valve 12, through the plastic tubing 10 again , through the spray ring 8 and out onto the interior surface of the bowl 4, dispensing 12-14 ounces of water. The amount of water and the placement of the holes 9 on the spray ring 8 should be able to fully rinse the interior surface of the bowl 4.
Then the control module 24 will alert the rinse solenoid 58 to close, thus shutting off the water supply to the bowl 4. This rinse cycle will take at most two seconds. One second after the initiation of the rinse cycle, the control module 24 will alert the flush solenoid 58 to actuate to the open position. Initially, the piston 64 will be located at the bottom of the chamber 60 due to the fact that the flush solenoid 58 is closed.
However, when the flush solenoid 58 is activated open, the needle 98 will move up, causing the flapper valve 140 to tilt and close off the third opening 96 linked to the bottom port 121 as shown in FIG. 11. The pure outside vacuum will enter the bottom cap 62 of the chamber 60 via the first port 90. The vacuum will then enter the second opening 92 linked to the second port 120 located in the top cap 61 via tube 94. This will create a vacuum in the top of the chamber 60, causing the piston 64 to rise.
As the piston 64 rises, ambient air will proceed through the tube 68 and then through the channel created by the recessed slots 74, 78, eventually bleeding off through the second opening 76 to an area below the piston 64 due to the fact that the diaphragm 70 is not blocking the opening 76.
When the piston 64 moves up, since it is connected to the valve blade 51 via the gasket 82, the blade 51 will move up through the slot 110 of the bottom cap 62. The lift of the blade 51 will cause the port 84 on the valve blade 51 to coincide with the interior bores of the waste line tubes 36. Thus, the outside vacuum contained in the waste line tubes 36 will suck the waste located in the toilet bowl 4 out to an outside waste tank (not shown). The flush solenoid 58 will remain open for approximately four seconds, allowing sufficient time for complete cleaning of the lines between the bowl 4 and tank.
Once the four seconds are up, the timing mechanism/control module 24 will close the flush solenoid 58. The closing of the flush solenoid 58 will cause the needle 98 to move down and block the second opening 92 linked to the port 120 in the top cap 61, as shown in FIG. 10. The flapper valve 140 will tilt back down, opening the third opening 96 which is linked to the port 121 located in the bottom cap 62. The needle 98 will eventually come to rest on top of the flapper valve 140 as shown in FIG. 10.
Now the vacuum located in the first port 90 will be redirected to the third opening 96, which is linked to the bottom port 121, creating a vacuum below the piston 64 in the bottom of the chamber 60. This will cause the piston 64 to move down. The main portion of the diaphragm 70 during the descent will move outward from the recess 107 of the top piece 65 such that it will block the second opening 76 on the bottom piece 66. Now ambient air from the air tube 68 will not be able to enter below the piston 64. As discussed earlier, the closing of the diaphragm 70 will allow a vacuum suction to be created below the piston 64 causing the piston 64 to descend. Air that was located in the tube 94 linking the second opening 92 to the port 120 on the top cap 61 will now bleed into the area above the piston 64 in the top of the chamber 60 facilitating the descent of the piston 64 with the air tube 68. As discussed earlier, this surplus ambient air is necessary to eliminate the vacuum that was present in top of the chamber 60 above the piston 64 to facilitate the descent of the piston 64. The lowering of the piston 64 will thus lower the blade 51, moving the opening 84 of the valve blade 51 away from the interior bores of the waste line tubes 36 thus closing off the vacuum suction to the bowl 4.
The control module 24 will then simultaneously shut off the outside vacuum source approximately six seconds after the start of the flush cycle. The flush cycle is now complete and ready for another cycle.
The present invention discloses a novel lightweight vacuum-operated flush waste toilet assembly utilizing a valve assembly having relatively few moving parts. The present toilet assembly uses lightweight yet strong composite material for many of the components of the assembly. Furthermore, the novel design of the support base provides for a more secure support of the toilet bowl. The composite materials used in this invention are substantially lighter in weight than their prior art counterparts. The reduction in the overall weight of the toilet assembly will lead to a substantial reduction in operation costs when the invention is used aboard commercial aircraft.
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A toilet assembly suitable for use on commercial passenger vehicles, including a bowl for receiving waste and waste outlet tubing connecting the bowl to a vacuum source. A flush valve assembly is provided in the outlet tubing and is selectively openable to connect the vacuum source to the bowl for sucking the waste out of the bowl. A disposable spray ring containing a plurality of holes and selectively coupled to a water source is wedged between the bowl and a separate lip member for dispensing water onto the interior surface of the bowl. The flush valve assembly includes a vacuum chamber with top and bottom vacuum inlet ports, a piston connected to a valve blade movable vertically within the chamber and a flush solenoid openable to selectively connect a second vacuum to the top and bottom inlet ports. The assembly is supported by a novel lightweight composite base having triangular composite legs.
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CROSS REFERENCES TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. non-Provisional Patent application Ser. No. 12/896,413 filed on Oct. 1, 2010, which is incorporated herein by reference.
[0002] application Ser. No. 12/896,413 claimed the benefit of U.S. Provisional Patent Application No. 61/278,045 filed Oct. 2, 2009, which is incorporated herein by reference.
FIELD OF THE INVENTION
[0003] The present invention relates to an apparatus for preventing an animal from kicking with its hind legs when the animal is retained in a squeeze chute.
BACKGROUND OF THE INVENTION
[0004] Livestock animals, such as cattle, may be directed into a squeeze chute adapted for restraining the animal for the administration of veterinary procedures such as vaccinations. A difficulty that occurs in connection with such a squeeze chute process is that an animal will struggle and kick its hind legs. This is especially dangerous to wranglers or operators who are performing veterinary tasks in the vicinity of the rear quarters of an animal. Often when such tasks are to the operators. A typical solution is to slide a member such as a 2×4 or a bar through the structure of the squeeze chute directly behind the animal's hind legs in order to prevent kicking However, even this solution presents risks to the operator and the animal if the animal is kicking when the board or bar is inserted through the squeeze chute. What is needed is a remotely actuated apparatus that can be moved into position to prevent an animal from kicking when placed in a squeeze chute.
SUMMARY
[0005] The above described need is satisfied by the addition of kick bar assemblies to a squeeze chute. Opposing kick bar assemblies are mounted to opposite side walls of a squeeze chute. Each kick bar assembly includes an upright shaft that is rotatably mounted to the squeeze chute wall, a generally horizontal top bracket that preferably extends from the upper end of the upright shaft and a kick bar that preferably extends from the lower end of the upright shaft. The kick bar is preferably located at a level that is suitable for preventing the kicking movement of the hind leg of the type of livestock animal intended for handling by the squeeze chute. A remotely controllable actuator extends between the distal end of the top bracket and the squeeze chute wall. The actuator is adapted to pivot the kick bar assembly between a first retracted position in which the kick bar assembly is preferably retracted into recesses in the squeeze chute wall, a second normal extended position in which the kick bar is generally normal to the wall of the squeeze chute, and a third forward position in which the kick bar is rotated forward of the normal position and defines an acute angle with the squeeze chute wall. It is preferable that the actuators controlling the motion of the kick bars are capable of being simultaneously controlled to act in unison.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a perspective view of a squeeze chute which includes opposite kick bar assemblies.
[0007] FIG. 2 is a perspective view showing only the side walls of a squeeze chute which includes opposite kick bar assemblies shown in the retracted position.
[0008] FIG. 3 is a perspective view showing only the side walls of a squeeze chute which includes opposite kick bar assemblies shown in the normal extended position.
[0009] FIG. 4 is a perspective view showing only the side walls of a squeeze chute which includes opposite kick bar assemblies shown in the forward position.
[0010] FIG. 5 is a perspective view showing only one side wall of a squeeze chute which includes a kick bar assembly in the retracted position.
[0011] FIG. 5A is a perspective view showing in isolation the retracted kick bar assembly of FIG. 5 .
[0012] FIG. 6 is a perspective view showing the side wall of FIG. 5 which includes a kick bar assembly in the normally extended position.
[0013] FIG. 6A is a perspective view showing in isolation the normally extended kick bar assembly of FIG. 5 .
[0014] FIG. 6B is a cut away view taken from plane A-A of FIG. 1 with the second set of forward head gates removed showing a steer placed in the squeeze chute with the left side kick bar of kick bar assembly 10 A in the normal extended position behind the left hind leg of the steer.
[0015] FIG. 7 is a perspective view showing the side wall of FIGS. 5 and 6 which includes a kick bar assembly in the normally extended position.
[0016] FIG. 7A is a perspective view showing in isolation the forwardly extended kick bar assembly of FIG. 7 .
DETAILED DESCRIPTION
[0017] Referring to the drawings, FIG. 1 shows a squeeze chute 2 oriented from left to right in the direction of movement of livestock animals through squeeze chute 2 as indicated by direction arrow D. Squeeze chute 2 includes a kick bar apparatus 10 that includes two kick bar assemblies 10 A and 10 B. (Squeeze chute 2 shown in FIG. 1 is shown with a second set of forward head gates which not a typical design as most squeeze chutes of this type typically have one set of head gates. Accordingly, the remaining figures do not show the second forward set of head gates.) As can be seen in FIG. 1 and subsequent figures, kick bar assemblies 10 A and 10 B are mounted to the inside surfaces of opposite squeeze chute side walls 4 and 5 . As can be seen more easily in FIGS. 2-7 , each side wall 4 and 5 (which are referred to by those skilled in the art as “gates”) carries opposite and symmetrically identical kick bar assemblies which may be denoted here as left kick bar assembly 10 A and right kick bar assembly 10 B. Because right and left kick bar assemblies 10 A and 10 B are symmetrical and identical, only left kick bar assembly 10 A will be described here in detail. The skilled reader should understand that all of the elements of left kick bar assembly 10 A can be found as corresponding, opposite and symmetrical elements in kick bar assembly 10 B.
[0018] As can be best seen in FIGS. 5 , 5 A, 6 , 6 A, 6 B, 7 and 7 A, kick bar assembly 10 A is mounted to side wall 4 . Side wall 4 is essentially a rectangular frame fashioned from upright and horizontal members. As can be best seen in the upright bearing member 12 , an upright shaft 14 , a pivot member assembly 16 , an actuator 18 and a kick bar 20 . Upright bearing member 12 is fixed to the frame of side wall 4 and is adapted to receive and upright shaft 14 so that upright shaft 14 may freely rotate about axis A. Pivot member assembly 16 is fixed to the upper end of upright shaft 14 . In this example, pivot member assembly 16 includes a first pivot arm 16 A which extends toward the rear of squeeze chute 2 when kick bar assembly 10 A is in the retracted position shown in FIGS. 5 and 5A . A second pivot arm 16 B is fixed to the distal end of first pivot arm 16 A extends generally normally from pivot arm 16 A and inboard toward the centerline of squeeze chute 2 when kick bar assembly 10 A is in the retracted position shown in FIGS. 5 and 5A . Actuator 18 in this example is a hydraulic cylinder that extends between a mounting bracket 18 A where it is pivotably attached by a first clevis 18 B. As can be seen in FIG. 5 , mounting bracket 18 A is fixed to a horizontal member of side wall 4 . At its opposite end, actuator 18 is pivotably attached by a second clevis 18 C to the distal end of second pivot arm 16 B of pivot member assembly 16 . Kick bar 20 is fixed to the lower end of upright shaft 14 and is generally parallel to first pivot arm 16 A of pivot assembly 16 so that kick bar 20 is retracted within a recess in side wall 4 when kick bar assembly 10 A is in the retracted position shown in FIGS. 5 and 5A . All of the members described above may be fashioned from steel or some other suitable strong durable material. Although not shown in the figures, kick bar 20 is preferably covered by protective padding in order to prevent injuries to animals.
[0019] The operation of kick bar assembly 10 A and by extension the simultaneous operation of kick bar assemblies 10 A and 10 B can be best understood by referring to FIGS. 5A , 6 A and 7 A. In FIG. 5A , hydraulic cylinder 18 is fully position shown in FIG. 5A . It is by the contraction of hydraulic cylinder 18 that kick bar assembly 10 A is rotated from the retracted position shown in FIG. 5A to the extended positions shown in FIGS. 6A and 7A . As hydraulic cylinder 18 contracts from its fully extended position shown in FIG. 5A to the partially contracted position shown in FIG. 5A , kick bar assembly 10 A and more particularly kick bar 20 rotates into a normal extended position shown in FIGS. 6A and 6B as upright shaft 14 is rotated within bearing member 12 by the rotation of pivot arm assembly 16 . As hydraulic cylinder 18 continues to contract to the fully contracted position shown in FIG. 7A , kick bar 20 continues to rotate into the forward position shown in FIG. 7A . Generally, the normal extended position shown in FIG. 6A and 6B is suitable for preventing an animal from kicking backwards. FIG. 6B shows the location of kick bar 20 with respect to a steer 6 and more particularly with respect to the left hind leg 6 A of steer 6 . Kick bar 20 , in this position, will prevent steer 6 from kicking its hind leg in a backward direction. The forward position shown in FIG. 7A , in which kick bar 20 defines an acute angle with side wall 4 , is suitable for urging the leg of the animal toward side wall 4 of squeeze chute 2 . Thus, the inboard end of kick bar 20 shown in FIG. 6B would move forward and outboard as the upper portion of the animal's leg is engaged and restrained by kick bar 20 . When this is accomplished in unison on both sides of squeeze chute 2 , the hind legs of the animal are urged apart, which, for example, is useful when conducting reproductive work. The skilled reader should understand that the operations described above are normally conducted in unison so that both kick bar assemblies 10 A and 10 B move together.
[0020] Kick bar assemblies 10 A and 10 B are employed in the following manner. When steer 6 enters squeeze chute 2 , kick bars 20 are in the first retracted position. Steer 6 is urged far enough forward in direction D (shown in FIG. 1 ) so that steer 6 may be captured by the head gates of squeeze chute 2 as shown in FIG. 6B . Kick bars 20 are then simultaneously actuated in a forward direction until they are generally normal to sidewalls 4 of squeeze chute 2 as shown in FIG. 6 . Further, kick may be moved to the forward position for restraining the hind legs of steer 6 . Prior to releasing the animal from squeeze chute 2 , if kick bars 20 are in the forward position, kick bars are preferably retracted to at least the normal position. If kick bars 20 are in the normal position when the steer 6 is released, then steer 6 is prevented from moving backwards in squeeze chute 2 . Accordingly, it is preferable to have kick bars 20 in the normal position as shown in FIG. 6B when steer 6 is released. After steer 6 is released, then kick bars 20 are returned to the retracted position shown in FIGS. 5 and 5A in preparation for receiving the next animal.
[0021] Thus, the objectives of the invention are accomplished by the above described kick bar assemblies. Kick bar assemblies 10 A and 10 B are arranged so that they can be retracted into the side walls of cattle chute 2 when not in use so that they present no impediment to the movement of an animal through squeeze chute 2 . Although second pivot arm 16 B and portions of actuator 18 are not flush within the side wall when a kick bar assembly is in the retracted position, because of the length of pivot shaft 14 , they are positioned well above an animal in the squeeze chute and present no obstacle to the movement of the animal. When kick bar assemblies 10 A and 10 B are extended for use, they can be used to restrain the violent and dangerous injury caused kicking of an animal and with further forward extension as described above can be used to urge the legs of an animal apart for various tasks as noted above.
[0022] It is to be understood that while certain forms of this invention have been illustrated and described, it is not limited thereto, except in so far as such limitations are included in the following claims and allowable equivalents thereof
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Kick bar assemblies mounted to an opposite side walls of a squeeze chute structure each include an upright shaft that is rotatably mounted to the squeeze chute wall. Each kick bar assembly connects at one end to an actuator for rotating the shaft and at the other end to a kick bar which may be pivoted by the actuator between a first retracted position, a second normal extended position in which the kick bar is generally normal to the wall of the squeeze chute and a third forward position in which the kick bar is rotated forward of the normal position and defines an acute angle with the squeeze chute wall. The actuators controlling the motion of the kick bars are capable of being simultaneously remotely controlled to act in unison.
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TECHNICAL FIELD
[0001] The present invention relates to a compound having a 1,2,4-triazolone skeleton showing an antagonistic activity on the arginine-vasopressin (AVP) V1b receptor and a pharmaceutical composition comprising the compound as an active ingredient, in particular, to a therapeutic or preventive agent for diseases such as mood disorder, anxiety disorder, schizophrenia, Alzheimer's disease, Parkinson's disease, Huntington's chorea, eating disorder, hypertension, gastrointestinal disease, drug addiction, epilepsy, cerebral infarction, cerebral ischemia, cerebral edema, head injury, inflammation, immune-related disease, and alopecia.
BACKGROUND ART
[0002] The arginine-vasopressin (AVP) is a peptide composed of nine amino acids, is biosynthesized mainly in the hypothalamus, and is highly involved in regulation of plasma osmolality, blood pressure, and body fluid volume as a posterior pituitary hormone.
[0003] Three subtypes of AVP receptors, V1a, V1b, and V2 receptors, have been cloned until now. They are all known to be seven-transmembrane receptors. The V2 receptor is coupled to Gs to increase the cAMP level. The V1a receptor is coupled to Gq/11 to facilitate PI response and increase the intracellular Ca level. The V1a receptor is expressed in, for example, the brain, liver, adrenal gland, and vascular smooth muscle and is involved in vasoconstriction. The V1b receptor is also coupled to Gq/11, like the Via receptor, to facilitate PI response (see Non-Patent Literatures 1 and 2). The V1b receptor is observed most commonly in the pituitary gland (expressed in 90% or more ACTH secreting cells of the anterior lobe) and is supposed to participate in the ACTH secretion from the anterior pituitary by AVP. The V1b receptor is present in various areas of the brain at high levels: the limbic cortex system including the hippocampus, amygdala, and entorhinal cortex, the cerebral cortex, the olfactory bulb, and the raphe nucleus, which are the origin of the serotonin nervous system, in addition to the pituitary gland (see Non-Patent Literatures 3 and 4).
[0004] In recent years, involvement of the V1b receptor in mood disorder or anxiety disorder has been suggested, and usefulness of V1b receptor antagonists has been being studied. The V1b receptor KO mice exhibit reduced aggressive behavior (see Non-Patent Literature 5). In addition, injection of a V1b receptor antagonist in the septal area prolonged the time spent in the open arm (anxiolytic-like effect) in an elevated plus-maze test (see Non-Patent Literature 6). In recent years, a V1b receptor specific antagonist, a 1,3-dihydro-2H-indol-2-one compound that can be administered peripherally, has been discovered (see Patent Literatures 1 to 3). In addition, the 1,3-dihydro-2H-indol-2-one compound was reported to show antidepressant- and anxiolytic-like effects in a variety of animal models (see Non-Patent Literatures 7 and 8). The compound disclosed in Patent Literature 1 shows a high affinity (1×10 −9 mol/L to 4×10 −9 mol/L) for and selectively acts on the V1b receptor, and this compound antagonizes AVP, AVP+CRF, and restraint stress-induced ACTH increases.
[0005] Recently, V1b receptor antagonists having structures different from that of the 1,3-dihydro-2H-indol-2-one compound have been reported, such as quinazolin-4-on derivatives (see Patent Literatures 4 and 10), β-lactam derivatives (see Patent Literatures 5 and 7), azinon/diazinon derivatives (see Patent Literature 6), benzimidazolone derivatives (Patent Literature 8), isoquinoline derivatives (see Patent Literatures 9 and 10), pyridopyrimidin-4-one derivatives (see Patent Literature 11), pyrrolo[1,2-a]pyrazine derivatives (see Patent Literature 12), pyrazolo[1,2-a]pyrazine derivatives (see Patent Literature 13), tetrahydroquinoline sulfonamide derivatives (see Non-Patent Literature 9), and thiazole derivatives (see Non-Patent Literature 10). However, compounds with a 1,2,4-triazolone skeleton disclosed in the present invention have not been reported.
CITATION LIST
Patent Literature
[0000]
Patent Literature 1: WO2001/055130
Patent Literature 2: WO2005/021534
Patent Literature 3: WO2005/030755
Patent Literature 4: WO2006/095014
Patent Literature 5: WO2006/102308
Patent Literature 6: WO2006/133242
Patent Literature 7: WO2007/109098
Patent Literature 8: WO2008/025736
Patent Literature 9: WO2008/033757
Patent Literature 10: WO2008/033764
Patent Literature 11: WO2009/017236
Patent Literature 12: WO2009/130231
Patent Literature 13: WO2009/130232
Non-Patent Literature
[0000]
Non-Patent Literature 1: Sugimoto T, Kawashima G, J. Biol. Chem., 269, 27088-27092, 1994
Non-Patent Literature 2: Lolait S, Brownstein M, PNAS, 92, 6783-6787, 1995
Non-Patent Literature 3: Vaccari C, Ostrowski N, Endocrinology, 139, 5015-5033, 1998
Non-Patent Literature 4: Hernando F, Burbach J, Endocrinology, 142, 1659-1668, 2001
Non-Patent Literature 5: Wersinger S R, Toung W S, Mol. Psychiatry, 7, 975-984, 2002
Non-Patent Literature 6: Liebsch G, Engelmann M, Neurosci. Lett., 217, 101-104, 1996
Non-Patent Literature 7: Gal C S, Le Fur G, 300, JPET, 1122-1130, 2002
Non-Patent Literature 8: Griebel G, Soubrie P, PNAS, 99, 6370-6375, 2002
Non-Patent Literature 9: Jack D. Scott, et al., Bioorganic & Medicinal Chemistry Letters, 19, 21, 6018-6022, 2009
Non-Patent Literature 10: Chris A S, et. al., Bioorganic & Medicinal Chemistry Letters, 21, 92-96, 2011
SUMMARY OF INVENTION
Technical Problem
[0029] It is an object of the present invention to find a novel compound having a V1b receptor antagonistic activity and to provide a therapeutic or preventive agent for diseases such as mood disorder, anxiety disorder, schizophrenia, Alzheimer's disease, Parkinson's disease, Huntington's chorea, eating disorder, hypertension, gastrointestinal disease, drug addiction, epilepsy, cerebral infarction, cerebral ischemia, cerebral edema, head injury, inflammation, immune-related disease, and alopecia. More specifically, the object is to find a novel compound having an excellent V1b receptor antagonistic activity and showing satisfactory drug migration to a target organ and high safety.
Solution to Problem
[0030] The present inventors, as a result of diligent studies, have found a novel compound with a 1,2,4-triazolone skeleton having a V1b receptor antagonistic activity (hereinafter, referred to as “1,2,4-triazolone derivative”), and have accomplished the present invention.
[0031] The present invention includes the following embodiments:
[0032] (I) A 1,2,4-triazolone derivative represented by Formula (1A):
[0000]
[0033] [in Formula (1A),
[0000] R 1 represents a C 1-5 alkyl (the C 1-5 alkyl is optionally substituted by one to three groups selected from the group consisting of hydroxy, halogen atoms, cyano, C 3-7 cycloalkyl, and C 1-5 alkoxy), C 3-7 cycloalkyl, or 4- to 8-membered saturated heterocycle;
R 2 represents a hydrogen atom or C 1-5 alkyl;
R 3 represents aryl or heteroaryl (the aryl or heteroaryl is optionally substituted by one or two groups selected from the group consisting of C 1-5 alkoxy, C 1-5 alkyl, halogen atoms, trifluoromethyl, trifluoromethoxy, cyano, hydroxy, difluoromethoxy, and C 1-5 alkylsulfonyl);
R 4 and R 5 may be the same or different and each represent a hydrogen atom, C 1-5 alkyl (the C 1-5 alkyl is optionally substituted by one to three groups selected from the group consisting of hydroxy, halogen atoms, cyano, C 3-7 cycloalkyl, and C 1-5 alkoxy), C 3-7 cycloalkyl, or 4- to 8-membered saturated or unsaturated heterocycle containing one or more nitrogen, oxygen, or sulfur atoms in the ring (the 4- to 8-membered saturated or unsaturated heterocycle is optionally substituted by one or two groups selected from the group consisting of hydroxy, C 1-5 alkyl, C 1-5 alkoxy, halogen atoms, cyano, C 2-5 alkanoyl, and trifluoromethyl), or R 4 and R 5 optionally, together with the adjoining nitrogen atom, form a 4- to 8-membered saturated or unsaturated heterocycle optionally containing one or more nitrogen, oxygen, or sulfur atoms, in addition to the adjoining nitrogen atom, in the ring (the 4- to 8-membered saturated or unsaturated heterocycle is optionally substituted by one or two groups selected from the group consisting of hydroxy, C 1-5 alkyl (the C 1-5 alkyl is optionally substituted by one or two hydroxy), C 1-5 alkoxy, halogen atoms, cyano, C 2-5 alkanoyl, oxo, aminocarbonyl, mono-C 1-5 alkylaminocarbonyl, di-C 1-5 alkylaminocarbonyl, trifluoromethyl, and amino (the amino is optionally substituted by one or two groups selected from the group consisting of C 1-5 alkyl and C 2-5 alkanoyl), and the 4- to 8-membered saturated or unsaturated heterocycle optionally has a C 1-5 alkylene group crosslinking two different carbon atoms in the ring) or form 2-oxa-6-azaspiro[3.3]hept-6-yl or 7-oxa-2-azaspiro[3.5]non-2-yl;
A represents phenylene or 6-membered heteroarylene (the phenylene and 6-membered heteroarylene are optionally substituted by one or two groups selected from halogen atoms and C 1-5 alkoxy);
X represents a single bond, —O—, or —NR 6 —;
R 6 represents a hydrogen atom, C 1-5 alkyl, or C 2-5 alkanoyl;
R a represents a hydrogen atom or C 1-5 alkyl; and
n is an integer of 0 to 3],
or a pharmaceutically acceptable salt of the 1,2,4-triazolone derivative;
[0034] (II) A 1,2,4-triazolone derivative represented by Formula (1A):
[0000]
[0035] [in Formula (1A),
[0000] R 1 represents a C 1-5 alkyl (the C 1-5 alkyl is optionally substituted by one to three groups selected from the group consisting of hydroxy, halogen atoms, cyano, C 3-7 cycloalkyl, and C 1-5 alkoxy), C 3-7 cycloalkyl, or 4- to 8-membered saturated heterocycle;
R 2 represents a hydrogen atom or C 1-5 alkyl;
R 3 represents aryl or heteroaryl (the aryl or heteroaryl is optionally substituted by one or two groups selected from the group consisting of C 1-5 alkoxy, C 1-5 alkyl, halogen atoms, trifluoromethyl, trifluoromethoxy, cyano, hydroxy, difluoromethoxy, and C 1-5 alkylsulfonyl);
R 4 and R 5 may be the same or different and each represent a hydrogen atom, C 1-5 alkyl (the C 1-5 alkyl is optionally substituted by one to three groups selected from the group consisting of hydroxy, halogen atoms, cyano, C 3-7 cycloalkyl, and C 1-5 alkoxy), C 3-7 cycloalkyl, or 4- to 8-membered saturated or unsaturated heterocycle containing one or more nitrogen, oxygen, or sulfur atoms in the ring (the 4- to 8-membered saturated or unsaturated heterocycle is optionally substituted by one or two groups selected from the group consisting of hydroxy, C 1-5 alkyl, C 1-5 alkoxy, halogen atoms, cyano, C 2-5 alkanoyl, and trifluoromethyl), or R 4 and R 5 optionally, together with the adjoining nitrogen atom, form a 4- to 8-membered saturated or unsaturated heterocycle optionally containing one or more nitrogen, oxygen, or sulfur atoms, in addition to the adjoining nitrogen atom, in the ring (the 4- to 8-membered saturated or unsaturated heterocycle is optionally substituted by one or two groups selected from the group consisting of hydroxy, C 1-5 alkyl (the C 1-5 alkyl is optionally substituted by one or two hydroxy), C 1-5 alkoxy, halogen atoms, cyano, C 2-5 alkanoyl, oxo, aminocarbonyl, mono-C 1-5 alkylaminocarbonyl, di-C 1-5 alkylaminocarbonyl, and trifluoromethyl, and the 4-to 8-membered saturated or unsaturated heterocycle optionally has a C 1-5 alkylene group crosslinking two different carbon atoms in the ring) or form 2-oxa-6-azaspiro[3.3]hept-6-yl;
A represents phenylene or 6-membered heteroarylene (the phenylene and 6-membered heteroarylene are optionally substituted by one or two groups selected from halogen atoms and C 1-5 alkoxy);
X represents a single bond, —O—, or —NR 6 —;
R 6 represents a hydrogen atom, C 1-5 alkyl, or C 2-5 alkanoyl;
R a represents a hydrogen atom or C 1-5 alkyl; and
n is an integer of 1 to 3],
[0036] or a pharmaceutically acceptable salt of the 1,2,4-triazolone derivative;
[0037] (III) A 1,2,4-triazolone derivative represented by Formula (1a):
[0000]
[0038] [in Formula (1a),
[0000] R 1 represents a C 1-5 alkyl (the C 1-5 alkyl is optionally substituted by one to three groups selected from the group consisting of hydroxy, halogen atoms, cyano, C 3-7 cycloalkyl, and C 1-5 alkoxy), C 3-7 cycloalkyl, or 4- to 8-membered saturated heterocycle;
R 2 represents a hydrogen atom or C 1-5 alkyl;
R 3 represents aryl or heteroaryl (the aryl or heteroaryl is optionally substituted by one or two groups selected from the group consisting of C 1-5 alkoxy, C 1-5 alkyl, halogen atoms, trifluoromethyl, trifluoromethoxy, cyano, hydroxy, and difluoromethoxy);
R 4 and R 5 may be the same or different and each represent a hydrogen atom, C 1-5 alkyl (the C 1-5 alkyl is optionally substituted by one to three groups selected from the group consisting of hydroxy, halogen atoms, cyano, C 3-7 cycloalkyl, and C 1-5 alkoxy), C 3-7 cycloalkyl, or 4- to 8-membered saturated or unsaturated heterocycle containing one or more nitrogen, oxygen, or sulfur atoms in the ring (the 4- to 8-membered saturated or unsaturated heterocycle is optionally substituted by one or two groups selected from the group consisting of hydroxy, C 1-5 alkyl, C 1-5 alkoxy, halogen atoms, cyano, C 2-5 alkanoyl, and trifluoromethyl), or R 4 and R 5 optionally, together with the adjoining nitrogen atom, form a 4- to 8-membered saturated or unsaturated heterocycle optionally containing one or more nitrogen, oxygen, or sulfur atoms, in addition to the adjoining nitrogen atom, in the ring (the 4- to 8-membered saturated or unsaturated heterocycle is optionally substituted by one or two groups selected from the group consisting of hydroxy, C 1-5 alkyl (the C 1-5 alkyl is optionally substituted by one or two hydroxy), C 1-5 alkoxy, halogen atoms, cyano, C 2-5 alkanoyl, oxo, aminocarbonyl, mono-C 1-5 alkylaminocarbonyl, di-C 1-5 alkylaminocarbonyl, and trifluoromethyl, and the 4- to 8-membered saturated or unsaturated heterocycle optionally has a C 1-5 alkylene group crosslinking two different carbon atoms in the ring) or form 2-oxa-6-azaspiro[3.3]hept-6-yl;
A represents phenylene or 6-membered heteroarylene;
X represents a single bond, —O—, or —NR 6 —;
R 6 represents a hydrogen atom, C 1-5 alkyl, or C 2-5 alkanoyl; and
n is an integer of 1 to 3],
or a pharmaceutically acceptable salt of the 1,2,4-triazolone derivative;
[0039] (IV) The 1,2,4-triazolone derivative or pharmaceutically acceptable salt thereof according to any one of embodiments (I) to (III), wherein
[0000] R 1 is a C 1-5 alkyl;
R 2 is a hydrogen atom; and
R 3 is phenyl or pyridyl (the phenyl or pyridyl is optionally substituted by one or two groups selected from the group consisting of C 1-5 alkyl, C 1-5 alkoxy, halogen atoms, cyano, hydroxy, trifluoromethyl, difluoromethoxy, and trifluoromethoxy);
[0040] (V) The 1,2,4-triazolone derivative or pharmaceutically acceptable salt thereof according to any one of embodiments (I) to (IV), wherein
[0000] A is phenylene, pyridinediyl, or pyrimidinediyl (the phenylene, pyridinediyl, and pyrimidinediyl are optionally substituted by one or two groups selected from halogen atoms and C 1-5 alkoxy);
[0041] (VI) The 1,2,4-triazolone derivative or pharmaceutically acceptable salt thereof according to any one of embodiments (I) to (IV), wherein
[0000] A is phenylene or pyridinediyl (the phenylene and pyridinediyl are optionally substituted by one or two groups selected from halogen atoms and C 1-5 alkoxy);
[0042] (VII) The 1,2,4-triazolone derivative or pharmaceutically acceptable salt thereof according to embodiments (VI), wherein
[0000] A represents any one of Formulae (2) to (4):
[0000]
[0043] (VIII) The 1,2,4-triazolone derivative or pharmaceutically acceptable salt thereof according to any one of embodiments (I) to (VII), wherein
[0000] X is a single bond;
n is an integer of 1; and
R 4 and R 5 optionally, together with the adjoining nitrogen atom, form a 4- to 8-membered saturated or unsaturated heterocycle optionally containing one or more nitrogen, oxygen, or sulfur atoms, in addition to the adjoining nitrogen atom, in the ring (the 4- to 8-membered saturated or unsaturated heterocycle is optionally substituted by one or two groups selected from the group consisting of hydroxy, C 1-5 alkyl (the C 1-5 alkyl is optionally substituted by one or two hydroxy), C 1-5 alkoxy, halogen atoms, cyano, C 2-5 alkanoyl, oxo, aminocarbonyl, mono-C 1-5 alkylaminocarbonyl, di-C 1-5 alkylaminocarbonyl, and trifluoromethyl, and the 4- to 8-membered saturated or unsaturated heterocycle optionally has a C 1-5 alkylene group crosslinking two different carbon atoms in the ring) or form 2-oxa-6-azaspiro[3.3]hept-6-yl;
[0044] (IX) The 1,2,4-triazolone derivative or pharmaceutically acceptable salt thereof according to any one of embodiments (I) to (VIII), wherein
[0000] R 4 and R 5 , together with the adjoining nitrogen atom, form a 5- or 6-membered saturated heterocycle optionally containing one or more nitrogen, oxygen, or sulfur atoms, in addition to the adjoining nitrogen atom, in the ring (the 5- or 6-membered saturated heterocycle is optionally substituted by one or two groups selected from the group consisting of hydroxy and C 1-5 alkyl, and the 5- or 6-membered saturated heterocycle optionally has a C 1-5 alkylene group crosslinking two different carbon atoms in the ring) or form 2-oxa-6-azaspiro[3.3]hept-6-yl;
[0045] (X) The 1,2,4-triazolone derivative or pharmaceutically acceptable salt thereof according to any one of embodiments (I) to (VIII), wherein
[0000] R 4 and R 5 , together with the adjoining nitrogen atom, form a 6-membered saturated heterocycle optionally containing one or more oxygen atoms, in addition to the adjoining nitrogen atom, in the ring (the 6-membered saturated heterocycle is optionally substituted by one or two hydroxy, and the 6-membered saturated heterocycle optionally has a C 1-5 alkylene group crosslinking two different carbon atoms in the ring) or form 2-oxa-6-azaspiro[3.3]hept-6-yl;
[0046] (XI) One substance selected from, or a mixture of two or more substances selected from the group consisting of the following compounds and pharmaceutically acceptable salts thereof according to embodiment (I):
2-[3-(3-chlorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chlorophenyl)-1-{4-[2-(3-hydroxypyrrolidin-1-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chlorophenyl)-1-(4-{2-[3-(hydroxymethyl)pyrrolidin-1-yl]ethyl}phenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chlorophenyl)-1-{4-[2-(3-hydroxy-8-azabicyclo[3.2.1]oct-8-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chlorophenyl)-1-{4-[2-(8-oxa-3-azabicyclo[3.2.1]oct-3-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chlorophenyl)-1-{4-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chlorophenyl)-5-oxo-1-{4-[2-(piperidin-1-yl)ethyl]phenyl}-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chlorophenyl)-1-{4-[2-(1,4-oxazepan-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chlorophenyl)-1-{5-[2-(morpholin-4-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chlorophenyl)-1-{5-[2-(3-hydroxy-8-azabicyclo[3.2.1]oct-8-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chlorophenyl)-1-{5-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chlorophenyl)-1-{6-[2-(morpholin-4-yl)ethyl]pyridin-3-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, N-tert-butyl-2-[3-(3-chlorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]acetamide, 2-[3-(3-chlorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(1,1,1-trifluoropropan-2-yl)acetamide, 2-[3-(3-chlorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(1-hydroxy-2-methylpropan-2-yl)acetamide, 2-[3-(3-chlorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-cyclobutylacetamide, 2-[3-(3-chlorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(oxetan-3-yl)acetamide, 2-[3-(3-chlorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(cyclopropylmethyl)acetamide, 2-[3-(3-methoxyphenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(4-fluoro-3-methoxyphenyl)-5-oxo-1-{4-[2-(piperidin-1-yl)ethyl]phenyl}-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(4-fluoro-3-methoxyphenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(4-fluoro-3-methoxyphenyl)-1-{4-[2-(3-hydroxy-8-azabicyclo[3.2.1]oct-8-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(4-fluoro-3-methoxyphenyl)-1-{4-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(4-fluoro-3-methoxyphenyl)-1-{5-[2-(morpholin-4-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(4-fluoro-3-methoxyphenyl)-1-{5-[2-(3-hydroxy-8-azabicyclo[3.2.1]oct-8-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(4-fluoro-3-methoxyphenyl)-1-{5-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chloro-4-fluorophenyl)-5-oxo-1-{4-[2-(piperidin-1-yl)ethyl]phenyl}-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chloro-4-fluorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chloro-4-fluorophenyl)-1-{4-[2-(2-oxa-6-azaspiro[3.3]hept-6-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chloro-4-fluorophenyl)-1-{4-[2-(1,4-oxazepan-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chloro-4-fluorophenyl)-1-{4-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chloro-4-fluorophenyl)-1-{4-[2-(3-hydroxy-8-azabicyclo[3.2.1]oct-8-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chloro-4-fluorophenyl)-5-oxo-1-{5-[2-(piperidin-1-yl)ethyl]pyridin-2-yl}-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chloro-4-fluorophenyl)-1-{5-[2-(morpholin-4-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chloro-4-fluorophenyl)-1-{5-[2-(2-oxa-6-azaspiro[3.3]hept-6-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chloro-4-fluorophenyl)-1-{5-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-cyanophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-fluorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-(1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-3-phenyl-1,5-dihydro-4H-1,2,4-triazol-4-yl)-N-(propan-2-yl)acetamide, 2-[3-(3-chlorophenyl)-1-{3-fluoro-4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chlorophenyl)-1-{3-fluoro-4-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chlorophenyl)-1-{3-methoxy-4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chlorophenyl)-1-{3-methoxy-4-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chlorophenyl)-1-{4-[2-(morpholin-4-yl)propyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chlorophenyl)-1-{4-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)propyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chlorophenyl)-1-{5-[2-(morpholin-4-yl)propyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(3-chlorophenyl)-1-{5-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)propyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, N-tert-butyl-2-[3-(3-chlorophenyl)-1-{5-[2-(morpholin-4-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]acetamide, N-tert-butyl-2-[3-(3-chlorophenyl)-1-{5-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]acetamide, 2-[3-(3-methoxyphenyl)-1-{4-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, N-tert-butyl-2-[3-(3-methoxyphenyl)-1-{5-[2-(morpholin-4-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]acetamide, N-tert-butyl-2-[3-(3-methoxyphenyl)-1-{5-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]acetamide, 2-[3-(2-bromo-5-chlorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-(3-[3-(methylsulfonyl)phenyl]-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl)-N-(propan-2-yl)acetamide, 2-[3-(3-chlorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, (+)-2-[3-(3-chlorophenyl)-1-{5-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)propyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, (−)-2-[3-(3-chlorophenyl)-1-{5-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)propyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(4-fluoro-3-methoxyphenyl)-1-{4-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)propyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, 2-[3-(4-fluoro-3-methoxyphenyl)-1-{5-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)propyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, N-tert-butyl-2-[3-(3-methoxyphenyl)-1-{4-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)propyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]acetamide, N-tert-butyl-2-[3-(3-methoxyphenyl)-1-{5-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)propyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]acetamide, 2-[3-(6-methoxypyridin-2-yl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide, and 2-[3-(6-methoxypyridin-2-yl)-1-{4-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide;
[0110] (XII) A pharmaceutical composition comprising the 1,2,4-triazolone derivative or pharmaceutically acceptable salt thereof according to any one of embodiments (I) to (XI) as an active ingredient; and
[0111] (XIII) A therapeutic or preventive agent comprising the 1,2,4-triazolone derivative or pharmaceutically acceptable salt thereof according to any one of embodiments (I) to (XI) as an active ingredient for mood disorder, anxiety disorder, schizophrenia, Alzheimer's disease, Parkinson's disease, Huntington's chorea, eating disorder, hypertension, gastrointestinal disease, drug addiction, epilepsy, cerebral infarction, cerebral ischemia, cerebral edema, head injury, inflammation, immune-related disease, or alopecia.
Advantageous Effects of Invention
[0112] The novel 1,2,4-triazolone derivative of the invention shows an affinity for the V1b receptor and has an antagonistic activity on a stimulus to the receptor by a physiological ligand.
DESCRIPTION OF EMBODIMENTS
[0113] The terms used in the specification have the following meanings.
[0114] The term “halogen atom” refers to a fluorine atom, a chlorine atom, a bromine atom, or an iodine atom.
[0115] The term “C 1-5 alkyl” refers to a linear or branched alkyl group having 1 to 5 carbon atoms, and examples thereof include methyl, ethyl, n-propyl, isopropyl, n-butyl, isobutyl, sec-butyl, tert-butyl, n-pentyl, isopentyl, neopentyl, and tert-pentyl.
[0116] The term “C 3-7 cycloalkyl” refers to a group such as cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, or cycloheptyl.
[0117] The term “C 1-5 alkoxy” refers to a linear or branched alkoxy group having 1 to 5 carbon atoms, and examples thereof include methoxy, ethoxy, n-propoxy, isopropoxy, n-butoxy, isobutoxy, sec-butoxy, tert-butoxy, n-pentyloxy, isopentyloxy, neopentyloxy, and tert-pentyloxy.
[0118] The term “C 1-5 alkylsulfonyl” refers to a sulfonyl group substituted by “C 1-5 alkyl” defined above, and examples thereof include methylsulfonyl, ethylsulfonyl, n-propylsulfonyl, isopropylsulfonyl, n-butylsulfonyl, isobutylsulfonyl, sec-butylsulfonyl, tert-butylsulfonyl, n-pentylsulfonyl, isopentylsulfonyl, neopentylsulfonyl, and tert-pentylsulfonyl.
[0119] The term “C 2-5 alkanoyl” refers to a linear or branched alkanoyl group having 2 to 5 carbon atoms, and examples thereof include acetyl, propionyl, butyryl, isobutyryl, valeryl, isovaleryl, and pivaloyl.
[0120] The term “mono-C 1-5 alkylaminocarbonyl” refers to a carbonyl group substituted by amino having one “C 1-5 alkyl” group defined above as a substituent, and examples thereof include methylaminocarbonyl, ethylaminocarbonyl, n-propylaminocarbonyl, isopropylaminocarbonyl, n-butylaminocarbonyl, isobutylaminocarbonyl, s-butylaminocarbonyl, t-butylaminocarbonyl, n-pentylaminocarbonyl, isopentylaminocarbonyl, and neopentylaminocarbonyl.
[0121] The term “di-C 1-5 alkylaminocarbonyl” refers to a carbonyl group substituted by amino having two identical or different “C 1-5 alkyl” groups defined above as substituents, and examples thereof include dimethylaminocarbonyl, diethylaminocarbonyl, di(n-propyl)aminocarbonyl, di(isopropyl)aminocarbonyl, ethylmethylaminocarbonyl, methyl(n-propyl)aminocarbonyl, and methyl(isopropyl)aminocarbonyl.
[0122] The term “aryl” refers to a monocyclic or bicyclic aromatic carbocycle, and examples thereof include phenyl, 1-naphthyl, and 2-naphthyl.
[0123] The term “heteroaryl” refers to a mono- or bi-cyclic aromatic group having 2 to 9 carbon atoms and having at least one hetero atom selected from oxygen, nitrogen, and sulfur atoms, and examples thereof include thienyl, furyl, pyrazolyl, imidazolyl, thiazolyl, isoxazolyl, oxazolyl, isoxazolyl, pyridyl, pyrimidinyl, quinolyl, indolyl, and benzofuranyl.
[0124] The term “4- to 8-membered saturated heterocycle” refers to a 4- to 8-membered saturated ring containing at least one hetero atom selected from nitrogen, oxygen, and sulfur atoms in the ring, and examples thereof include oxetan-3-yl, azetidin-1-yl, 1-pyrrolidinyl, piperidino, 2-piperidyl, 3-piperidyl, 1-piperazinyl, morpholin-4-yl, morpholin-3-yl, thiomorpholin-4-yl, thiomorpholin-3-yl, azepan-1-yl, 1,4-oxazepan-4-yl, and azocan-1-yl.
[0125] The term “4- to 8-membered saturated or unsaturated heterocycle containing one or more nitrogen, oxygen, or sulfur atoms in the ring” refers to, for example, oxetan-3-yl, azetidin-1-yl, 1-pyrrolidinyl, piperidino, 2-piperidyl, 3-piperidyl, 1-piperazinyl, morpholin-4-yl, morpholin-3-yl, thiomorpholin-4-yl, thiomorpholin-3-yl, azepan-1-yl, 1,4-oxazepan-4-yl, azocan-1-yl, 5,6-dihydropyridin-1(2H)-yl, 1,4-diazepan-1-yl, or 1,2,3,6-tetrahydropyridin-1-yl.
[0126] The term “a 4- to 8-membered saturated or unsaturated heterocycle formed together with the adjoining nitrogen atom and optionally containing one or more nitrogen, oxygen, or sulfur atoms, in addition to the adjoining nitrogen atom, in the ring” refers to a group such as azetidin-1-yl, 1-pyrrolidinyl, piperidino, 1-piperazinyl, morpholin-4-yl, thiomorpholin-4-yl, azepan-1-yl, 1,4-oxazepan-4-yl, azocan-1-yl, 5,6-dihydropyridin-1(2H)-yl, 1,4-diazepan-1-yl, or 1,2,3,6-tetrahydropyridin-1-yl.
[0127] The term “C 1-5 alkylene” refers to a divalent group having one hydrogen atom removed from “C 1-5 alkyl” defined above, and examples thereof include methylene, ethylene, methylmethylene, trimethylene, propylene, tetramethylene, and pentamethylene.
[0128] The term “4- to 8-membered saturated or unsaturated heterocycle having a C 1-5 alkylene group crosslinking two different carbon atoms in the ring” refers to a ring which is “4- to 8-membered saturated or unsaturated heterocycle formed together with the adjoining nitrogen atom and optionally containing one or more nitrogen, oxygen, or sulfur atoms, in addition to the adjoining nitrogen atom, in the ring” defined above, and has a C 1-5 alkylene crosslinking two different carbon atoms in the ring; and examples thereof include 8-azabicyclo[3.2.1]oct-8-yl (tropinyl), 8-oxa-3-azabicyclo[3.2.1]oct-3-yl, and 3-oxa-8-azabicyclo[3.2.1]oct-8-yl. Examples of the 8-azabicyclo[3.2.1]oct-8-yl having a hydroxy substituent include 3-hydroxy-8-azabicyclo[3.2.1]oct-8-yl.
[0129] The term “a 5- or 6-membered saturated heterocycle formed together with the adjoining nitrogen atom and optionally containing one or more nitrogen, oxygen, or sulfur atoms, in addition to the adjoining nitrogen atom, in the ring (the 5- or 6-membered saturated heterocycle optionally has a C 1-5 alkylene group crosslinking two different carbon atoms in the ring)” refers to a group such as 1-pyrrolidinyl, piperidino, 1-piperazinyl, morpholin-4-yl, thiomorpholin-4-yl, 8-azabicyclo[3.2.1]oct-8-yl (tropinyl), 8-oxa-3-azabicyclo[3.2.1]oct-3-yl, or 3-oxa-8-azabicyclo[3.2.1]oct-8-yl.
[0130] The term “a 6-membered saturated heterocycle formed together with the adjoining nitrogen atom and optionally containing one or more oxygen atoms, in addition to the adjoining nitrogen atom, in the ring (the 6-membered saturated heterocycle optionally has a C 1-5 alkylene group crosslinking two different carbon atoms in the ring)” refers to a group such as piperidino, morpholin-4-yl, 8-azabicyclo[3.2.1]oct-8-yl (tropinyl), 8-oxa-3-azabicyclo[3.2.1]oct-3-yl, or 3-oxa-8-azabicyclo[3.2.1]oct-8-yl.
[0131] The term “phenylene” refers to a group such as 1,2-phenylene, 1,3-phenylene, or 1,4-phenylene.
[0132] The term “6-membered heteroarylene” refers to a group such as 2,3-pyridinediyl, 2,4-pyridinediyl, 2,5-pyridinediyl, 2,6-pyridinediyl, 3,5-pyridinediyl, or 2,5-pyrimidinediyl.
[0133] In the present invention, R 1 is preferably C 1-5 alkyl and more preferably isopropyl or tert-butyl.
[0134] In the present invention, R 2 is preferably a hydrogen atom.
[0135] In the present invention, R 3 is preferably phenyl or pyridyl (the phenyl or pyridyl is optionally substituted by one or two groups selected from the group consisting of C 1-5 alkyl, C 1-5 alkoxy, halogen atoms, cyano, hydroxy, trifluoromethyl, difluoromethoxy, trifluoromethoxy, and C 1-5 alkylsulfonyl).
[0136] More preferably, R 3 is phenyl (the phenyl is optionally substituted by one or two groups selected from C 1-5 alkyl, C 1-5 alkoxy, halogen atoms, cyano, hydroxy, trifluoromethyl, difluoromethoxy, trifluoromethoxy, and C 1-5 alkylsulfonyl) or pyridyl (the pyridyl is optionally substituted by one or two groups selected from C 1-5 alkyl, C 1-5 alkoxy, halogen atoms, cyano, hydroxy, trifluoromethyl, difluoromethoxy, and trifluoromethoxy).
[0137] More preferably, R 3 is phenyl (the phenyl is optionally substituted by one or two groups selected from C 1-5 alkoxy, chlorine atoms, fluorine atoms, cyano, and C 1-5 alkylsulfonyl) or pyridyl (the pyridyl is optionally substituted by C 1-5 alkoxy).
[0138] More preferably, R 3 is a group represented by Formula (5), (6), (7), (8), (9), (10), (11), (12), or (13). Most preferably, R 3 is a group represented by Formula (5), (6), (7), (8), or (9).
[0000]
[0139] In the present invention, A is preferably phenylene, pyridinediyl, or pyrimidinediyl (the phenylene, pyridinediyl, and pyrimidinediyl are optionally substituted by one or two groups selected from halogen atoms and C 1-5 alkoxy).
[0140] More preferably, A is a group represented by Formula (2), (2-F1), (2-F2), (2-Me1), (2-Me2), (3), or (4). Most preferably, A is a group represented by Formula (2) or (3).
[0000]
[0141] In the present invention, X is preferably a single bond.
[0142] In the present invention, R a is preferably a hydrogen atom or a methyl group.
[0143] In the present invention, n is preferably 1.
[0144] In the present invention, R 4 and R 5 preferably, together with the adjoining nitrogen atom, form a 4- to 8-membered saturated or unsaturated heterocycle optionally containing one or more nitrogen, oxygen, or sulfur atoms, in addition to the adjoining nitrogen atom, in the ring (the 4- to 8-membered saturated or unsaturated heterocycle is optionally substituted by one or two groups selected from the group consisting of hydroxy, C 1-5 alkyl (the C 1-5 alkyl is optionally substituted by one or two hydroxy), C 1-5 alkoxy, halogen atoms, cyano, C 2-5 alkanoyl, and trifluoromethyl, or the 4- to 8-membered saturated or unsaturated heterocycle optionally has a C 1-5 alkylene group crosslinking two different carbon atoms in the ring) or form 2-oxa-6-azaspiro[3.3]hept-6-yl. More preferably, R 4 and R 5 , together with the adjoining nitrogen atom, form a 5- or 6-membered saturated heterocycle optionally containing one or more nitrogen, oxygen, or sulfur atoms, in addition to the adjoining nitrogen atom, in the ring (the 5- or 6-membered saturated heterocycle is optionally substituted by one or two groups selected from the group consisting of hydroxy and C 1-5 alkyl, or the 5- or 6-membered saturated heterocycle optionally has a C 1-5 alkylene group crosslinking two different carbon atoms in the ring) or form 2-oxa-6-azaspiro[3.3]hept-6-yl. More preferably, R 4 and R 5 , together with the adjoining nitrogen atom, form a 6-membered saturated heterocycle optionally containing one or more oxygen atoms, in addition to the adjoining nitrogen atom, in the ring (the 6-membered saturated heterocycle is optionally substituted by one or two hydroxy, or the 6-membered saturated heterocycle optionally has a C 1-5 alkylene group crosslinking two different carbon atoms in the ring) or form 2-oxa-6-azaspiro[3.3]hept-6-yl. Most preferred examples of the ring formed by R 4 and R 5 together with the adjoining nitrogen atom include 1-pyrrolidinyl, piperidino (here, 1-pyrrolidinyl and piperidino are optionally substituted by one or two hydroxy), morpholin-4-yl (here, the morpholinyl group is optionally substituted by one or two C 1-5 alkyl groups, and the morpholin-4-yl can be, for example, 3-methylmorpholin-4-yl), 1,4-oxazepan-4-yl, thiomorpholin-4-yl, 8-azabicyclo[3.2.1]oct-8-yl (tropinyl), 3-hydroxy-8-azabicyclo[3.2.1]oct-8-yl, 8-oxa-3-azabicyclo[3.2.1]oct-3-yl, 3-oxa-8-azabicyclo[3.2.1]oct-8-yl, 2-oxa-6-azaspiro[3.3]hept-6-yl, and 7-oxa-2-azaspiro[3.5]non-2-yl.
[0145] 1,2,4-Triazolone derivatives represented by Formulae (1A) and (1a) or pharmaceutically acceptable salts thereof show high safety. The safety was confirmed by various safety tests such as a cytochrome P450 (CYP) activity inhibition test, a CYP metabolism-dependent inhibition test, a covalent bonding test, a trapping test, a hERG test, a cytotoxicity test, a phototoxicity test, a single-dose safety test, and a repeated-dose safety test.
[0146] Examples of the “pharmaceutically acceptable salt” include salts with inorganic acids, such as sulfuric acid, hydrochloric acid, hydrobromic acid, phosphoric acid, and nitric acid; salts with organic acids such as formic acid, trifluoroacetic acid, acetic acid, oxalic acid, lactic acid, tartaric acid, fumaric acid, maleic acid, citric acid, benzenesulfonic acid, methanesulfonic acid, p-toluenesulfonic acid, benzoic acid, camphorsulfonic acid, ethanesulfonic acid, glucoheptonic acid, gluconic acid, glutamic acid, glycolic acid, malic acid, malonic acid, mandelic acid, galactaric acid, and naphthalene-2-sulfonic acid; salts with one or more metal ions such as lithium, sodium, potassium, calcium, magnesium, zinc, and aluminum ions; and salts with amines such as ammonia, arginine, lysine, piperazine, choline, diethylamine, 4-phenylcyclohexylamine, 2-aminoethanol, and benzathine.
[0147] The compound of the present invention can be also present in the form of a solvate. From the aspect of applicability as medicine, the compound may be present in the form of a hydrate.
[0148] The compound of the present invention includes its enantiomers, diastereomers, equilibrium compounds, mixtures thereof at any proportion, and racemic mixtures.
[0149] The compound of the present invention can be formulated into a pharmaceutical preparation together with one or more pharmaceutically acceptable carriers, excipients, or diluents. Examples of the carrier, excipient, and diluent include water, lactose, dextrose, fructose, sucrose, sorbitol, mannitol, polyethylene glycol, propylene glycol, starch, gum, gelatin, alginate, calcium silicate, calcium phosphate, cellulose, water syrup, methylcellulose, polyvinylpyrrolidone, alkyl parahydroxybenzosorbate, talc, magnesium stearate, stearic acid, glycerine, and various oils such as sesame oil, olive oil, and soybean oil.
[0150] The above-mentioned carrier, excipient, or diluent is optionally mixed with commonly used additives, such as an bulking agent, a binder, a disintegrant, a pH adjuster, or a solubilizer, and can be prepared in the form of oral or parenteral agents, such as tablets, pills, capsules, granules, powder, liquid, emulsion, suspension, ointment, injection, or patches, by common preparation technology. The compound of the present invention can be orally or parenterally administered to adult patients in a dosage of 0.001 to 500 mg once or several times per day. The dosage can be appropriately adjusted depending on, for example, the type of the disease to be treated and the age, weight, and symptoms of the patient.
[0151] In the compound of the present invention, one or more of the hydrogen, fluorine, carbon, nitrogen, oxygen, and sulfur atoms may be replaced with radioisotopes or stable isotopes thereof. These labeled compounds are useful, for example, for metabolic or pharmacokinetic study or as ligands of receptors in biological analysis.
[0152] The compound of the present invention can be produced, for example, in accordance with the method shown below.
[0153] The compound represented by Formula (1) can be produced by the synthetic process shown in Scheme 1:
[0000]
[0154] (wherein, R 1 , R 2 , R 3 , R 4 , R 5 , R a , A, X, and n are the same as above; and L represents a leaving group such as a p-toluenesulfonyloxy group, a methanesulfonyloxy group, or a halogen atom).
[0155] The compound represented by Formula (1) can be prepared by conversion of the hydroxy group of a compound represented by Formula (14) into a common leaving group (Step 1-1) and reaction of the leaving group with a corresponding amine (17) (Step 1-2). The reaction in Step 1-1 (conversion to a leaving group) is performed by, for example, chlorination, bromination, iodination, methanesulfonylation, or p-toluenesulfonylation.
[0156] Examples of the chlorination include a method of using carbon tetrachloride and triphenylphosphine, a method of using thionyl chloride or phosphorus oxychloride, and a method of introducing a leaving group using p-toluenesulfonyl chloride or the like and substituting the leaving group by lithium chloride or any other reagent. These reactions can be performed using a solvent such as tetrahydrofuran, dioxane, dichloromethane, chloroform, N,N-dimethylformamide, or a mixture thereof at −50 to 100° C.
[0157] Examples of the bromination include a method of using carbon tetrabromide and triphenylphosphine. This reaction can be performed in a solvent such as tetrahydrofuran, dioxane, dichloromethane, chloroform, N,N-dimethylformamide, or a mixture thereof at −50 to 50° C.
[0158] Examples of the iodination include a method of using iodine, triphenylphosphine, and imidazole. This reaction can be performed using a solvent such as tetrahydrofuran, dioxane, dichloromethane, chloroform, N,N-dimethylformamide, or a mixture thereof at a temperature of −50 to 100° C.
[0159] The methanesulfonylation and the p-toluenesulfonylation can be performed using, for example, methanesulfonyl chloride and p-toluenesulfonyl chloride, respectively. These reactions may be performed in the presence of an appropriate base. Examples of the base include organic amines such as triethylamine and diisopropylethylamine; and inorganic bases such as potassium carbonate. The reactions can be performed in a reaction solvent such as N,N-dimethylformamide, tetrahydrofuran, dioxane, dichloromethane, chloroform, 1,2-dichloroethane, or a mixture thereof at a temperature of −50 to 50° C.
[0160] The reaction in Step 1-2 proceeds in the absence of solvent, or in a solvent such as tetrahydrofuran, acetonitrile, N,N-dimethylformamide, dimethyl sufoxide, ethanol, isopropyl alcohol, or a mixture thereof at a temperature of room temperature to near the boiling point of the solvent. The reaction more smoothly proceeds in the presence of sodium iodide or potassium iodide, in addition to an inorganic base, such as potassium carbonate or cesium carbonate, or an organic base such as triethylamine or diisopropylethylamine.
[0161] The compound represented by Formula (1) can be prepared through common oxidation to convert the hydroxy group of a compound represented by Formula (14) into a carbonyl group (Step 1-3) and reductive amination with a corresponding amine (17) (Step 1-4).
[0162] The oxidation reaction in Step 1-3 can be performed using chromic acid such as pyridinium chlorochromate or pyridinium dichromate in a reaction solvent such as dichloromethane or chloroform at a reaction temperature of 0° C. to near the boiling point of the reaction solvent.
[0163] In addition, the oxidation reaction can be performed using, for example, a Dess-Martin reagent (1,1,1-triacetoxy-1,1-dihydro-1,2-benziodoxol-3(1H)-one) in a reaction solvent such as dichloromethane or chloroform at a reaction temperature of 0 to 40° C.
[0164] In another example, the oxidation reaction can be performed using, for example, IBX (1-hydroxy-1,2-benziodoxol-3(1H)-one 1-oxide) in a reaction solvent, such as dimethyl sufoxide, by further diluting with a solvent not participating in the reaction, such as tetrahydrofuran, dichloromethane, or chloroform, at a reaction temperature of 0 to 40° C.
[0165] In addition to the above-described methods, the oxidation reaction may be performed by any method that can oxidize alcohol into carbonyl, such as a reaction of dimethyl sufoxide with an activating reagent (e.g., oxalyl chloride, N-chlorosuccinimide, or dicyclohexyl carbodiimide) or oxidation using tetra-n-propylammonium perruthenate (VII) and N-methylmorpholine oxide. The comprehensive general view of the oxidation reaction can be found in Richard C. Larock, Comprehensive Organic Transformation, WILEY-VCH, 1999, 604.
[0166] The reductive amination in Step 1-4 is achieved through a reaction between carbonyl (16) and a corresponding amine (17) to generate an imine derivative and reduction with a reducing agent such as sodium triacetoxyborohydride. The reaction proceeds in an inert solvent such as methanol, ethanol, tetrahydrofuran, dichloromethane, chloroform, or a mixture thereof at a temperature of −70° C. to room temperature. The reaction can be also performed using, for example, a hydrogen gas with a catalyst such as palladium on carbon or another boron reagent such as borohydride, sodium borohydride, or sodium cyanoborohydride.
[0167] Among the compounds represented by Formula (14), the compound represented by Formula (25) can be produced by the synthetic process shown in Scheme 2:
[0000]
[0168] (wherein, R 1 , R 2 , R 3 , and A are the same as above; and Hal represents a halogen atom).
[0169] The compound represented by Formula (20) can be prepared by a reaction of ketocarboxylic acid (18) with a hydrazine derivative (19) under an acidic condition (Step 2-1). The reaction in Step 2-1 proceeds in a solvent such as water, ethanol, isopropyl alcohol, acetonitrile, tetrahydrofuran, N,N-dimethylformamide, or dimethyl sufoxide or mixture thereof, in the presence of an inorganic acid such as hydrochloric acid or sulfuric acid or an organic acid such as p-toluenesulfonic acid, methanesulfonic acid, or camphorsulfonic acid.
[0170] The compound represented by Formula (21) can be prepared by a Curtius rearrangement reaction of the compound represented by Formula (20) (Step 2-2). The Curtius rearrangement reaction in this step proceeds by the use of diphenylphosphonyl azide (DPPA) in a solvent such as toluene, tetrahydrofuran, acetonitrile, or a mixture thereof, in the presence of a base such as triethylamine or diisopropylethylamine. The comprehensive general view of the Curtius rearrangement reaction is found in Chem. Rev., 1988, 88, 297-368 and Tetrahedron, 1974, 30, 2151-2157.
[0171] The compound represented by Formula (23) can be prepared by reacting the compound represented by Formula (21) with a separately prepared alkyl halide (22) in a solvent such as tetrahydrofuran, N,N-dimethylformamide, dimethyl sulfoxide, acetonitrile, or a mixture thereof, in the presence of an inorganic base such as potassium carbonate, cesium carbonate, or sodium hydride, or an organic base such as diisopropylethylamine, at a temperature of room temperature to near the boiling point of the solvent (Step 2-3).
[0172] The compound represented by Formula (24) can be prepared by introducing ethylene into the compound represented by Formula (23) by a Migita-Kosugi-Stille cross coupling reaction or a Suzuki-Miyaura cross coupling reaction (Step 2-4). The comprehensive general view of the Migita-Kosugi-Stille cross coupling reaction is found in Angew. Chem. Int., Ed. 2004, 43, 4704-4734. The comprehensive general view of the Suzuki-Miyaura cross coupling reaction is found in Chem. Rev., 1995, 95, 2457-2483.
[0173] The compound represented by Formula (25) can be prepared through common hydroboration of the compound represented Formula (24) and a subsequent oxidation reaction (Step 2-5). The reaction in Step 2-5 proceeds by hydroboration of the alkene moiety of the compound represented by Formula (24) with, for example, a borane-tetrahydrofuran complex, 9-borabicyclo[3.3.1]nonane, disiamylborane, or thexylborane in a solvent such as tetrahydrofuran, toluene, acetonitrile, or a mixture thereof at a temperature of near −10° C. to near room temperature; and subsequent use of, for example, hydrogen peroxide in the presence of a base such as sodium perborate (monohydrate or tetrahydrate) or sodium hydroxide.
[0174] The comprehensive general view of the hydroboration is found in J. Am. Chem. Soc., 1956, 78, 5694-5695 and J. Org. Chem., 1986, 51, 439-445.
[0175] Among the compounds represented by Formula (1), the compound represented by Formula (32) can be produced by the synthetic process shown in Scheme 3:
[0000]
[0176] (wherein, R 1 , R 2 , R 3 , R 4 , R 5 , A, Hal, and n are the same as above; L 1 and L 2 each represent the same leaving group as that defined above; and Pr represents a common protecting group described in Protective Groups in Organic Chemistry written by J. F. W. McOmie or Protective Groups in Organic Synthesis written by T. W. Greene and P. G. M. Wuts and is used for protection and deprotection).
[0177] The compound represented by Formula (29) can be prepared through imine formation with an oxygen-function hydrazine derivative (26) as in Scheme 2 (Step 3-1), a Curtius rearrangement reaction (Step 3-2), and alkylation (Step 3-3). The compound represented by Formula (30) can be prepared by deprotecting the protecting group of the compound represented by Formula (29) under appropriate conditions.
[0178] The compound represented by Formula (32) can be prepared by reacting the compound represented by Formula (30) with a compound represented by Formula (31) under Mitsunobu reaction conditions (Step 3-5). The comprehensive general view of the Mitsunobu reaction is found in Synthesis, 1981, 1-28; Chem. Asian J., 2007, 2, 1340-1355; and Chem. Pharm. Bull., 2003, 51(4), 474-476.
[0179] The compound represented by Formula (34) can be prepared by reacting the compound represented by Formula (30) with a compound represented by Formula (33) under basic conditions (Step 3-6). The reaction in Step 3-6 proceeds in a solvent such as N,N-dimethylformamide, dimethyl sufoxide, tetrahydrofuran, acetonitrile, ethanol, isopropyl alcohol, or a mixture thereof, in the presence of an inorganic base such as potassium carbonate or cesium carbonate, or an organic base such as triethylamine or diisopropylethylamine, at a temperature of near 0° C. to near the boiling point of the solvent.
[0180] The compound represented by Formula (32) can be prepared by a reaction between the compound represented by Formula (34) and an amine compound represented by Formula (17) (Step 3-7). The reaction in Step 3-7 proceeds under the same conditions as those in Step 1-2.
[0181] The compound represented by Formula (1) can also be produced by the synthetic process shown in Scheme 4:
[0000]
[0182] (wherein, R 1 , R 2 , R 3 , R 4 , R 5 , A, n, X, R a and Hal are the same as above; and R L represents a common protecting group for carboxylic acid, such as C 1-5 alkoxy or benzyloxy).
[0183] The compound represented by Formula (1) can be prepared through imine formation using a hydrazine derivative (35) (Step 4-1), a Curtius rearrangement reaction (Step 4-2), and alkylation (Step 4-3) as in Scheme 2. The compound represented by Formula (1) can also be prepared through alkylation of a compound represented by Formula (37) (Step 4-4), deprotection (Step 4-5), and then amidation (Step 4-6). The reaction in Step 4-4 proceeds under the same conditions as those in Step 2-3. The deprotection in Step 4-5 can be performed under conditions described in Protective Groups in Organic Chemistry written by J. F. W. McOmie or Protective Groups in Organic Synthesis written by T. W. Greene and P. G. M. Wuts. Examples of the amidation reaction usable in Step 4-6 include a method using a dehydration-condensation agent. Examples of the dehydration-condensation agent include 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride, dicyclohexyl carbodiimide, diphenylphosphonyl azide, and carbonyldiimidazole. In addition, an activating reagent such as 1-hydroxybenzotriazole or hydroxysuccinimide can be optionally used. Examples of the reaction solvent include dichloromethane, chloroform, 1,2-dichloroethane, N,N-dimethylformamide, tetrahydrofuran, dioxane, toluene, ethyl acetate, and mixtures thereof. The reaction in this step can be performed using a base, examples of which include organic amines, such as triethylamine and diisopropylethylamine; organic acid salts, such as sodium 2-ethylhexoate and potassium 2-ethylhexoate; and inorganic bases, such as potassium carbonate. The reaction can be performed at a temperature of −50° C. to near the boiling point of the reaction solvent.
[0184] The compound represented by Formula (18) can be produced by the synthetic process shown in Scheme 5:
[0000]
[0185] (wherein, R 3 is the same as above; and R 7 represents C 1-5 alkyl).
[0186] The compound represented by Formula (18) can be prepared through hydrolysis of a compound represented by Formula (42) (Step 5-1). The reaction in Step 5-1 proceeds in a solvent such as water, methanol, ethanol, or a mixture thereof, in the presence of a base such as sodium hydroxide, potassium hydroxide, lithium hydroxide, or barium hydroxide, at a temperature of near 0° C. to near the boiling point of the solvent.
[0187] The compound represented by Formula (18) can also be prepared through oxidation of a compound represented by Formula (43) (Step 5-2). The reaction in Step 5-2 proceeds in a solvent such as pyridine, in the presence of selenium dioxide, at a temperature of room temperature to near the boiling point of the solvent.
[0188] Among the compounds represented by Formula (22), commercially available are 2-chloro-N-methylacetamide, 2-chloro-N-ethylacetamide, 2-chloro-N-propylacetamide, N-isopropyl-2-chloroacetamide, N-butyl-2-chloroacetamide, N-(sec-butyl)-2-chloroacetamide, 2-chloro-N-isobutylacetamide, N-(tert-butyl)-2-chloroacetamide, N1-cyclopropyl-2-chloroacetamide, 2-chloro-N-(cyclopropylmethyl)acetamide, and 2-chloro-N-cyclobutylacetamide.
[0189] The hydrazine derivatives represented by Formulae (19) and (26) can be produced using a corresponding raw-material amine by the method described in, for example, JCS, Transactions, 1922, 121, 715-721; J. Am. Chem. Soc., 1953, 75, 1873-1876; or US Patent Publication No. 20050215577.
[0190] The compound represented by Formula (31) can be produced by the synthetic process shown in Scheme 6:
[0000]
[0191] (wherein, R 4 , R 5 , n, Pr, and L are the same as above).
[0192] The compound represented by Formula (45) can be prepared by reacting an amine (17) with a compound represented by Formula (44) under basic conditions (Step 6-1). The reaction conditions in Step 6-1 are the same as those in Step 1-2. The compound represented by Formula (31) can be prepared by deprotection of the protecting group (Pr) of the compound represented by Formula (45) by a common procedure (Step 6-2).
[0193] Among the compounds represented by Formula (31), commercially available are, for example, 3-dimethylamino-1-propanol, 3-diethylamino-1-propanol, 3-(isopropylamino)-propan-1-ol, 3-(dibutylamino)-1-propanol, 3-piperidin-1-yl-propan-1-ol, 1-(3-hydroxypropyl)-pyrrolidine, 4-(3-hydroxypropyl)morpholine, and 1-(3-hydroxypropyl)-piperazine.
[0194] The hydrazine derivative represented by Formula (35) can be prepared by the synthetic process shown in Scheme 7:
[0000]
[0195] (wherein, R 4 , R 5 , R a , X, n, and L are the same as above).
[0196] The compound represented by Formula (48) can be prepared by conversion of the hydroxy group of a compound represented by Formula (46) into a common leaving group (Step 7-1) and then reaction of the leaving group with a corresponding amine (17) (Step 7-2). The reactions in Steps 7-1 and 7-2 proceed under the same reaction conditions as those in Steps 1-1 and 1-2, respectively. The compound represented by Formula (48) can also be prepared through a common oxidation reaction to convert the hydroxy group of a compound represented by Formula (46) into carbonyl (Step 7-3) and common reductive amination with a corresponding amine (17) (Step 7-4). The reactions in Steps 7-3 and 7-4 proceed under the same reaction conditions as those in Steps 1-3 and 1-4, respectively. The compound represented by Formula (50) can be prepared by reduction of the nitro group of the compound represented by Formula (48) (Step 7-5). The comprehensive general view of the reduction in Step 7-5 is found in Comprehensive Organic Transformation, Second Edition, written by Richard C. Larock. The hydrazine derivative compound represented by Formula (35) can be prepared through diazotization of the amino group of the compound represented by Formula (50) and subsequent reduction (Step 7-6). The reaction shown by Step 7-6 is the same process as that described in JCS, Transactions, 121, 715-21 (1922); J. Am. Chem. Soc., 1953, 75, 1873-6; or US Patent Application No. 20050215577.
[0197] The compound represented by Formula (1) can also be synthesized by the synthetic process shown in Scheme 8:
[0000]
[0198] (wherein, R 1 , R 2 , R 3 , R 4 , R 5 , R a , X, n, Hal, and A are the same as above.).
[0199] The compound represented by Formula (1) can be prepared by a coupling reaction between a compound represented by Formula (51) and a compound represented by Formula (52) (Step 8-1). The reaction in Step 8-1 is performed by common Ullmann reaction or Buchwald-Hartwig amination. The comprehensive general view of the Ullmann reaction is found in Ley, S. V., Thomas, A. W., Angew. Chem. Int. Ed., 2003, 42, 5400-5449. The comprehensive general view of the Buchwald-Hartwig amination is found in A. S. Guram, R. A. Rennels, S. L. Buchwald, Angew. Chem., Int. Ed. Engl., 1995, 34, 1348; J. Louie, J. F. Hartwig, Tetrahedron Lett., 1995, 36, 3609; J. F. Hartwig, Angew. Chem. Int. Ed. Engl., 1998, 37, 2046-2067; Muci, A. R., Buchwald, S. L., Top. Curr. Chem., 2002, 219, 131; or J. P. Wolfe, H. Tomori, J. P. Sadighi, J. Yin, S. L. Buchwald, J. Org. Chem., 2000, 365, 1158-1174.
[0200] The compound represented by Formula (51) can be prepared by the synthetic process shown in Scheme 9:
[0000]
[0201] (wherein, R 1 , R 2 , R 3 , R L and Pr are the same as above).
[0202] The compound represented by Formula (55) can be prepared through a reaction between an acid chloride represented by Formula (53) and a hydrazine protected by protecting group (54) (Step 9-1). The reaction in Step 9-1 proceeds in a solvent such as chloroform, toluene, tetrahydrofuran, acetonitrile, or a mixture thereof, in the presence of a base such as triethylamine or diisopropylethylamine, at a temperature of near 0° C. to near room temperature. The compound represented by Formula (56) can be prepared by a conventional deprotection of the protecting group of the compound represented by Formula (55) (Step 9-2). The reaction conditions for Step 9-2 are those for a common deprotection reaction described in Protective Groups in Organic Chemistry written by J. F. W. McOmie or Protective Groups in Organic Synthesis written by T. W. Greene and P. G. M. Wuts. The compound represented by Formula (56) may be prepared in the form of a salt of an acid, while it can be prepared in a free form by treating with a base. The compound represented by Formula (58) can be prepared by a reaction of an isocyanate derivative (57) with the compound represented by Formula (56) (Step 9-3). The reaction in Step 9-3 proceeds in a solvent such as chloroform, toluene, tetrahydrofuran, acetonitrile, or a mixture thereof at a temperature of near room temperature to near the boiling point of the solvent. The compound represented by Formula (59) can be prepared through a reaction of the compound represented by Formula (58) under basic conditions (Step 9-4). The reaction in Step 9-4 proceeds in a solvent such as water, tetrahydrofuran, 1,4-dioxane, N,N-dimethylformamide, or a mixture thereof, in the presence of an inorganic base such as sodium hydroxide, potassium hydroxide, lithium hydroxide, or barium hydroxide, at a temperature of near room temperature to near the boiling point of the solvent. The compound represented by Formula (51) can be prepared through amidation of the compound represented by Formula (59) with an amine (60) (Step 9-5). Examples of the amidation reaction usable in Step 9-5 include a method using a dehydration-condensation agent. Examples of the dehydration-condensation agent include 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride, dicyclohexyl carbodiimide, diphenylphosphonyl azide, and carbonyldiimidazole. An activating reagent, such as 1-hydroxybenzotriazole or hydroxysuccinimide, can also be optionally used. Examples of the reaction solvent include dichloromethane, chloroform, 1,2-dichloroethane, N,N-dimethylformamide, tetrahydrofuran, dioxane, toluene, ethyl acetate, and mixtures thereof. The reaction in this step can be performed using a base, examples of which include organic amines, such as triethylamine and diisopropylethylamine; organic acid salts, such as sodium 2-ethylhexoate and potassium 2-ethylhexoate; and inorganic bases, such as potassium carbonate. The reaction can be performed at a temperature of −50° C. to near the boiling point of the reaction solvent.
[0203] Among the compounds represented by Formula (57), commercially available are methyl isocyanatoacetate, ethyl isocyanatoacetate, isopropyl isocyanatoacetate, and n-butyl isocyanatoacetate.
[0204] Among the compounds represented by Formula (52), the compounds represented by Formulae (65) and (70) can be prepared by the synthetic process shown in Scheme 10:
[0000]
[0205] (wherein, R 4 , R 5 , Hal, and L are the same as above; R a represents C 1-5 alkyl; and Met represents MgBr, MgCl, or a metal such as Li).
[0206] The compound represented by Formula (62) can be prepared through Arndt-Eistert reaction of a compound represented by Formula (61) (Step 10-1). The overview of the Arndt-Eistert reaction can be found in Chem. Ber., 1927, 60, 1364. The compound represented by Formula (63) can be prepared by reduction of the compound represented by Formula (62) (Step 10-2). The reduction in Step 10-2 proceeds in a solvent such as tetrahydrofuran, 1,4-dioxane, diethyl ether, diisopropyl ether, or a mixture thereof, in the presence of a reducing agent such as a borane-THF complex or lithium aluminum hydride, at a temperature of −78° C. to near room temperature. The compound represented by Formula (65) can be prepared by conversion of the hydroxy group of the compound represented by Formula (63) into a leaving group (Step 10-3) and then reaction of the resulting compound with an amine (17) (Step 10-4). The compound represented by Formula (65) can also be prepared through oxidation of the hydroxy group of the compound represented by Formula (63) into aldehyde (Step 10-5) and subsequent reductive amination with an amine (17). Step 10-3, Step 10-4, Step 10-5, and Step 10-6 proceed under the same reaction conditions as those for Step 1-1, Step 1-2, Step 1-3, and Step 1-4, respectively. The compound represented by Formula (70) can be prepared through conversion of the compound represented by Formula (62) into a Weinreb amide (Step 10-7), conversion of the amide into a ketone (69) by a reaction with a corresponding organic metal reagent (e.g., a Grignard reagent or an organic lithium reagent) (Step 10-8), and then reductive amination with an amine (17) (Step 10-9). The reaction in Step 10-7 proceeds in the presence of N,O-dimethylhydroxylamine, under similar amidation conditions to those in Step 9-5. The reaction in Step 10-8 is a reaction of the compound (a metal reagent such as a Grignard reagent or an organic lithium reagent) represented by Formula (68) in a solvent such as tetrahydrofuran, 1,4-dioxane, diethyl ether, diisopropyl ether, or a mixture thereof at a temperature of −78° C. to near room temperature.
[0207] Among the compounds represented by Formula (14), the compound represented by Formula (74) can be prepared by the synthetic process shown in Scheme 11:
[0000]
[0208] The compound represented by Formula (72) can be prepared by introducing ethoxyethylene into the compound represented by (71) by a Migita-Kosugi-Stille cross coupling reaction or a Suzuki-Miyaura cross coupling reaction (Step 11-1). The reaction in Step 11-1 is performed under the same conditions as those in the reaction in Step 2-4. The compound represented by Formula (73) can be prepared by a coupling reaction of the compound represented by Formula (73) and a compound represented by Formula (51) (Step 11-2). The reaction in Step 11-2 proceeds in a solvent such as tetrahydrofuran, 1,4-dioxane, N,N-dimethylformamide, or a mixture thereof, in the presence of an inorganic base such as sodium hydroxide, potassium hydroxide, lithium hydroxide, barium hydroxide, or cesium carbonate, at a temperature of near room temperature to near the boiling point of the solvent. The compound represented by Formula (74) can be produced by inducing the compound represented by Formula (73) into corresponding aldehyde in a solvent such as water, ethanol, isopropyl alcohol, acetonitrile, tetrahydrofuran, N,N-dimethylformamide, dimethyl sulfoxide, or a mixture thereof, in the presence of an inorganic acid such as hydrochloric acid or sulfuric acid, or an organic acid such as p-toluenesulfonic acid, methanesulfonic acid, or camphorsulfonic acid, and reacting a reducing agent with the aldehyde (see Comprehensive Organic Transformations Second Edition, 1999, John Wiley & Sons, Inc.). The reducing agent in the step can reduce an aldehyde compound into an alcohol compound, and examples thereof include lithium borohydride, sodium borohydride, calcium borohydride, zinc borohydride, lithium aluminum hydride, sodium aluminum hydride, and diisobutyl aluminum hydride.
EXAMPLES
[0209] The present invention will now be described in more detail by Reference Examples, Examples, and Test Examples, which are not intended to limit the present invention and may be modified within the scope of the present invention.
[0210] In Reference Examples and Examples, the “phase separator” in post-treatment is an ISOLUTE® Phase Separator of Biotage Inc. In purification by column chromatography, “SNAP Cartridge KP-NH” of Biotage Inc., “SNAP Cartridge HP-Sil” of Biotage Inc., or “Chromatorex® NH” of Fuji Silysia Chemical Ltd. was used. In purification by preparative thin-layer chromatography (PTLC), Silica Gel 60F 254 , 20×20 cm, of Merck was used. In purification by “reverse-phase column chromatography”, Waters SunFire prep C18 OBD, 5.0 μm, φ 30×50 mm was used.
[0211] The data described in Reference Examples and Examples below were obtained by measurement with the following instruments:
[0212] NMR spectrometer: JNM-ECA 600 (600 MHz, JEOL Ltd.), JNM-ECA 500 (500 MHz, JEOL Ltd.), UNITY INOVA 300 (300 MHz, Varian, Inc.), or GEMINI 2000/200 (200 MHz, Varian, Inc.),
[0213] MS spectrometer: LCMS-2010EV (Shimadzu Corporation) or Platform LC (Micromass, Ltd.).
[0214] In Reference Examples and Examples, high-performance liquid chromatography-mass spectrum (LCMS) was measured under the following conditions:
[0215] Condition 1
[0216] Instrument: Platform LC (Micromass, Ltd.) and Agilent 1100 (Agilent Technologies, Inc.),
[0217] Column: SunFire C18, 2.5 μm, φ 4.6×50 mm (Waters Corporation),
[0218] Solvent: Solution A: water containing 0.1% trifluoroacetic acid, and Solution B: acetonitrile containing 0.1% trifluoroacetic acid,
[0219] Gradient: 0 min (Solution A/Solution B=90/10), 0.5 min (Solution A/Solution B=90/10), 5.5 min (Solution A/Solution B=20/80), 6.0 min (Solution A/Solution B=1/99), and 6.3 min (Solution A/Solution B=1/99),
[0220] Flow rate: 1 mL/min, Detection: 254 nm, and
[0221] Ionization: electron spray ionization (ESI);
[0222] Condition 2-1
[0223] Instrument: Agilent 2900 and Agilent 6150,
[0224] Column: Waters Acquity CSH C18, 1.7 μm, φ 2.1×50 mm,
[0225] Solvent: Solution A: water containing 0.1% formic acid, and Solution B: acetonitrile containing 0.1% formic acid,
[0226] Gradient: 0 min (Solution A/Solution B=80/20), 1.2 to 1.4 min (Solution A/Solution B=1/99), and
[0227] Flow rate: 0.8 mL/min, Detection: 254 nm;
[0228] Condition 2-2
[0229] Instrument, column, and solvent are the same as those in Condition 2-1,
[0230] Gradient and flow rate: 0.8 mL/min for 0 min (Solution A/Solution B=95/5), 1.20 min (Solution A/Solution B=50/50), and 1.0 mL/min for 1.38 min (Solution A/Solution B=3/97), and
[0231] Detection: 254 nm.
[0232] In Reference Examples and Examples, optical isomers were measured under the following conditions:
[0233] Instrument: HPLC system (Gilson, Inc.),
[0234] Solvent: n-hexane/EtOH=70/30 (v/v),
[0235] Column: CHIRALPAK AD-H, 3.0 μm, φ 4.6×250 mm, and
[0236] Flow rate: 1 mL/min.
[0237] In Reference Examples and Examples, optical rotations were measured with the following instrument:
[0238] Instrument: JASCO P-2300 Polarimeter.
[0239] In Reference Examples and Examples, compounds were named using ACD/Name (ACD/Labs 12.01, Advanced Chemistry Development Inc.).
[0240] Terms and reagent names in Examples are denoted by the following abbreviations:
[0241] Brine (saturated brine), MeOH (methanol), MgSO 4 (anhydrous magnesium sulfate), K 2 CO 3 (potassium carbonate), Na 2 CO 3 (sodium carbonate), Na 2 SO 4 (anhydrous sodium sulfate), NaHCO 3 (sodium bicarbonate), NaOH (sodium hydroxide), KOH (potassium hydroxide), HCl (hydrochloric acid), IPE (diisopropyl ether), THF (tetrahydrofuran), DMF (N,N-dimethylformamide), Et 2 O (diethyl ether), EtOH (ethanol), NH 4 OH (25 to 28% aqueous ammonia), EtOAc (ethyl acetate), CHCl 3 (chloroform), DMSO (dimethyl sulfoxide), MeCN (acetonitrile), n-Hexane (n-hexane), Et 3 N (triethylamine), iPr 2 NEt (diisopropylethylamine), Pd(PPh 3 ) 4 [tetrakistriphenylphosphine palladium(0)], HATU [O-(7-azabenzotriazol-1-yl)-N,N,N,N-tetramethyluronium hexafluorophosphate], DPPA (diphenylphosphoryl azide), BH 3 .THF (borane-tetrahydrofuran complex), NaBO 3 .4H 2 O (sodium perborate tetrahydrate), 9-BBN (9-borabicyclo[3.3.1]nonane), IBX (1-hydroxy-1,2-benziodoxol-3(1H)-one 1-oxide), BBr 3 (boron tribromide), MsCl (methanesulfonyl chloride), TMSCH 2 N 2 (TMS diazomethane), n-BuLi (n-butyllithium), EDC.HCl [ 1 -ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride], HOBt.H 2 O (1-hydroxybenzotriazole monohydrate), Cs 2 CO 3 (cesium carbonate), PdCl 2 (PPh 3 ) 2 [bis(triphenylphosphine)palladium(II) dichloride], and NaBH 4 (sodium borohydride).
Synthesis of Reference Example P-A1
(3-Chlorophenyl)(oxo)acetic acid
[0242]
[0243] An aqueous 2 mol/L NaOH solution (24 mL) was added to a solution of ethyl (3-chlorophenyl)(oxo)acetate (2.00 g) in THF/MeOH (1:1) (48 mL) in an ice bath, followed by stirring at room temperature overnight. The solvent was distilled off under reduced pressure, and an aqueous 3 mol/L HCl solution was added thereto in an ice bath. The precipitated solid was collected by filtration to yield the title compound (2.00 g, colorless solid).
[0244] MS (ESI neg.) m/z: 183 ([M−H] − ).
[0245] The following compound was synthesized as in Reference Example P-A1.
Reference Example P-A2
(3-Chloro-4-fluorophenyl)(oxo)acetic acid
[Synthesis from ethyl (3-chloro-4-fluorophenyl)(oxo)acetate]
[0246]
Synthesis of Reference Example P-A3
(3-Methoxyphenyl)(oxo)acetic acid
[0247]
[0248] A pyridine solution (27 mL) containing 1-(3-methoxyphenyl)ethanone (8.00 g) and selenium dioxide (8.87 g) was stirred at an outside temperature of 100° C. for 4 hours. After cooling, the reaction solution was filtered through Celite (registered trademark). The filtrate was diluted with EtOAc, followed by washing with an aqueous 1 mol/L HCl solution and brine and drying with Na 2 SO 4 . The solvent was distilled off under reduced pressure to yield the title compound (10.6 g, gray solid).
[0249] MS (ESI neg.) m/z: 179 ([M−H] − ).
[0250] The following compounds were synthesized as in Reference Example P-A3.
Reference Example P-A4
(4-Fluoro-3-methoxyphenyl)(oxo)acetic acid
[Synthesis from 1-(4-fluoro-3-methoxyphenyl)ethanone]
[0251]
[0252] MS (ESI neg.) m/z: 197 ([M−H] − ).
Reference Example P-A5
(3-Cyanophenyl)(oxo)acetic acid
[Synthesis from 3-acetylbenzonitrile]
[0253]
Reference Example P-A6
(3-Fluorophenyl)(oxo)acetic acid
[Synthesis from 1-(3-fluorophenyl)ethanone]
[0254]
Reference Example P-A7
(2-Bromo-5-chlorophenyl)(oxo)acetic acid
[Synthesis from 1-(2-bromo-5-chlorophenyl)ethanone]
[0255]
[0256] MS (ESI neg.) m/z: 261 ([M−H] − ).
Synthesis of Reference Example P-B1
2-Chloro-5-hydrazinylpyridine hydrochloride
[0257]
[0258] An aqueous sodium nitrite solution (3.49 g of sodium nitrite in 12.5 mL of water) was dropwise added to a solution of 6-chloropyridine-3-amine (5.00 g) in hydrochloric acid (77.8 mL) over 10 minutes (such that the temperature does not exceed −20° C.) under dry ice-acetone cooling (−20 to −40° C.), followed by stirring under the same conditions for 1 hour. A solution of tin chloride (14.8 g) in hydrochloric acid (25 mL) was dropwise added thereto over 15 minutes, followed by stirring at approximately 0° C. for 2 hours. The precipitated solid was collected by filtration (washed with water and n-hexane) and was vacuum dried at 40° C. to yield the title compound (9.45 g, brown solid).
[0259] MS (ESI pos.) m/z: 144 ([M+H] + ).
Synthesis of Reference Example P-C1
2-[2-(4-Bromophenyl)hydrazinylidene]3-chlorophenyl)ethanoic acid
[0260]
[0261] Concentrated hydrochloric acid (0.4 mL) and a suspension of the compound (3.00 g) prepared in Reference Example P-A1 in water (10 mL) were sequentially added to a suspension of (4-bromophenyl)hydrazine hydrochloride (3.58 g) in water (15 mL) at room temperature, followed by stirring for 3 days. The solid in the system was collected by filtration to yield the title compound (5.14 g, yellow solid).
[0262] MS (ESI neg.) m/z: 351, 353 ([M−H] − ).
[0263] The following compounds were synthesized as in Reference Example P-C1.
Reference Example P-C2
2-[2-(4-Bromophenyl)hydrazinylidene](3-cyanophenyl)ethanoic acid (Synthesis from Reference Example P-A5 and (4-bromophenyl)hydrazine hydrochloride)
[0264]
[0265] MS (ESI neg.) m/z: 342, 344 ([M−H] − ).
Reference Example P-C3
2-(3-Chlorophenyl) [2-(4-methoxyphenyl)hydrazinylidene]ethanoic acid (Synthesis from Reference Example P-A1 and (4-methoxyphenyl)hydrazine hydrochloride)
[0266]
[0267] MS (ESI neg.) m/z: 303 ([M−H] − ).
Reference Example P-C4
2-[2-(5-Bromopyridin-2-yl)hydrazinylidene]3-chlorophenyl)ethanoic acid (Synthesis from Reference Example P-A1 and 5-bromo-2-hydrazinylpyridine)
[0268]
[0269] MS (ESI pos.) m/z: 354, 356 ([M+H] + ).
Reference Example P-C5
2-(3-Chlorophenyl) [2-(6-chloropyridin-3-yl)hydrazinylidene]ethanoic acid (Synthesis from Reference Example P-A1 and Reference Example P-B1)
[0270]
[0271] MS (ESI pos.) m/z: 310 ([M+H] + ).
Reference Example P-C6
2-[2-(4-Bromophenyl)hydrazinylidene](3-methoxyphenyl)ethanoic acid (Synthesis from Reference Example P-A3 and (4-bromophenyl)hydrazine hydrochloride)
[0272]
Reference Example P-C7
2-[2-(4-Bromophenyl)hydrazinylidene](4-fluoro-3-methoxyphenyl)ethanoic acid (Synthesis from Reference Example P-A4 and (4-bromophenyl)hydrazine hydrochloride)
[0273]
[0274] MS (ESI neg.) m/z: 365, 367 ([M−H] − ).
Reference Example P-C8
2-[2-(5-Bromopyridin-2-yl)hydrazinylidene](4-fluoro-3-methoxyphenyl)ethanoic acid (Synthesis from Reference Example P-A4 and 5-bromo-2-hydrazinylpyridine)
[0275]
[0276] MS (ESI pos.) m/z: 368, 370 ([M+H] + ).
Reference Example P-C9
2-[2-(4-Bromophenyl)hydrazinylidene](3-chloro-4-fluorophenyl)ethanoic acid (Synthesis from Reference Example P-A2 and (4-bromophenyl)hydrazine hydrochloride)
[0277]
Reference Example P-C10
2-[2-(5-Bromopyridin-2-yl)hydrazinylidene](3-chloro-4-fluorophenyl)ethanoic acid (Synthesis from Reference Example P-A2 and 5-bromo-2-hydrazinylpyridine)
[0278]
Reference Example P-C11
2-[2-(5-Bromopyridin-2-yl)hydrazinylidene](3-methoxyphenyl)ethanoic acid (Synthesis from Reference Example P-A3 and 5-bromo-2-hydrazinylpyridine)
[0279]
[0280] MS (ESI pos.) m/z: 350, 352 ([M+H] + ).
Synthesis of Reference Example P-D1
2-(4-Bromophenyl)-5-(3-chlorophenyl)-2,4-dihydro-3H-1,2,4-triazol-3-one
[0281]
[0282] Et 3 N (2.1 mL) was added to a suspension of the compound (5.14 g) prepared in Reference Example P-C1 in toluene (100 mL) under a nitrogen atmosphere, followed by stirring at room temperature to give a solution. DPPA (3.1 mL) was added thereto, and the mixture was gradually heated with stirring, followed by reflux for 8 hours. After cooling, an aqueous 10% KOH solution (120 mL) was added to the reaction solution, followed by stirring at room temperature for a while. The organic layer was removed, and concentrated hydrochloric acid was added to the aqueous layer in an ice bath. The precipitated solid was collected by filtration to yield the title compound (4.92 g, colorless solid).
[0283] MS (ESI neg.) m/z: 348, 350 ([M−H] − ).
[0284] The following compounds were synthesized as in Reference Example P-D1.
Reference Example P-D2
3-[1-(4-Bromophenyl)-5-oxo-4,5-dihydro-1H-1,2,4-triazol-3-yl]benzonitrile (Synthesis from Reference Example P-C2)
[0285]
[0286] MS (ESI neg.) m/z: 339, 341 ([M−H] − ).
Reference Example P-D3
5-(3-Chlorophenyl)-2-(4-methoxyphenyl)-2,4-dihydro-3H-1,2,4-triazol-3-one (Synthesis from Reference Example P-C3)
[0287]
[0288] MS (ESI pos.) m/z: 324 ([M+Na] + ).
Reference Example P-D4
2-(5-Bromopyridin-2-yl)-5-(3-chlorophenyl)-2,4-dihydro-3H-1,2,4-triazol-3-one (Synthesis from Reference Example P-C4)
[0289]
[0290] MS (ESI pos.) m/z: 351, 353 ([M+H] + ).
Reference Example P-D5
5-(3-Chlorophenyl)-2-(6-chloropyridin-3-yl)-2,4-dihydro-3H-1,2,4-triazol-3-one (Synthesis from Reference Example P-C5)
[0291]
[0292] MS (ESI pos.) m/z: 307 ([M+H] + ).
Reference Example P-D6
2-(4-Bromophenyl)-5-(3-methoxyphenyl)-2,4-dihydro-3H-1,2,4-triazol-3-one (Synthesis from Reference Example P-C6)
[0293]
[0294] MS (ESI pos.) m/z: 346, 348 ([M+H] + ).
Reference Example P-D7
2-(4-Bromophenyl)-5-(4-fluoro-3-methoxyphenyl)-2,4-dihydro-3H-1,2,4-triazol-3-one (Synthesis from Reference Example P-C7)
[0295]
[0296] MS (ESI neg.) m/z: 362, 364 ([M−H] − ).
Reference Example P-D8
2-(5-Bromopyridin-2-yl)-5-(4-fluoro-3-methoxyphenyl)-2,4-dihydro-3H-1,2,4-triazol-3-one (Synthesis from Reference Example P-C8)
[0297]
[0298] MS (ESI pos.) m/z: 365, 367 ([M+H] + ).
Reference Example P-D9
2-(4-Bromophenyl)-5-(3-chloro-4-fluorophenyl)-2,4-dihydro-3H-1,2,4-triazol-3-one (Synthesis from Reference Example P-C9)
[0299]
[0300] MS (ESI neg.) m/z: 366, 368 ([M−H] − ).
Reference Example P-D10
2-(5-Bromopyridin-2-yl)-5-(3-chloro-4-fluorophenyl)-2,4-dihydro-3H-1,2,4-triazol-3-one (Synthesis from Reference Example P-C10)
[0301]
[0302] MS (ESI pos.) m/z: 369, 371 ([M+H] + ).
Reference Example P-D11
2-(5-Bromopyridin-2-yl)-5-(3-methoxyphenyl)-2,4-dihydro-3H-1,2,4-triazol-3-one (Synthesis from Reference Example P-C11)
[0303]
[0304] MS (ESI pos.) m/z: 347 ([M+H] + ).
Synthesis of Reference Example P-E1
2-[1-(4-Bromophenyl)-3-(3-chlorophenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide
[0305]
[0306] K 2 CO 3 (3.87 g) and 2-bromo-N-(propan-2-yl)acetamide (3.78 g) were added to a suspension of the compound (4.92 g) prepared in Reference Example P-D1 in DMF (90 mL), followed by stirring at an outside temperature of 90° C. for 1.5 hours. After cooling, water (200 mL) was added thereto. The precipitated solid was collected by filtration to yield title compound (5.40 g, colorless solid).
[0307] MS (ESI pos.) m/z: 449, 451 ([M+H] + ).
[0308] The following compounds were synthesized as in Reference Example P-E1.
Reference Example P-E2
2-[1-(4-Bromophenyl)-3-(3-cyanophenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-D2 and 2-bromo-N-(propan-2-yl)acetamide)
[0309]
[0310] MS (ESI pos.) m/z: 462, 464 ([M+Na] + ).
Reference Example P-E3
2-[3-(3-Chlorophenyl)-1-(4-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-D3 and 2-bromo-N-(propan-2-yl)acetamide)
[0311]
[0312] MS (ESI pos.) m/z: 401 ([M+H] + ).
Reference Example P-E4
2-[1-(5-Bromopyridin-2-yl)-3-(3-chlorophenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-D4 and 2-bromo-N-(propan-2-yl)acetamide)
[0313]
[0314] MS (ESI pos.) m/z: 450, 452 ([M+H] + ).
Reference Example P-E5
2-[3-(3-Chlorophenyl)-1-(6-chloropyridin-3-yl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-D5 and 2-bromo-N-(propan-2-yl)acetamide)
[0315]
[0316] MS (ESI pos.) m/z: 406 ([M+H] + ).
Reference Example P-E6
2-[1-(4-Bromophenyl)-3-(3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-D6 and 2-bromo-N-(propan-2-yl)acetamide)
[0317]
[0318] MS (ESI pos.) m/z: 445, 447 ([M+H] + ).
Reference Example P-E7
2-[1-(4-Bromophenyl)-3-(4-fluoro-3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-D7 and 2-bromo-N-(propan-2-yl)acetamide)
[0319]
[0320] MS (ESI pos.) m/z: 463, 465 ([M+H] + ).
Reference Example P-E8
2-[1-(5-Bromopyridin-2-yl)-3-(4-fluoro-3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-D8 and 2-bromo-N-(propan-2-yl)acetamide)
[0321]
[0322] MS (ESI pos.) m/z: 464, 466 ([M+H] + ).
Reference Example P-E9
2-[1-(4-Bromophenyl)-3-(3-chloro-4-fluorophenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-D9 and 2-bromo-N-(propan-2-yl)acetamide)
[0323]
[0324] MS (ESI pos.) m/z: 467, 469 ([M+H] + ).
Reference Example P-E10
2-[1-(5-Bromopyridin-2-yl)-3-(3-chloro-4-fluorophenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-D10 and 2-bromo-N-(propan-2-yl)acetamide)
[0325]
[0326] MS (ESI pos.) m/z: 468, 470 ([M+H] + ).
Reference Example P-E11
2-[1-(5-Bromopyridin-2-yl)-3-(3-chlorophenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-tert-butylacetamide (Synthesis from Reference Example P-D4 and 2-bromo-N-tert-butylacetamide)
[0327]
[0328] MS (ESI pos.) m/z: 464, 466 ([M+H] + ).
Reference Example P-E12
2-[1-(5-Bromopyridin-2-yl)-3-(3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-tert-butylacetamide (Synthesis from Reference Example P-D11 and 2-bromo-N-tert-butylacetamide)
[0329]
[0330] MS (ESI pos.) m/z: 460, 462 ([M+H] + ).
Synthesis of Reference Example P-F1
2-[3-(3-Chlorophenyl)-1-(4-ethenylphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide
[0331]
[0332] A mixture of the compound (500 mg) prepared in Reference Example P-E1, tributyl(vinyl) tin (0.25 mL), Pd(PPh 3 ) 4 (128 mg), and toluene (10 mL) was stirred under a nitrogen atmosphere at an outside temperature of 100° C. for 5 hours. After cooling, the solvent was distilled off under reduced pressure, and the residue was purified by column chromatography (SNAP Cartridge KP-NH: 28 g, mobile phase: n-hexane/CHCl 3 =75/25 to 0/100 (v/v)). The resulting crude product was washed with a solvent mixture of EtOAc and n-hexane (EtOAc/n-hexane=1/6 (v/v)) with stirring to yield the title compound (222 mg; colorless solid).
[0333] MS (ESI pos.) m/z: 397 ([M+H] + ).
[0334] The following compounds were synthesized as in Reference Example P-F1.
Reference Example P-F2
2-[3-(3-Cyanophenyl)-1-(4-ethenylphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-E2)
[0335]
[0336] MS (ESI pos.) m/z: 388 ([M+H] + ).
Reference Example P-F3
2-[3-(3-Chlorophenyl)-1-(5-ethenylpyridin-2-yl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-E4)
[0337]
[0338] MS (ESI pos.) m/z: 398 ([M+H] + ).
Reference Example P-F4
2-[3-(3-Chlorophenyl)-1-(6-ethenylpyridin-3-yl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-E5)
[0339]
[0340] MS (ESI pos.) m/z: 398 ([M+H] + ).
Reference Example P-F5
2-[1-(4-Ethenylphenyl)-3-(3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-E6)
[0341]
[0342] MS (ESI pos.) m/z: 393 ([M+H] + ).
Reference Example P-F6
2-[1-(4-Ethenylphenyl)-3-(4-fluoro-3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-E7)
[0343]
[0344] MS (ESI pos.) m/z: 411 ([M+H] + ).
Reference Example P-F7
2-[1-(5-Ethenylpyridin-2-yl)-3-(4-fluoro-3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-E8)
[0345]
[0346] MS (ESI pos.) m/z: 412 ([M+H] + ).
Reference Example P-F8
2-[3-(3-Chloro-4-fluorophenyl)-1-(4-ethenylphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-E9)
[0347]
[0348] MS (ESI pos.) m/z: 415 ([M+H] + ).
Reference Example P-F9
2-[3-(3-Chloro-4-fluorophenyl)-1-(5-ethenylpyridin-2-yl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-E10)
[0349]
[0350] MS (ESI pos.) m/z: 416 ([M+H] + ).
Reference Example P-F10
N-Tert-Butyl-2-[3-(3-chlorophenyl)-1-(5-ethenylpyridin-2-yl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]acetamide (Synthesis from Reference Example P-E11)
[0351]
[0352] MS (ESI pos.) m/z: 412 ([M+H] + ).
Reference Example P-F11
N-Tert-Butyl-2-[1-(5-ethenylpyridin-2-yl)-3-(3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]acetamide (Synthesis from Reference Example P-E12)
[0353]
[0354] MS (ESI pos.) m/z: 408 ([M+H] + ).
Synthesis of Reference Example P-G1
2-{3-(3-Chlorophenyl)-1-[4-(2-hydroxyethyl)phenyl]-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl}-N-(propan-2-yl)acetamide
[0355]
[0356] A 1.09 mol/L solution of BH 3 .THF in THF (0.77 mL) was dropwise added to a solution of the compound (222 mg) prepared in Reference Example P-F1 in THF (6.0 mL) under a nitrogen atmosphere in an ice bath, followed by stirring for 1 hour. Subsequently, water (9 mL) and NaBO 3 .4H 2 O (387 mg) were added thereto, followed by stirring at room temperature overnight. The solvent was distilled off under reduced pressure, and water was added to the residue, followed by extraction with CHCl 3 . The organic layer was filtered through a phase separator, and the solvent was distilled off under reduced pressure. The residue was washed with a solvent mixture of EtOAc and n-hexane (EtOAc/n-hexane=1/4 (v/v)) with stirring to yield the title compound (170 mg, colorless solid).
[0357] MS (ESI pos.) m/z: 415 ([M+H] + ).
[0358] The following compounds were synthesized as in Reference Example P-G1.
Reference Example P-G2
2-{3-(3-Cyanophenyl)-1-[4-(2-hydroxyethyl)phenyl]-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl}-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-F2)
[0359]
[0360] MS (ESI pos.) m/z: 428 ([M+Na] + ).
Reference Example P-G3
2-{3-(3-Chlorophenyl)-1-[5-(2-hydroxyethyl)pyridin-2-yl]-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl}-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-F3)
[0361]
[0362] MS (ESI pos.) m/z: 416 ([M+H] + ).
Reference Example P-G4
2-{1-[4-(2-Hydroxyethyl)phenyl]-3-(3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl}-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-F5)
[0363]
[0364] MS (ESI pos.) m/z: 411 ([M+H] + ).
Reference Example P-G5
2-{3-(4-Fluoro-3-methoxyphenyl)-1-[4-(2-hydroxyethyl)phenyl]-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl}-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-F6)
[0365]
[0366] MS (ESI pos.) m/z: 429 ([M+H] + ).
Reference Example P-G6
2-{3-(4-Fluoro-3-methoxyphenyl)-1-[5-(2-hydroxyethyl)pyridin-2-yl]-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl}-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-F7)
[0367]
[0368] MS (ESI pos.) m/z: 430 ([M+H] + ).
Reference Example P-G7
2-{3-(3-Chloro-4-fluorophenyl)-1-[4-(2-hydroxyethyl)phenyl]-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl}-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-F8)
[0369]
[0370] MS (ESI pos.) m/z: 433 ([M+H] + ).
Synthesis of Reference Example P-H1
2-{3-(3-Chlorophenyl)-1-[6-(2-hydroxyethyl)pyridin-3-yl]-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl}-N-(propan-2-yl)acetamide
[0371]
[0372] A solution of 0.5 mol/L 9-BBN in THF (0.25 mL) was added to a solution of the compound (50 mg) prepared in Reference Example P-F4 in THF (1.5 mL) under a nitrogen atmosphere in an ice bath, followed by stirring at room temperature overnight. A solution of 0.5 mol/L 9-BBN in THF (0.5 mL) was added thereto in an ice bath, followed by stirring at room temperature for 6 hours. Furthermore, a solution of 0.5 mol/L 9-BBN in THF (0.5 mL) was added thereto in an ice bath, followed by stirring at room temperature overnight. An aqueous 2 M NaOH solution (1.0 mL) and a hydrogen peroxide solution (1.0 mL) were added thereto in an ice bath, followed by stirring at room temperature overnight. Subsequently, 80 mg of Na 2 SO 3 was added thereto, and the mixture was stirred for 30 minutes. The solvent was distilled off under reduced pressure, and water was added to the residue, followed by extraction with CHCl 3 . The organic layer was filtered through a phase separator, and the solvent was distilled off under reduced pressure. The residue was purified by column chromatography (SNAP Cartridge HP-Sil: 10 g, mobile phase: CHCl 3 /MeOH=99/1 to 90/10 (v/v)) to yield the title compound (15.2 mg, light yellow powder).
[0373] MS (ESI pos.) m/z: 416 ([M+H] + ).
[0374] The following compounds were synthesized as in Reference Example P-H1.
Reference Example P-H2
2-{3-(3-Chloro-4-fluorophenyl)-1-[5-(2-hydroxyethyl)pyridin-2-yl]-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl}-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-F9)
[0375]
[0376] MS (ESI pos.) m/z: 434 ([M+H] + ).
Reference Example P-H3
N-Tert-Butyl-2-{3-(3-chlorophenyl)-1-[5-(2-hydroxyethyl)pyridin-2-yl]-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl}acetamide (Synthesis from Reference Example P-F10)
[0377]
[0378] MS (ESI pos.) m/z: 430 ([M+H] + ).
Reference Example P-H4
N-Tert-Butyl-2-{1-[5-(2-hydroxyethyl)pyridin-2-yl]-3-(3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl}acetamide (Synthesis from Reference Example P-F11)
[0379]
[0380] MS (ESI pos.) m/z: 426 ([M+H] + ).
Synthesis of Reference Example P-I1
2-(4-{3-(3-Chlorophenyl)-5-oxo-4-[2-oxo-2-(propan-2-ylamino)ethyl]-4,5-dihydro-1H-1,2,4-triazol-1-yl}phenyl)ethyl methanesulfonate
[0381]
[0382] Et 3 N (0.09 mL) and MsCl (0.04 mL) were added to a suspension of the compound (170 mg) prepared in Reference Example P-G1 in CHCl 3 (5.0 mL) in an ice bath, followed by stirring at room temperature overnight. Water was added to the reaction solution in an ice bath, followed by extraction with CHCl 3 . The organic layer was filtered through a phase separator, and the solvent was distilled off under reduced pressure. The residue was purified by column chromatography (SNAP Cartridge HP-Sil: 10 g, mobile phase: CHCl 3 /MeOH=99/1 to 94/6 (v/v)) to yield the title compound (100 mg, colorless solid).
[0383] MS (ESI pos.) m/z: 493 ([M+H] + ).
[0384] The following compounds were synthesized as in Reference Example P-I1.
Reference Example P-I2
2-(4-{3-(3-Cyanophenyl)-5-oxo-4-[2-oxo-2-(propan-2-ylamino)ethyl]-4,5-dihydro-1H-1,2,4-triazol-1-yl}phenyl)ethyl methanesulfonate (Synthesis from Reference Example P-G2)
[0385]
[0386] MS (ESI pos.) m/z: 506 ([M+Na] + ).
Reference Example P-I3
2-(6-{3-(3-Chlorophenyl)-5-oxo-4-[2-oxo-2-(propan-2-ylamino)ethyl]-4,5-dihydro-1H-1,2,4-triazol-1-yl}pyridin-3-yl)ethyl methanesulfonate (Synthesis from Reference Example P-G3)
[0387]
[0388] MS (ESI pos.) m/z: 494 ([M+H] + ).
Reference Example P-I4
2-(5-{3-(3-Chlorophenyl)-5-oxo-4-[2-oxo-2-(propan-2-ylamino)ethyl]-4,5-dihydro-1H-1,2,4-triazol-1-yl}pyridin-2-yl)ethyl methanesulfonate (Synthesis from Reference Example P-H1)
[0389]
[0390] MS (ESI pos.) m/z: 494 ([M+H] + ).
Reference Example P-I5
2-(4-{3-(3-Methoxyphenyl)-5-oxo-4-[2-oxo-2-(propan-2-ylamino)ethyl]-4,5-dihydro-1H-1,2,4-triazol-1-yl}phenyl)ethyl methanesulfonate (Synthesis from Reference Example P-G4)
[0391]
[0392] MS (ESI pos.) m/z: 489 ([M+H] + ).
Reference Example P-I6
2-(4-{3-(4-Fluoro-3-methoxyphenyl)-5-oxo-4-[2-oxo-2-(propan-2-ylamino)ethyl]-4,5-dihydro-1H-1,2,4-triazol-1-yl}phenyl)ethyl methanesulfonate (Synthesis from Reference Example P-G5)
[0393]
[0394] MS (ESI pos.) m/z: 507 ([M+H] + ).
Reference Example P-I7
2-(6-{3-(4-Fluoro-3-methoxyphenyl)-5-oxo-4-[2-oxo-2-(propan-2-ylamino)ethyl]-4,5-dihydro-1H-1,2,4-triazol-1-yl}pyridin-3-yl)ethyl methanesulfonate (Synthesis from Reference Example P-G6)
[0395]
[0396] MS (ESI pos.) m/z: 508 ([M+H] + ).
Reference Example P-I8
2-(4-{3-(3-Chloro-4-fluorophenyl)-5-oxo-4-[2-oxo-2-(propan-2-ylamino)ethyl]-4,5-dihydro-1H-1,2,4-triazol-1-yl}phenyl)ethyl methanesulfonate (Synthesis from Reference Example P-G7)
[0397]
[0398] MS (ESI pos.) m/z: 511 ([M+H] + ).
Reference Example P-I9
2-(6-{3-(3-Chloro-4-fluorophenyl)-5-oxo-4-[2-oxo-2-(propan-2-ylamino)ethyl]-4,5-dihydro-1H-1,2,4-triazol-1-yl}pyridin-3-yl)ethyl methanesulfonate (Synthesis from Reference Example P-H2)
[0399]
[0400] MS (ESI pos.) m/z: 512 ([M+H] + ).
Reference Example P-I10
2-(6-{4-[2-(Tert-Butylamino)-2-oxoethyl]-3-(3-chlorophenyl)-5-oxo-4,5-dihydro-1H-1,2,4-triazol-1-yl}pyridin-3-yl)ethyl methanesulfonate (Synthesis from Reference Example P-H3)
[0401]
[0402] MS (ESI pos.) m/z: 508 ([M+H] + ).
Reference Example P-I11
2-(6-{4-[2-(Tert-Butylamino)-2-oxoethyl]-3-(3-methoxyphenyl)-5-oxo-4,5-dihydro-1H-1,2,4-triazol-1-yl}pyridin-3-yl)ethyl methanesulfonate (Synthesis from Reference Example P-H4)
[0403]
[0404] MS (ESI pos.) m/z: 504 ([M+H] + ).
Synthesis of Reference Example P-J1
2-{3-(3-Chlorophenyl)-5-oxo-1-[4-(2-oxoethyl)phenyl]-1,5-dihydro-4H-1,2,4-triazol-4-yl}-N-(propan-2-yl)acetamide
[0405]
[0406] The compound (300 mg) prepared in Reference Example P-G1 was added to a solution of IBX (243 mg) in DMSO (5 mL), followed by stirring at room temperature for 4 hours. The mixture was diluted with EtOAc, and a saturated NaHCO 3 solution was added thereto, followed by extraction with EtOAc. The organic layer was washed with water and saturated brine and was then dried over Na 2 SO 4 . The desiccant was removed by filtration. The solvent was distilled off under reduced pressure to yield the title compound (360 mg, colorless solid).
[0407] MS (ESI pos.) m/z: 413 ([M+H] + ).
Synthesis of Reference Example P-K1
2-[3-(3-Chlorophenyl)-1-(4-hydroxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide
[0408]
[0409] Under a nitrogen atmosphere, a solution of 1 mol/L BBr 3 in n-hexane (1.8 mL) was gradually added to a suspension of the compound (286 mg) prepared in Reference Example P-E3 in CHCl 3 (3 mL) in an ice bath, followed by stirring at room temperature overnight. A saturated aqueous NaHCO 3 solution was gradually added thereto in a salt-ice bath. IPE (containing 10% EtOAc) was added to the mixture, followed by stirring at room temperature for 1 hour. The precipitated solid was collected by filtration to yield the title compound (254 mg, colorless solid).
[0410] MS (ESI pos.) m/z: 409 ([M+Na] + ).
Synthesis of Reference Example P-L1
2-(4-Nitrophenyl)ethyl methanesulfonate
[0411]
[0412] Under a nitrogen atmosphere, MsCl (13.9 mL) was dropwise added to a suspension of 2-(4-nitrophenyl)ethanol (25.0 g) and Et 3 N (31.3 mL) in CHCl 3 (including amylene, 625 mL) over 10 minutes under ice cooling, followed by stirring at room temperature for 2 hours. A saturated aqueous NaHCO 3 solution was added to the reaction solution, and the aqueous layer was extracted with CHCl 3 . The combined organic layer was dried over MgSO 4 , and then the desiccant was removed by filtration. The filtrate was concentrated under reduced pressure to yield the title compound (41.8 g, light yellow solid).
[0413] 1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 2.95 (3H, s), 3.18 (2H, t, J=6.4 Hz), 4.47 (2H, t, J=6.6 Hz), 7.39-7.45 (2H, m), 8.17-8.23 (2H, m).
Synthesis of Reference Example P-L2
4-[2-(4-Nitrophenyl)ethyl]morpholine
[0414]
[0415] A suspension of the compound (41.8 g) prepared in Reference Example P-L1, morpholine (24.8 g), potassium iodide (23.6 g), and N,N-diisopropylethylamine (36.8 g) in MeCN (712 mL) was heated with stirring under a nitrogen atmosphere at 80° C. for 3.5 hours and then at 100° C. for 6 hours. After cooling, EtOAc and water were added to the reaction solution, and then were separated between EtOAc and water. The aqueous layer was extracted with EtOAc. The combined organic layer was washed with brine and dried over MgSO 4 , and the desiccant was removed by filtration. The filtrate was concentrated under reduced pressure to give a crude product, which was purified by silica gel column chromatography (Chromatorex NH, mobile phase: EtOAc/n-hexane=1/9 to 1/1 (v/v)) to yield the title compound (30.9 g, orange oily compound).
[0416] MS (ESI pos.) m/z: 237 ([M+H] + ).
Synthesis of Reference Example P-L3
4-[2-(Morpholin-4-yl)ethyl]aniline
[0417]
[0418] A solution of the compound (30.0 g) prepared in Reference Example P-L2 and tin chloride (96.3 g) in hydrochloric acid (100 mL) was heated under reflux for 1 hour. After cooling, the reaction solution was stirred at room temperature for 1 hour. CHCl 3 was added thereto, and the mixture was neutralized with a saturated aqueous NaHCO 3 solution. The solution was filtered through Celite (registered trademark). The filtrate was separated into two layers, and the aqueous layer was extracted with CHCl 3 . The insoluble matter separated by Celite (registered trademark) filtration was stirred in a mixture of the aqueous layers obtained by the separation and an organic layer at room temperature for 4 hours. The insoluble matter was removed by filtration, and the filtrate was separated into two layers. The aqueous layer was extracted with CHCl 3 , and the combined organic layer was dried over MgSO 4 . The desiccant was removed by filtration, and the filtrate was concentrated under reduced pressure. The residue was dissolved in IPE (100 mL) by heating with stirring. The solution was cooled to room temperature with stirring, followed by stirring under ice cooling for 1 hour. The precipitated solid was collected by filtration (washed with IPE) to yield the title compound (24.6 g, orange solid).
[0419] MS (ESI pos.) m/z: 207 ([M+H] + ).
Synthesis of Reference Example P-L4
4-[2-(4-Hydrazinylphenyl)ethyl]morpholine
[0420]
[0421] An aqueous sodium nitrite (7.53 g) solution (dissolved in 105 mL of water) was dropwise added to a solution of the compound (15.0 g) prepared in Reference Example P-L3 in hydrochloric acid (150 mL) over 30 minutes under dry ice-acetone cooling (−20 to 40° C.), followed by stirring under the same conditions for 1 hour and then at room temperature for about 17 hours. A solution of tin chloride (55.1 g) in hydrochloric acid (105 mL) was dropwise added thereto over 15 minutes under dry ice-acetone cooling (−20 to 40° C.), followed by stirring at approximately 0° C. for 2 hours. Chloroform was added to the reaction solution, and the mixture was neutralized with a saturated aqueous NaHCO 3 solution, followed by separation into two layers. The aqueous layer was extracted with chloroform. The combined organic layer was dried over MgSO 4 , and the desiccant was removed by filtration. The filtrate was concentrated under reduced pressure. The residue was purified by silica gel column chromatography (Silica gel 60, mobile phase: CHCl 3 /MeOH/NH 4 OH=99/1/0.1 to 95/5/0.5 (v/v/v)) to yield the title compound (3.88 g, orange oily compound).
[0422] MS (ESI pos.) m/z: 222 ([M+H] + ).
Synthesis of Reference Example P-M1
2-(3-Fluorophenyl)(2-{4-[2-(morpholin-4-yl)ethyl]phenyl}hydrazinylidene)ethanoic acid
[0423]
[0424] A solution of 2 mol/L HCl in IPA (0.669 mL) was added to a suspension of the compound (150 mg) prepared in Reference Example P-A6 and the compound (197 mg) prepared in Reference Example P-L4 in EtOH (3.0 mL), followed by stirring at room temperature for 16 hours. The reaction solution was concentrated under reduced pressure to yield the title compound (453 mg, brown solid)
[0425] MS (ESI pos.) m/z: 372 ([M+H] + ).
[0426] The following compounds were synthesized as in Reference Example P-M1.
Reference Example P-M2
2-(3-Chlorophenyl)(2-{4-[2-(morpholin-4-yl)ethyl]phenyl}hydrazinylidene)ethanoic acid (Synthesis from Reference Example P-A1 and Reference Example P-L4)
[0427]
[0428] MS (ESI pos.) m/z: 388 ([M+H] + ).
Reference Example P-M3
2-(2-Bromo-5-chlorophenyl)(2-{4-[2-(morpholin-4-yl)ethyl]phenyl}hydrazinylidene)ethanoic acid (Synthesis from Reference Example P-A7 and Reference Example P-L4)
[0429]
[0430] MS (ESI pos.) m/z: 467 ([M+H] + ).
Synthesis of Reference Example P-N1
5-(3-Fluorophenyl)-2-{4-[2-(morpholin-4-yl)ethyl]phenyl}-2,4-dihydro-3H-1,2,4-triazol-3-one
[0431]
[0432] A solution of the compound (453 mg) prepared in Reference Example P-M1, Et 3 N (0.261 mL), and DPPA (0.211 mL) in toluene (8.9 mL) was heated at 100° C. with stirring for 3 hours. After cooling, the solution was separated between CHCl 3 and a saturated aqueous NaHCO 3 solution. The aqueous layer was extracted with CHCl 3 . The combined organic layer was dried over MgSO 4 . The desiccant was removed by filtration, and the filtrate was concentrated under reduced pressure. The residue was purified by silica gel column chromatography (SNAP Cartridge HP-Sil: 50 g, mobile phase: CHCl 3 /MeOH/NH 4 OH=99/1/0.1 to 95/5/0.5 (v/v/v)) to yield the title compound (209 mg, orange solid).
[0433] MS (ESI pos.) m/z: 369 ([M+H] + ).
[0434] The following compounds were synthesized as in Reference Example P-N1.
Reference Example P-N2
5-(3-Chlorophenyl)-2-{4-[2-(morpholin-4-yl)ethyl]phenyl}-2,4-dihydro-3H-1,2,4-triazol-3-one (Synthesis from Reference Example P-M2)
[0435]
[0436] MS (ESI pos.) m/z: 385 ([M+H] + ).
P-N3: 5-(2-Bromo-5-chlorophenyl)-2-{4-[2-(morpholin-4-yl)ethyl]phenyl}-2,4-dihydro-3H-1,2,4-triazol-3-one (Synthesis from Reference Example P-M3)
[0437]
[0438] MS (ESI pos.) m/z: 463, 465 ([M+H] + ).
Synthesis of Reference Example P-O1
Tert-Butyl[3-(3-chlorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]acetate
[0439]
[0440] K 2 CO 3 (405 mg) and tert-butyl bromoacetate (0.258 mL) were added to a suspension of the compound (564 mg) prepared in Reference Example P-N2 in DMF (10 mL), followed by stirring at room temperature for 3 hours. The reaction solution was separated between water (30 mL) and ethyl acetate (30 mL). The organic layer was washed with saturated brine (30 mL) and was dried over Na 2 SO 4 . The desiccant was removed by filtration, and the filtrate was concentrated under reduced pressure. The residue was purified by silica gel column chromatography (SNAP Cartridge HP-Sil: 50 g, mobile phase: CHCl 3 /MeOH=100/0 to 96/4 (v/v)) to yield the title compound (550 mg, light brown oil).
[0441] MS (ESI pos.) m/z: 499 ([M+H] + ).
Synthesis of Reference Example P-P1
[3-(3-Chlorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]acetic acid
[0442]
[0443] Trifluoroacetic acid (5 mL) was added to a solution of the compound (440 mg) prepared in Reference Example P-O1 in chloroform (15 mL), followed by stirring at room temperature for 1 day. After ice cooling, the pH of the reaction solution was adjusted to about 7 with an aqueous NaOH solution. The solution was separated between chloroform (20 mL) and saturated brine (20 mL). The aqueous layer was extracted with chloroform (20 mL) four times. The combined organic layer was dried over Na 2 SO 4 . The desiccant was removed by filtration, and the mother liquid was concentrated. Chloroform was added to the residue, and the solid was collected by filtration and dried to yield the title compound (321 mg, colorless solid).
[0444] MS (ESI pos.) m/z: 443 ([M+H] + ).
Synthesis of Reference Example P-Q1a
3-(Methylsulfonyl)benzoyl chloride
[0445]
[0446] DMF (0.4 mL) and oxalyl chloride (1.90 g) were added to a solution of 3-(methylsulfonyl)benzoic acid (2.00 g) in CHCl 3 (including amylene, 40 mL) in a nitrogen gas flow under ice cooling, followed by stirring at room temperature for 2 hours. The reaction solution was concentrated under reduced pressure to yield a crude product as a yellow solid, which was used in the subsequent reaction.
Synthesis of Reference Example P-Q1b
Tert-Butyl 2-[3-(methylsulfonyl)benzoyl]hydrazinecarboxylate
[0447]
[0448] A solution of the compound (9.99 mmol) prepared in Reference Example P-Q1a in CHCl 3 (10 mL) was dropwise added to a solution of tert-butyl carbazate (1.58 g) and triethylamine (2.09 mL) in CHCl 3 (including amylene, 40 mL) over 5 minutes in a nitrogen gas flow under ice cooling, followed by stirring at room temperature overnight. A saturated aqueous sodium bicarbonate solution (100 mL) and ethyl acetate (100 mL) were added to the reaction solution, followed by stirring at room temperature. The solid was collected by filtration to yield a colorless solid (2.00 g). The filtrate was separated into two layers, and the aqueous layer was extracted with ethyl acetate. The combined organic layer was concentrated to yield the title compound (2.53 g, colorless solid).
[0449] MS (ESI pos.) m/z: 337 ([M+Na] + ).
Synthesis of Reference Example P-Q1c
3-(Methylsulfonyl)benzohydrazide
[0450]
[0451] A solution of 4 mol/L hydrochloric acid in 1,4-dioxane (20 mL) was added to a solution of the compound (1.95 g+2.50 g) prepared in Reference Example P-Q1b in 1,4-dioxane (50 mL) in a nitrogen gas flow, followed by heating at 60° C. with stirring for 4 hours. The reaction solution was cooled and was then concentrated under reduced pressure to give a crude product. Ethyl acetate (100 mL) and a saturated aqueous NaHCO 3 solution (100 mL) were added to the crude product, and ammonium sulfate was added thereto until precipitation occurs, followed by separation into two layers. The aqueous layer was extracted with ethyl acetate (100 mL×6). The combined organic layer was dried over MgSO 4 , and the desiccant was removed by filtration. The filtrate was concentrated under reduced pressure to yield the title compound (1.56 g, light yellow solid).
[0452] MS (ESI pos.) m/z: 237 ([M+Na] + ).
Synthesis of Reference Example P-Q1d
Ethyl N-({2-[3-(methylsulfonyl)benzoyl]hydrazinyl}carbonyl)glycinate
[0453]
[0454] A solution of ethyl isocyanatoacetate (0.83 mL) in THF (5 mL) was dropwise added to a solution of the compound (1.52 g) prepared in Reference Example Q1c in THF (20 mL) over 2 minutes with heating at 50° C. in a nitrogen gas flow, followed by stirring under the same conditions for 1 hour and then at room temperature for 1 hour. The reaction solution was purified by silica gel column chromatography (SNAP Cartridge KP-NH: 55 g, mobile phase: CHCl 3 /MeOH/NH 4 OH=98/2/0.2 to 90/10/1 (v/v/v)) to yield the title compound (2.20 g, yellow amorphous compound).
[0455] MS (ESI pos.) m/z: 366 ([M+Na] + ).
Synthesis of Reference Example P-Q1e
{3-[3-(Methylsulfonyl)phenyl]-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl}acetic acid
[0456]
[0457] The compound (1.52 g) prepared in Reference Example P-Q1d was heated in an aqueous 3 mol/L sodium hydroxide solution (16.3 mL) with stirring at 120° C. for 2 hours and then at 100° C. for 18.5 hours. The pH of the reaction solution was adjusted to be lower than 1 with a concentrated hydrochloric acid, followed by extraction with ethyl acetate. The combined organic layer was dried over MgSO 4 , and the desiccant was removed by filtration. The filtrate was concentrated under reduced pressure to yield the title compound (1.56 g, light yellow solid).
[0458] MS (ESI pos.) m/z: 320 ([M+Na] + ).
Synthesis of Reference Example P-Q1
2-{3-[3-(Methylsulfonyl)phenyl]-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl}-N-(propan-2-yl)acetamide
[0459]
[0460] EDC.HCl (1.18 g) was added to a solution of the compound (1.52 g) prepared in Reference Example P-Q1e and HOBt.H 2 O (1.17 g) in DMF (20 mL) in a nitrogen gas flow, followed by stirring at room temperature for 10 minutes. Isopropylamine (0.66 mL) was added thereto, followed by stirring for 1 hour. The reaction solution was separated between a saturated aqueous NaHCO 3 solution (100 mL) and CHCl 3 (50 mL). The aqueous layer was extracted with CHCl 3 (30 mL). The combined organic layer was dried over MgSO 4 , and the desiccant was removed by filtration. The filtrate was concentrated under reduced pressure. The residue was purified by silica gel column chromatography (SNAP Cartridge HP-Sil: 50 g, mobile phase: CHCl 3 /MeOH/NH 4 OH=99/1/0.1 to 92/8/0.8 (v/v/v)) to yield the title compound (580 mg, colorless solid).
[0461] MS (ESI pos.) m/z: 361 ([M+Na] + ).
Synthesis of Reference Example P-Q2a
Tert-Butyl 2-(3-chlorobenzoyl)hydrazinecarboxylate
[0462]
[0463] The title compound (4.41 g, colorless powder) was synthesized from 3-chlorobenzoyl chloride (2 mL) and tert-butyl carbazate (2.49 g), as in Reference Example P-Q1b.
[0464] MS (ESI neg.) m/z: 269 ([M−H] − ).
Synthesis of Reference Example P-Q2b
3-Chlorobenzohydrazide hydrochloride
[0465]
[0466] The title compound (3.26 g, colorless powder) was synthesized from the compound (4.41 g) prepared in Reference Example P-Q2a, as in Reference Example P-Q1c.
[0467] MS (ESI pos.) m/z: 171 ([M+H] + ).
Synthesis of Reference Example P-Q2b-f
3-Chlorobenzohydrazide
[0468]
[0469] A saturated aqueous NaHCO 3 solution (40 mL) was added to a suspension of the compound (2.73 g) prepared in Reference Example P-Q2b in water (20 mL) under ice cooling. EtOAc (50 mL) was added thereto, followed by stirring at room temperature for a while. EtOAc was added to the mixture with heating until the suspension was dissolved. The solution was separated to two layers, and the aqueous layer was extracted with EtOAc (50 mL×6). The combined organic layer was dried over Na 2 SO 4 , and the desiccant was removed by filtration. The filtrate was concentrated under reduced pressure to yield the title compound (2.18 g, colorless powder).
[0470] MS (ESI pos.) m/z: 171 ([M+H] + ).
Synthesis of Reference Example P-Q2c
Ethyl N-{[2-(3-chlorobenzoyl)hydrazinyl]carbonyl}glycinate
[0471]
[0472] The title compound (430 mg, colorless powder) was synthesized from the compound (500 mg) prepared in Reference Example P-Q2b-f, as in Reference Example P-Q1d.
[0473] MS (ESI pos.) m/z: 322 ([M+Na] + ).
Synthesis of Reference Example P-Q2d
[3-(3-Chlorophenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]acetic acid
[0474]
[0475] The title compound (2.85 g, colorless powder) was synthesized from the compound (3.89 g) prepared in Reference Example P-Q2c, as in Reference Example P-Q1e.
[0476] MS (ESI pos.) m/z: 254 ([M+H] + ).
Synthesis of Reference Example P-Q2
2-[3-(3-Chlorophenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide
[0477]
[0478] The title compound (2.23 g, colorless powder) was synthesized from the compound (2.84 g) prepared in Reference Example P-Q2d, as in Reference Example P-Q1.
[0479] MS (ESI pos.) m/z: 295 ([M+H] + ).
Synthesis of Reference Example P-Q3a
4-Fluoro-3-methoxybenzoyl chloride
[0480]
[0481] The title compound was prepared from 4-fluoro-3-methoxybenzoic acid (5.00 g), as in Reference Example P-Q1a. The crude product was used in the subsequent reaction.
Synthesis of Reference Example P-Q3b
Tert-Butyl 2-(4-fluoro-3-methoxybenzoyl)hydrazinecarboxylate
[0482]
[0483] The title compound (8.19 g, colorless solid) was prepared from Reference Example P-Q3a, as in Reference Example P-Q1b.
[0484] MS (ESI pos.) m/z: 307 ([M+Na] + ).
Synthesis of Reference Example P-Q3c
4-Fluoro-3-methoxybenzohydrazide
[0485]
[0486] The title compound (5.12 g, colorless solid) was prepared from Reference Example P-Q3b (8.19 g), as in Reference Example P-Q1c.
[0487] MS (ESI pos.) m/z: 185 ([M+H] + ).
Synthesis of Reference Example P-Q3d
Ethyl N-{[2-(4-fluoro-3-methoxybenzoyl)hydrazinyl]carbonyl}glycinate
[0488]
[0489] The title compound (8.55 g, colorless solid) was prepared from Reference Example P-Q3c (5.12 g), as in Reference Example P-Q1d.
[0490] MS (ESI pos.) m/z: 314 ([M+H] + ).
Synthesis of Reference Example P-Q3e
[3-(4-Fluoro-3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]acetic acid
[0491]
[0492] The title compound (7.25 g, colorless solid) was prepared from Reference Example P-Q3d (8.55 g), as in Reference Example P-Q1e.
[0493] MS (ESI pos.) m/z: 290 ([M+Na] + ).
Synthesis of Reference Example P-Q3
2-[3-(4-Fluoro-3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide
[0494]
[0495] The title compound (5.82 g, colorless solid) was prepared from Reference Example P-Q3e (7.25 g), as in Reference Example P-Q1.
[0496] MS (ESI pos.) m/z: 309 ([M+H] + ).
Synthesis of Reference Example P-Q4d
Ethyl N-{[2-(3-methoxybenzoyl)hydrazinyl]carbonyl}glycinate
[0497]
[0498] The title compound (17.5 g, colorless solid) was prepared from 3-methoxybenzohydrazide (10.0 g), as in Reference Example P-Q1d.
[0499] MS (ESI pos.) m/z: 296 ([M+H] + ).
Synthesis of Reference Example P-Q4e
[3-(3-Methoxyphenyl)-5-oxo-1,5-dihydro-4′-1,2,4-triazol-4-yl]acetic acid
[0500]
[0501] The title compound (14.4 g, colorless solid) was prepared from Reference Example P-Q4d (17.4 g), as in Reference Example P-Q1e.
[0502] MS (ESI pos.) m/z: 250 ([M+H] + ).
Synthesis of Reference Example P-Q4
N-Tert-Butyl-2-[3-(3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]acetamide
[0503]
[0504] A mixture of Reference Example P-Q4e (1.00 g), tert-butylamine (4.2 mL), HATU (2.29 g), DIEA (1.4 mL), and DMF (10 mL) was stirred at room temperature overnight. Water (20 mL) and an aqueous 3 M HCl solution (20 mL) were added thereto in an ice bath, followed by extraction with ethyl acetate. The organic layer was washed with water and brine, and the solvent was distilled off under reduced pressure. The residue was purified by silica gel column chromatography (SNAP Cartridge HP-Sil: 50 g, mobile phase: CHCl 3 /MeOH=98/2 to 90/10 (v/v)) to yield the title compound (743 mg, colorless solid).
[0505] MS (ESI pos.) m/z: 305 ([M+H] + ).
Synthesis of Reference Example P-Q5a
6-Methoxypyridine-2-carbonyl chloride
[0506]
[0507] The title compound was prepared from 6-methoxypyridine-2-carboxylic acid (2.50 g), as in Reference Example P-Q1a. The crude product was used in the subsequent reaction.
Synthesis of Reference Example P-Q5b
Tert-Butyl 2-[(6-methoxypyridin-2-yl)carbonyl]hydrazinecarboxylate
[0508]
[0509] The title compound (4.62 g, colorless solid) was prepared from Reference Example P-Q5a, as in Reference Example P-Q1b.
[0510] MS (ESI pos.) m/z: 290 ([M+Na] + ).
Synthesis of Reference Example P-Q5c
6-Methoxypyridine-2-carbohydrazide
[0511]
[0512] The title compound (2.81 g, light yellow solid) was prepared from Reference Example P-Q5b (4.62 g), as in Reference Example P-Q1c.
[0513] MS (ESI pos.) m/z: 168 ([M+H] + ).
Synthesis of Reference Example P-Q5d
Ethyl N-({2-[(6-methoxypyridin-2-yl)carbonyl]hydrazinyl}carbonyl)glycinate
[0514]
[0515] The title compound (4.72 g, colorless solid) was prepared from Reference Example P-Q5c (2.81 g), as in Reference Example P-Q1d.
[0516] MS (ESI pos.) m/z: 297 ([M+H] + ).
Synthesis of Reference Example P-Q5e
[3-(6-Methoxypyridin-2-yl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]acetic acid
[0517]
[0518] The title compound (4.83 g, colorless solid) was prepared from Reference Example P-Q5d (4.72 g), as in Reference Example P-Q1e.
[0519] MS (ESI pos.) m/z: 251 ([M+H] + ).
Synthesis of Reference Example P-Q5
2-[3-(6-Methoxypyridin-2-yl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide
[0520]
[0521] The title compound (1.80 g, colorless solid) was prepared from Reference Example P-Q5e (2.00 g), as in Reference Example P-Q1.
[0522] MS (ESI pos.) m/z: 292 ([M+H] + ).
Synthesis of Reference Example P-R1a
(4-Bromo-2-fluorophenyl)acetic acid
[0523]
[0524] Oxalyl chloride (3.2 mL) and DMF (one drop) were added to a suspension of 4-bromo-2-fluorobenzoic acid (4.0 g) in CHCl 3 (40 mL) in an ice bath, followed by stirring at room temperature for 3 hours. After concentration, a mixture of THF and MeCN (1/1 (v/v), 40 mL) was added to the residue. TMSCH 2 N 2 (2 mol/L Et 2 O solution, 18.3 mL) was added thereto at 0° C., followed by stirring at room temperature for 2 hours. After concentration, a mixture of 1,4-dioxane and water (1/1 (v/v), 60 mL) and then silver acetate (916 mg) were added thereto, followed by stirring at 100° C. for 2 hours. After concentration, a saturated aqueous NaHCO 3 solution was added thereto, followed by stirring at room temperature for 1 hour. EtOAc was added thereto, and the solid was removed by filtration through Celite (registered trademark) to separate the organic layer. Under ice cooling, 3 mol/L HCl was added to the aqueous layer to make the system acidic. The aqueous layer was extracted from CHCl 3 (50 ml×9). The combined organic layer was filtered through a phase separator, and the filtrate was concentrated under reduced pressure to yield the title compound (2.46 g, colorless powder).
[0525] MS (ESI neg.) m/z: 231, 233 ([M−H] − ).
[0526] The following compounds were synthesized as in Reference Example P-R1a.
Reference Example P-R2a
(4-Bromo-2-methoxyphenyl)acetic acid (Synthesis from 4-bromo-2-methoxybenzoic acid)
[0527]
[0528] MS (ESI neg.) m/z: 243, 245 ([M−H] − ).
Synthesis of Reference Example P-R3a
(4-Bromo-3-fluorophenyl)acetic acid (Synthesis from 4-bromo-3-fluorobenzoic acid)
[0529]
[0530] MS (ESI neg.) m/z: 231, 233 ([M−H] − ).
Synthesis of Reference Example P-R4a
(4-Bromo-3-methoxyphenyl)acetic acid (Synthesis from 4-bromo-3-methoxybenzoic acid)
[0531]
[0532] MS (ESI neg.) m/z: 243, 245 ([M−H] − ).
Synthesis of Reference Example P-R1b
2-(4-Bromo-2-fluorophenyl)ethanol
[0533]
[0534] Under ice cooling, 1.09 mol/L BH 3 .THF (14.5 mL) was added to a solution of the compound (2.460 g) prepared in Reference Example P-R1a in THF (40 mL). The mixture was stirred with gradually raising the temperature to room temperature for 5 hours. Under ice cooling, MeOH was added to the reaction system until foaming stopped. The solvent was distilled off under reduced pressure. Water (40 mL) and CHCl 3 (20 mL) were added to the residue, followed by stirring at room temperature. After extraction with CHCl 3 , filtration through a phase separator was performed. The solvent was distilled off under reduced pressure. The residue was purified by silica gel column chromatography (SNAP Cartridge HP-Sil: 50 g, n-hexane/EtOAc=90/10 to 50/50 (v/v)) to yield the title compound (1.93 g, colorless oil).
[0535] MS (E1 pos.) m/z: 218, 220 (M + ).
[0536] The following compounds were synthesized as in Reference Example P-R1b.
Synthesis of Reference Example P-R2b
2-(4-Bromo-2-methoxyphenyl)ethanol (Synthesis from Reference Example P-2a)
[0537]
[0538] MS (ESI pos.) m/z: 231, 233 ([M+H] + ).
Synthesis of Reference Example P-R3b
2-(4-Bromo-3-fluorophenyl)ethanol (Synthesis from Reference Example P-R3a)
[0539]
[0540] MS (E1 pos.) m/z: 218, 220 (M + ).
Synthesis of Reference Example P-R4b
2-(4-Bromo-3-methoxyphenyl)ethanol (Synthesis from Reference Example P-R4a)
[0541]
[0542] MS (ESI neg.) m/z: 227, 229 ([M−H] − ).
Synthesis of Reference Example P-R1c
2-(4-Bromo-2-fluorophenyl)ethyl methanesulfonate
[0543]
[0544] Under ice cooling, Et 3 N (0.48 mL) and mesyl chloride (0.21 mL) were sequentially added to a solution of the compound (500 mg) prepared in Reference Example P-R1b in CHCl 3 (8 mL), followed by stirring at room temperature for 1 hour. Water (10 mL) was added thereto, followed by extraction with CHCl 3 . The organic layer was filtered through a phase separator. The filtrate was concentrated under reduced pressure to yield the title compound (675 mg, light yellow oily compound).
[0545] MS (E1, pos.) m/z: 296, 298 (M + ).
[0546] The following compounds were synthesized as in Reference Example P-R1c.
Synthesis of Reference Example P-R2c
2-(4-Bromo-2-methoxyphenyl)ethyl methanesulfonate (Synthesis from Reference Example P-R2b)
[0547]
[0548] MS (E1 pos.) m/z: 308, 310 (M + ).
Synthesis of Reference Example P-R3c
2-(4-Bromo-3-fluorophenyl)ethyl methanesulfonate (Synthesis from Reference Example P-R3b)
[0549]
[0550] MS (E1 pos.) m/z: 296, 298 (M + ).
Synthesis of Reference Example P-R4c
2-(4-Bromo-3-methoxyphenyl)ethyl methanesulfonate (Synthesis from Reference Example P-R4b)
[0551]
[0552] MS (E1 pos.) m/z: 308, 310 (M + ).
Synthesis of Reference Example P-R1-1
4-[2-(4-Bromo-2-fluorophenyl)ethyl]morpholine
[0553]
[0554] The compound (337 mg) prepared in Reference Example P-R1c was dissolved in MeCN (6 mL), and iPr 2 NEt (0.40 mL) and morpholine (0.20 mL) were added thereto, followed by stirring at 100° C. overnight. After concentration, the residue was purified by silica gel column chromatography (SNAP Cartridge HP-Sil: 10 g, mobile phase: CHCl 3 /MeOH=99/1 to 95/5 (v/v)) to yield the title compound (315 mg, light brown oil).
[0555] MS (ESI pos.) m/z: 288, 290 ([M+H] + ).
[0556] The following compounds were synthesized as in Reference Example P-R1-1.
Synthesis of Reference Example P-R1-2
8-[2-(4-Bromo-2-fluorophenyl)ethyl]-3-oxa-8-azabicyclo[3.2.1]octane (Synthesis from the compound prepared in Reference Example P-R1c and 3-oxa-8-azabicyclo[3.2.1]octane)
[0557]
[0558] MS (ESI pos.) m/z: 314, 316 ([M+H] + ).
Synthesis of Reference Example P-R2-1
4-[2-(4-Bromo-2-methoxyphenyl)ethyl]morpholine (Synthesis from the compound prepared in Reference Example P-R2c and morpholine)
[0559]
[0560] MS (ESI pos.) m/z: 300, 302 ([M+H] + ).
Synthesis of Reference Example P-R2-2
8-[2-(4-Bromo-2-methoxyphenyl)ethyl]-3-oxa-8-azabicyclo[3.2.1]octane (Synthesis from the compound prepared in Reference Example P-R2c and 3-oxa-8-azabicyclo[3.2.1]octane)
[0561]
[0562] MS (ESI pos.) m/z: 326, 328 ([M+H] + ).
Synthesis of Reference Example P-R3-1
4-[2-(4-Bromo-3-fluorophenyl)ethyl]morpholine (Synthesis from the compound prepared in Reference Example P-R3c and morpholine)
[0563]
[0564] MS (ESI pos.) m/z: 288, 290 ([M+H] + ).
Reference Example P-R4-1
4-[2-(4-Bromo-3-methoxyphenyl)ethyl]morpholine (Synthesis from the compound prepared in Reference Example P-R4c and morpholine)
[0565]
[0566] MS (ESI pos.) m/z: 300, 302 ([M+H] + ).
Synthesis of Reference Example P-R5-1
4-[1-(4-Bromophenyl)propan-2-yl]morpholine
[0567]
[0568] 1-(4-Bromophenyl)propan-2-one (2.03 g) was dissolved in CHCl 3 (40 mL), and morpholine (1.24 mL) was added thereto, followed by stirring at room temperature overnight and then at 60° C. for 4 hours. NaBH(OAc) 3 (4.03 g) and acetic acid (1.1 mL) were sequentially added thereto, followed by stirring overnight. The reaction was terminated by addition of water, and the reaction solution was separated between CHCl 3 and a saturated aqueous NaHCO 3 solution. The residue was purified by silica gel column chromatography (mobile phase: CHCl 3 /EtOAc=80/20 to 60/40 (v/v)) to yield the title compound (1.67 g, colorless oil).
[0569] MS (ESI pos.) m/z: 284, 286 ([M+H] + ).
Synthesis of Reference Example P-R5-2
8-[1-(4-Bromophenyl)propan-2-yl]-3-oxa-8-azabicyclo[3.2.1]octane
[0570]
[0571] The title compound (54 mg, colorless oil) was prepared from 1-(4-bromophenyl)propan-2-one (130 mg) and 3-oxa-8-azabicyclo[3.2.1]octane (100 mg), as in Reference Example P-R5-1.
[0572] MS (ESI pos.) m/z: 310, 312 ([M+H] + ).
Synthesis of Reference Example P-R6a
2-(6-Chloropyridin-3-yl)-N-methoxy-N-methylacetamide
[0573]
[0574] A solution of (6-chloropyridin-3-yl)acetic acid (5.0 g), N,O-dimethylhydroxyamine hydrochloride (2.98 g), EDC.HCl (5.87 g), and N-methylmorpholine (9.6 mL) in DMF (70 mL) was stirred at room temperature for 4 days. Under ice cooling, water (150 mL) was added thereto, followed by extraction with EtOAc. The organic layer was sequentially washed with water and brine and was dried over Na 2 SO 4 . The desiccant was removed by filtration and the filtrate was concentrated under reduced pressure. The residue was purified by silica gel column chromatography (SNAP Cartridge HP-Sil: 50 g, mobile phase: n-hexane/EtOAc=75/25 to 0/100 (v/v)) to yield the title compound (3.56 g, light yellow oil).
[0575] MS (ESI pos.) m/z: 215 ([M+H] + ).
Synthesis of Reference Example P-R6b
1-(6-Chloropyridin-3-yl)propan-2-one
[0576]
[0577] Under ice cooling, a solution of 3 mol/L methyl magnesium bromide in Et 2 O (1.6 mL) was dropwise added to a solution of the compound (1.0 g) prepared in Reference Example P-R6a in THF (15 mL) in a nitrogen gas flow, followed stirring at room temperature for 1 hour. Under ice cooling, a 3 mol/L hydrochloric acid (2 mL) and an aqueous 2 mol/L sodium hydroxide solution (30 mL) was added thereto. After extraction with EtOAc, the organic layer was washed with brine. After drying with Na 2 SO 4 , the desiccant was removed by filtration. The filtrate was concentrated under reduced pressure. The residue was purified by silica gel column chromatography (SNAP Cartridge HP-Sil: 50 g, mobile phase: n-hexane/EtOAc=80/20 to 0/100 (v/v)) to yield the title compound (235 mg, light yellow oil).
[0578] MS (ESI pos.) m/z: 170 ([M+H] + ).
Synthesis of Reference Example P-R6-1
4-[1-(6-Chloropyridin-3-yl)propan-2-yl]morpholine
[0579]
[0580] A borane-2-picoline complex (252 mg) was added to a solution of the compound (235 mg) prepared in Reference Example P-R6b and morpholine (0.21 mL) in a mixture of methanol and acetic acid (5 ml, 10/1 (v/v)), followed by stirring at an outside temperature of 60° C. for 5 hours and then at an outside temperature of 70° C. overnight. After extraction with CHCl 3 , the organic layer was filtered through a phase separator. The solvent was distilled off under reduced pressure. The residue was purified by silica gel column chromatography (SNAP Cartridge HP-Sil: 25 g, mobile phase: EtOAc/MeOH=100/0 to 90/10 (v/v)) to yield the title compound (166 mg, light yellow oil).
[0581] MS (ESI pos.) m/z: 241 ([M+H] + ).
[0582] The following compounds were synthesized as in Reference Example P-R6-1.
Reference Example P-R6-2
8-[1-(6-Chloropyridin-3-yl)propan-2-yl]-3-oxa-8-azabicyclo[3.2.1]octane (Synthesis from the compound prepared in Reference Example P-R6b and 3-oxa-8-azabicyclo[3.2.1]octane)
[0583]
[0584] MS (ESI pos.) m/z: 267 ([M+H] + ).
Synthesis of Reference Example P-R7-1
8-[2-(4-Bromophenyl)ethyl]-3-oxa-8-azabicyclo[3.2.1]octane
[0585]
[0586] Under ice cooling, Et 3 N (1.3 mL) and methanesulfonyl chloride (0.64 mL) were sequentially added to a solution of 2-(4-bromophenyl)ethanol (1.5 g) in CHCl 3 (10 mL), followed by stirring at room temperature for 2 hours. Under ice cooling, water was added thereto, followed by extraction with CHCl 3 . The organic layer was filtered through a phase separator, and the filtrate was concentrated under reduced pressure.
[0587] A mixture of the residue (light brown oil), 3-oxa-8-azabicyclo[3.2.1]octane (904 mg), 2,2,6,6-tetramethylpiperidine (2.0 mL), and MeCN (10 mL) was stirred at an outside temperature of 95° C. for 4 days. After cooling, water was added thereto, followed by extraction with CHCl 3 . The organic layer was filtered through a phase separator, and the solvent was distilled off under reduced pressure. The residue was purified by silica gel column chromatography (SNAP Cartridge HP-Sil: 50 g, mobile phase: EtOAc/MeOH=99/1 to 90/10 (v/v)) to yield the title compound (1.47 g, light brown solid).
[0588] MS (ESI pos.) m/z: 296, 298 ([M+H] + ).
Synthesis of Reference Example P-S1
{4-[2-(Morpholin-4-yl)propyl]phenyl}boronic acid
[0589]
[0590] The compound (1.61 g) prepared in Reference Example P-R5-1 was dissolved in THF (32.3 mL). A solution of 2.66 mol/L n-BuLi in n-hexane (2.6 mL) was added to the resulting solution at −78° C., followed by stirring for 30 minutes. Subsequently, triisopropyl borate (1.6 mL) was added thereto, followed by stirring with gradually raising the temperature to room temperature for 3 hours. A 2 mol/L hydrochloric acid solution (16 mL) was added thereto, followed by stirring overnight. Subsequently, the reaction solution was adjusted to basic with a saturated aqueous NaHCO 3 solution. After concentration, extraction with CHCl 3 was performed. The organic layer was purified by silica gel column chromatography (mobile phase: CHCl 3 /MeOH=100/0 to 90/10 (v/v)) to yield the title compound (1.09 g, cream-colored powder).
[0591] MS (ESI pos.) m/z: 250 ([M+H] + ).
Synthesis of Reference Example P-T1
2-{3-(4-Fluoro-3-methoxyphenyl)-1-[5-(2-hydroxyethyl)pyrimidin-2-yl]-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl}-N-(propan-2-yl)acetamide
[0592]
[0593] A mixture of 5-bromo-2-chloropyrimidine (800 mg), CIS-tributyl[2-ethoxyethenyl] tin (1.80 g), PdCl 2 (PPh 3 ) 2 (30 mg), and toluene (10 mL) was stirred under a nitrogen atmosphere at an outside temperature of 100° C. for 4 hours. After cooling, the solvent was distilled off under reduced pressure. The residue was purified by column chromatography (SNAP Cartridge KP-NH: 28 g, mobile phase: n-hexane/EtOAc=100/0 to 85/15 (v/v)) to yield 2-chloro-5-[(Z)-2-ethoxyethenyl]pyrimidine (250 mg, colorless solid).
[0594] Cs 2 CO 3 (975 mg) was added to a solution of the resulting 2-chloro-5-[(Z)-2-ethoxyethenyl]pyrimidine (184 mg) and the compound (308 mg) prepared in Reference Example P-Q3 in DMSO (4.0 mL), followed by stirring at room temperature for 12 hours and then at an outside temperature of 85° C. for 8 hours. After cooling, CHCl 3 and water were added to the reaction solution, and then were separated between CHCl 3 and water. The aqueous layer was extracted with CHCl 3 . The combined organic layer was washed with water and brine and was concentrated under reduced pressure. The residue was purified by silica gel column chromatography (SNAP Cartridge HP-Sil: 25 g, mobile phase: CHCl 3 /MeOH=100/0 to 90/10 (v/v)) to yield 2-[1-{5-[(Z)-2-ethoxyethenyl]pyrimidin-2-yl}-3-(4-fluoro-3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (50 mg).
[0595] A solution of 4 mol/L hydrochloric acid in 1,4-dioxane (10 drops) was added to a solution of the resulting 2-[1-{5-[(Z)-2-ethoxyethenyl]pyrimidin-2-yl}-3-(4-fluoro-3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (50 mg) in a mixture of MeCN and H 2 O (10/1 (v/v)), followed by stirring at room temperature for 12 hours. After concentration, CHCl 3 and a saturated aqueous sodium bicarbonate solution were added to the residue, and then were separated between CHCl 3 and a saturated aqueous sodium bicarbonate solution. The aqueous layer was extracted with CHCl 3 . The combined organic layer was sequentially washed with water and brine and was dried over Na 2 SO 4 . The desiccant was removed by filtration. The filtrate was concentrated under reduced pressure to yield an aldehyde. NaBH 4 was added to a solution of the aldehyde in MeOH (5 mL), followed by stirring at room temperature for 30 minutes. A saturated aqueous sodium bicarbonate solution and CHCl 3 were added to the reaction solution, and then were separated between a saturated aqueous sodium bicarbonate solution and CHCl 3 . The aqueous layer was extracted with CHCl 3 . The combined organic layer was sequentially washed with water and brine and was dried over Na 2 SO 4 . The desiccant was removed by filtration, and the filtrate was concentrated under reduced pressure. The residue was purified by silica gel column chromatography (SNAP Cartridge HP-Sil: 10 g, mobile phase: CHCl 3 /MeOH=100/0 to 90/10 (v/v)) to yield the title compound (70 mg, light yellow solid).
[0596] 1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.18 (6H, m), 2.90 (2H, s), 3.88-3.93 (2H, m), 3.98 (3H, d, J=0.8 Hz), 4.03-4.15 (1H, m), 4.33 (2H, s), 6.51-6.63 (1H, m), 7.14-7.23 (1H, m), 7.36-7.47 (1H, m), 7.51-7.63 (1H, m), 8.74 (2H, s).
Synthesis of Reference Example P-U1
Tert-Butyl[2-(4-{3-(3-chlorophenyl)-5-oxo-4-[2-oxo-2-(propan-2-ylamino)ethyl]-4,5-dihydro-1H-1,2,4-triazol-1-yl}phenyl)ethyl]carbamate
[0597]
[0598] A suspension of the compound (73 mg) prepared in Reference Example P-Q2, N-BOC-2-(4-bromophenyl)-ethylamine (78 mg), copper iodide (47 mg), tripotassium phosphate (105 mg), and trans-(1R,2R)-N,N′-bismethyl-1,2-cyclohexanediamine (0.039 mL) in 1,4-dioxane (2 mL) was stirred in a nitrogen gas flow at an outside temperature of 100° C. for 2 days. After cooling, 20% aqueous ammonia was added thereto, followed by extraction with CHCl 3 . The organic layer was filtered through a phase separator, and the filtrate was concentrated under reduced pressure. The residue was purified by silica gel column chromatography (SNAP Cartridge HP-Sil: 10 g, mobile phase: CHCl 3 /MeOH=100/0 to 90/10 (v/v)) to yield the title compound (84 mg, colorless solid).
[0599] MS (ESI pos.) m/z: 536 ([M+Na] + ).
Synthesis of Example Aa-1
2-[3-(3-Chlorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide
[0600]
[0601] A mixture of the compound (100 mg) prepared in Reference Example P-I1, morpholine (0.03 mL), N,N-diisopropylethylamine (0.35 mL), and MeCN (3.00 mL) was stirred at an outside temperature of 80° C. overnight. After cooling, the solvent was distilled off under reduced pressure. The residue was purified by column chromatography (SNAP Cartridge HP-Sil: 10 g, mobile phase: CHCl 3 /MeOH=98/2 to 85/15 (v/v); and SNAP Cartridge KP-NH: 28 g, mobile phase: n-hexane/CHCl 3 =80/20 to 0/100 (v/v)) and preparative thin-layer chromatography (PTLC) (1.0 mm silica gel 60F 254 plate, mobile phase: EtOAc/MeOH=95/5 (v/v)). The resulting crude product was washed with a solvent mixture of EtOAc and n-hexane (EtOAc/n-hexane=1/4 (v/v)) with stirring to yield the title compound (70 mg, colorless solid).
[0602] MS (ESI pos.) m/z: 484 ([M+H] + ).
[0603] 1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.20 (6H, d, J=6.4 Hz), 2.48-2.67 (6H, m), 2.80-2.88 (2H, m), 3.76 (4H, br. s.), 4.06-4.13 (1H, m), 4.36 (2H, s), 6.37-6.45 (1H, m), 7.31 (2H, d, J=8.3 Hz), 7.46-7.50 (1H, m), 7.51-7.55 (1H, m), 7.74-7.77 (1H, m), 7.85-7.88 (1H, m), 7.94 (2H, d, J=8.7 Hz).
Synthesis of Example Aa-2
2-[3-(3-Chlorophenyl)-1-{4-[2-(2-oxa-6-azaspiro[3.3]hept-6-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide
[0604]
[0605] A suspension of the compound (150 mg) prepared in Reference Example P-J1, 2-oxa-6-azaspiro[3.3]heptane oxalate (2:1) (157 mg), and acetic acid (0.1 mL) in CHCl 3 (3 mL) was stirred at room temperature for a while, and then sodium triacetoxyborohydride (231 mg) was added thereto, followed by stirring for 3 days. A saturated NaHCO 3 solution was added to the reaction solution, followed by extraction with CHCl 3 . The organic layer was filtered through a phase separator, and the solvent was distilled off under reduced pressure. The residue was purified by preparative thin-layer chromatography (PTLC) (1.0 mm silica gel 60F 254 plate, mobile phase: CHCl 3 /MeOH=90/10 (v/v)) and column chromatography (SNAP Cartridge KP-NH: 11 g, mobile phase: EtOAc/MeOH=100/0 to 95/5 (v/v)). The resulting crude product was washed with a solvent mixture of EtOAc and n-hexane (EtOAc/n-hexane=1/6 (v/v)) with stirring to yield the title compound (13 mg, colorless solid).
[0606] MS (ESI pos.) m/z: 496 ([M+H] + ).
[0607] 1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.19 (6H, d, J=6.9 Hz), 2.59-2.72 (4H, m), 3.36 (4H, br. s.), 4.06-4.13 (1H, m), 4.35 (2H, s), 4.74 (4H, s), 6.36-6.43 (1H, m), 7.23-7.29 (2H, m), 7.49 (1H, d, J=7.8 Hz), 7.51-7.54 (1H, m), 7.75 (1H, d, J=9.2 Hz), 7.85-7.88 (1H, m), 7.93 (2H, d, J=8.3 Hz).
Synthesis of Example Aa-3
2-[3-(3-Chlorophenyl)-5-oxo-1-{4-[2-(piperidin-1-yl)ethoxy]phenyl}-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide
[0608]
[0609] A mixture of the compound (70.0 mg) prepared in Reference Example P-K1, 1-piperidineethanol (0.03 mL), a solution of 1.9 mol/L diisopropyl azodicarboxylate in toluene (0.29 mL), triphenylphosphine (142 mg), and THF (2.0 mL) was stirred under a nitrogen atmosphere at an outside temperature of 40° C. for 3 hours and then at room temperature overnight. Furthermore, 1-piperidine ethanol (0.06 mL), a solution of 1.9 mol/L diisopropyl azodicarboxylate in toluene (0.29 mL), and triphenylphosphine (142 mg) were added thereto, followed by stirring at an outside temperature of 85° C. for 8 hours. After cooling, the solvent was distilled off under reduced pressure. The residue was purified by column chromatography (SNAP Cartridge KP-Sil: 25 g, mobile phase: CHCl 3 /MeOH=98/2 to 95/5 (v/v)). The resulting crude product was washed with a solvent mixture of EtOAc and IPE (EtOAc/IPE=1/1 (v/v)) with stirring to yield the title compound (53 mg, colorless solid).
[0610] MS (ESI pos.) m/z: 498 ([M+H] + ).
[0611] 1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.20 (6H, d, J=6.4 Hz), 1.43-1.50 (2H, m), 1.60-1.68 (4H, m), 2.46-2.61 (4H, m), 2.77-2.86 (2H, m), 4.06-4.19 (3H, m), 4.35 (2H, s), 6.44-6.49 (1H, m), 6.97-7.01 (2H, m), 7.46-7.54 (2H, m), 7.74-7.77 (1H, m), 7.85-7.91 (3H, m).
[0612] The following compounds were synthesized as in Example Aa-1:
[0613] Example Aa-4: 2-[3-(3-Chlorophenyl)-1-{4-[2-(4-hydroxypiperidin-1-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I1 and piperidin-4-ol),
[0614] Example Aa-5: 2-[3-(3-Chlorophenyl)-1-{4-[2-(3-hydroxypiperidin-1-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I1 and piperidin-3-ol),
[0615] Example Aa-6: 2-[3-(3-Chlorophenyl)-1-{4-[2-(3-hydroxypyrrolidin-1-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I1 and pyrrolidin-3-ol),
[0616] Example Aa-7: 2-[3-(3-Chlorophenyl)-1-(4-{2-[3-(hydroxymethyl)pyrrolidin-1-yl]ethyl}phenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I1 and pyrrolidin-3-ylmethanol),
[0617] Example Aa-8: 2-[3-(3-Chlorophenyl)-1-{4-[2-(3-hydroxy-8-azabicyclo[3.2.1]oct-8-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I1 and 8-azabicyclo[3.2.1]octan-3-ol),
[0618] Example Aa-9: 2-[3-(3-Chlorophenyl)-1-{4-[2-(8-oxa-3-azabicyclo[3.2.1]oct-3-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I1 and 8-oxa-3-azabicyclo[3.2.1]octane),
[0619] Example Aa-10: 2-[3-(3-Chlorophenyl)-1-{4-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I1 and 3-oxa-8-azabicyclo[3.2.1]octane),
[0620] Example Aa-11: 2-[3-(3-Chlorophenyl)-5-oxo-1-{4-[2-(piperidin-1-yl)ethyl]phenyl}-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I1 and piperidine),
[0621] Example Aa-12: 2-[3-(3-Chlorophenyl)-1-(4-{2-[(2-hydroxyethyl)amino]ethyl}phenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I1 and 2-aminoethanol),
[0622] Example Aa-13: 2-[3-(3-Chlorophenyl)-1-{4-[2-(1,4-oxazepan-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I1 and 1,4-oxazepam),
[0623] Example Ab-1: 2-[3-(3-Chlorophenyl)-5-oxo-1-{5-[2-(piperidin-1-yl)ethyl]pyridin-2-yl}-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I3 and piperidine),
[0624] Example Ab-2: 2-[3-(3-Chlorophenyl)-1-{5-[2-(morpholin-4-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I3 and morpholine),
[0625] Example Ab-3: 2-[3-(3-Chlorophenyl)-1-{5-[2-(1,4-oxazepan-4-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I3 and 1,4-oxazepam),
[0626] Example Ab-4: 2-[3-(3-Chlorophenyl)-1-{5-[2-(3-hydroxy-8-azabicyclo[3.2.1]oct-8-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I3 and 8-azabicyclo[3.2.1]octan-3-ol),
[0627] Example Ab-5: 2-[3-(3-Chlorophenyl)-1-{5-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I3 and 3-oxa-8-azabicyclo[3.2.1]octane),
[0628] Example Ac-1: 2-[3-(3-Chlorophenyl)-5-oxo-1-{6-[2-(piperidin-1-yl)ethyl]pyridin-3-yl}-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I4 and piperidine),
[0629] Example Ac-2: 2-[3-(3-Chlorophenyl)-1-{6-[2-(morpholin-4-yl)ethyl]pyridin-3-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I4 and morpholine),
[0630] Example Ba-1: 2-[3-(3-Methoxyphenyl)-5-oxo-1-{4-[2-(piperidin-1-yl)ethyl]phenyl}-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I5 and piperidine),
[0631] Example Ba-2: 2-[3-(3-Methoxyphenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I5 and morpholine),
[0632] Example Ca-1: 2-[3-(4-Fluoro-3-methoxyphenyl)-5-oxo-1-{4-[2-(piperidin-1-yl)ethyl]phenyl}-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I6 and piperidine),
[0633] Example Ca-2: 2-[3-(4-Fluoro-3-methoxyphenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I6 and morpholine),
[0634] Example Ca-3: 2-[3-(4-Fluoro-3-methoxyphenyl)-1-{4-[2-(3-hydroxy-8-azabicyclo[3.2.1]oct-8-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I6 and 8-azabicyclo[3.2.1]octan-3-ol),
[0635] Example Ca-4: 2-[3-(4-Fluoro-3-methoxyphenyl)-1-{4-[2-(8-oxa-3-azabicyclo[3.2.1]oct-3-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I6 and 8-oxa-3-azabicyclo[3.2.1]octane),
[0636] Example Ca-5: 2-[3-(4-Fluoro-3-methoxyphenyl)-1-{4-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I6 and 3-oxa-8-azabicyclo[3.2.1]octane),
[0637] Example Cb-1: 2-[3-(4-Fluoro-3-methoxyphenyl)-5-oxo-1-{5-[2-(piperidin-1-yl)ethyl]pyridin-2-yl}-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-17 and piperidine),
[0638] Example Cb-2: 2-[3-(4-Fluoro-3-methoxyphenyl)-1-{5-[2-(morpholin-4-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-17 and morpholine),
[0639] Example Cb-3: 2-[3-(4-Fluoro-3-methoxyphenyl)-1-{5-[2-(1,4-oxazepan-4-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I7 and 1,4-oxazepam),
[0640] Example Cb-4: 2-[3-(4-Fluoro-3-methoxyphenyl)-1-{5-[2-(3-hydroxy-8-azabicyclo[3.2.1]oct-8-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I7 and 8-azabicyclo[3.2.1]octan-3-ol),
[0641] Example Cb-5: 2-[3-(4-Fluoro-3-methoxyphenyl)-1-{5-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I7 and 3-oxa-8-azabicyclo[3.2.1]octane),
[0642] Example Da-1: 2-[3-(3-Chloro-4-fluorophenyl)-5-oxo-1-{4-[2-(piperidin-1-yl)ethyl]phenyl}-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I8 and piperidine),
[0643] Example Da-2: 2-[3-(3-Chloro-4-fluorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I8 and morpholine),
[0644] Example Da-3: 2-[3-(3-Chloro-4-fluorophenyl)-1-{4-[2-(2-oxa-6-azaspiro[3.3]hept-6-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I8 and 2-oxa-6-azaspiro[3.3]heptane),
[0645] Example Da-4: 2-[3-(3-Chloro-4-fluorophenyl)-1-{4-[2-(1,4-oxazepan-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I8 and 1,4-oxazepam),
[0646] Example Da-5: 2-[3-(3-Chloro-4-fluorophenyl)-1-{4-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I8 and 3-oxa-8-azabicyclo[3.2.1]octane),
[0647] Example Da-6: 2-[3-(3-Chloro-4-fluorophenyl)-1-{4-[2-(3-hydroxy-8-azabicyclo[3.2.1]oct-8-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I8 and 8-azabicyclo[3.2.1]octan-3-ol),
[0648] Example Db-1: 2-[3-(3-Chloro-4-fluorophenyl)-5-oxo-1-{5-[2-(piperidin-1-yl)ethyl]pyridin-2-yl}-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I9 and piperidine),
[0649] Example Db-2: 2-[3-(3-Chloro-4-fluorophenyl)-1-{5-[2-(morpholin-4-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I9 and morpholine),
[0650] Example Db-3: 2-[3-(3-Chloro-4-fluorophenyl)-1-{5-[2-(2-oxa-6-azaspiro[3.3]hept-6-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I9 and 2-oxa-6-azaspiro[3.3]heptane),
[0651] Example Db-4: 2-[3-(3-Chloro-4-fluorophenyl)-1-{5-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I9 and 3-oxa-8-azabicyclo[3.2.1]octane),
[0652] Example Db-5: 2-[3-(3-Chloro-4-fluorophenyl)-1-{5-[2-(3-hydroxy-8-azabicyclo[3.2.1]oct-8-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I9 and 8-azabicyclo[3.2.1]octan-3-ol),
[0653] Example Ea-1: 2-[3-(3-Cyanophenyl)-5-oxo-1-{4-[2-(piperidin-1-yl)ethyl]phenyl}-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I2 and piperidine),
[0654] Example Ea-2: 2-[3-(3-Cyanophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I2 and morpholine),
[0655] Example Ea-3: 2-[3-(3-Cyanophenyl)-1-{4-[2-(2-oxa-6-azaspiro[3.3]hept-6-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I2 and 2-oxa-6-azaspiro[3.3]heptane)
[0656] Example Ad-17: N-Tert-Butyl-2-[3-(3-chlorophenyl)-1-{5-[2-(morpholin-4-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]acetamide (Synthesis from Reference Example P-I10 and morpholine),
[0657] Example Ad-18: N-Tert-Butyl-2-[3-(3-chlorophenyl)-1-{5-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]acetamide (Synthesis from Reference Example P-I10 and 3-oxa-8-azabicyclo[3.2.1]octane),
[0658] Example Ba-3: 2-[3-(3-Methoxyphenyl)-1-{4-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-I5 and 3-oxa-8-azabicyclo[3.2.1]octane),
[0659] Example Bd-1: N-Tert-Butyl-2-[3-(3-methoxyphenyl)-1-{5-[2-(morpholin-4-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]acetamide (Synthesis from Reference Example P-I11 and morpholine), and
[0660] Example Bd-2: N-Tert-Butyl-2-[3-(3-methoxyphenyl)-1-{5-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]acetamide (Synthesis from Reference Example P-I11 and 3-oxa-8-azabicyclo[3.2.1]octane).
[0661] The results of 1 H-NMR and MS of Examples Aa-4 to Aa-13, Ab-1 to Ab-5, Ac-1 to Ac-2, Ba-1 to Ba-2, Ca-1 to Ca-5, Cb-1 to Cb-5, Da-1 to Da-6, Db-1 to Db-5, Ea-1 to Ea-3, Ad-17, Ad-18, Ba-3, Bd-1, and Bd-2 are shown in Tables 1-1 to 1-8.
[0000]
TABLE 1-1
Ex-
MS (ESI pos.)
ample
Structure
1 H NMR
m/z
Aa-4
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.19 (6H, d, J = 6.4 Hz), 1.35-1.44 (1H, m), 1.60-1.70 (2H, m), 1.89-2.00 (2H, m), 2.18-2.31 (2H, m), 2.57-2.68 (2H, m), 2.78-2.94 (4H, m), 3.68-3.79 (1H, m), 4.06-4.13 (1H, m), 4.36 (2H, s), 6.38-6.46 (1H, m), 7.30 (2H, d, J = 8.3 Hz), 7.45-7.50 (1H, m), 7.50- 7.54 (1H, m), 7.76 (1H, d, J = 7.8 Hz), 7.85-7.88 (1H, m), 7.03 (2H, d, J = 8.3 Hz).
498([M + H] + )
Aa-5
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.20 (6H, d, J = 6.9 Hz), 1.50-1.68 (4H, m), 1.80-1.92 (1H, m), 2.31-2.72 (6H, m), 2.80-2.89 (2H, m), 3.83-3.91 (1H, m), 4.06-4.13 (1H, m), 4.36 (2H, s), 6.38- 6.46 (1H, m), 7.29 (2H, d, J = 8.3 Hz), 7.46-7.50 (1H, m), 7.51-7.54 (1H, m), 7.76 (1H, d, J = 7.8 Hz), 7.85-7.88 (1H, m), 7.94 (2H, d, J = 8.7 Hz).
498([M + H] + )
Aa-6
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.19 (6H, d, J = 6.9 Hz), 1.75-1.82 (1H, m), 2.18-2.25 (1H, m), 2.34-2.41 (1H, m), 2.57-2.62 (1H, m), 2.73-2.82 (3H, m), 2.84-2.90 (2H, m), 2.97-3.02 (1H, m), 4.06-4.13 (1H, m), 4.34-4.40 (3H, m), 6.40-6.45 (1H, m), 7.31 (2H, d, J = 8.7 Hz), 7.46-7.50 (1H, m), 7.51-7.54 (1H, m), 7.76 (1H, d, J = 7.8 Hz), 7.86 (1H, t, J = 1.8 Hz), 7.93 (2H, d, J = 8.7 Hz).
484([M + H] + )
Aa-7
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.19 (6H, d, J = 6.9 Hz), 1.74-1.82 (1H, m), 2.02-2.12 (1H, m), 2.40-2.47 (1H, m), 2.66-3.07 (8H, m), 3.58 (1H, dd, J = 10.1, 5.5 Hz), 3.71 (1H, dd, J = 10.3, 4.4 Hz), 4.06-4.13 (1H, m), 4.35 (2H, s), 6.41-6.45 (1H, m), 7.30 (2H, d, J = 8.7 Hz), 7.46-7.54 (2H, m), 7.75 (1H, d, J = 7.8 Hz), 7.85-7.87 (1H, m), 7.95 (2H, d, J = 8.3 Hz).
498([M + H] + )
Aa-8
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.18 (6H, d, J = 6.9 Hz,) 1.24-1.33 (2H, m), 1.67-1.76 (2H, m), 1.93-2.03 (2H, m), 2.09-2.24 (3H, m), 2.60-2.76 (2H, m), 2.82-2.98 (2H, m), 3.26-3.41 (2H, m), 4.05-4.13 (2H, m), 4.35 (2H, s), 6.38-6.44 (1H, m), 7.28-7.34 (2H, m), 7.45-7.50 (1H, m), 7.50- 7.54 (1H, m) 7.72-7.77 (1H, m), 7.85 (1H, t, J = 1.8 Hz), 7.90-7.95 (2H, m).
524([M + H] + )
Aa-9
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.19 (6H, d, J = 6.9 Hz), 1.80-1.91 (4H, m), 2.34-2.38 (2H, m), 2.56 (2H, t, J = 7.6 Hz), 2.60-2.64 (2H, m), 2.76 (2H, t, J = 7.6 Hz), 4.05-4.12 (1H, m), 4.26-4.30 (2H, m), 4.35 (2H, s), 6.40-6.45 (1H, m), 7.30 (2H, d, J = 8.3 Hz), 7.45-7.53 (2H, m), 7.74-7.77 (1H, m), 7.85- 7.87 (1H, m), 7.89-7.94 (2H, m).
510([M + H] + )
[0000]
TABLE 1-2
Aa-10
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.18 (6H, d, J = 6.4 Hz), 1.85-1.94 (4H, m), 2.49-2.56 (2H, m), 2.77-2.84 (2H, m), 3.05-3.12 (2H, m), 3.49-3.58 (2H, m), 3.69-3.77 (2H, m), 4.04-4.13 (1H, m), 4.35 (2H, s), 6.45 (1H, d, J = 7.3 Hz), 7.28-7.33 (2H, m), 7.44-7.54 (2H, m), 7.75 (1H, d, J = 7.8 Hz), 7.85 (1H, s), 7.89-7.95 (2H, m).
510([M + H] + )
Aa-11
1 H NMR (600 MHz, DMSO-d 6 ) δ (ppm); 1.00 (6H, d, J = 6.9 Hz), 1.34-1.42 (2H, m), 1.46-1.52 (4H, m), 2.39 (4H, d, J = 1.4 Hz), 2.44-2.53 (2H, m), 2.71- 2.77 (2H, m), 3.74-3.82 (1H, m), 4.38 (2H, s), 7.34 (2H, d, J = 8.7 Hz), 7.56-7.61 (1H, m), 7.63-7.69 (2H, m), 7.73 (1H, s), 7.86 (2H, d, J = 8.3 Hz), 8.21 (1H, d, J = 7.8 Hz).
482([M + H] + )
Aa-12
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.18 (6H, d, J = 6.4 Hz), 2.76-2.86 (4H, m), 2.89-2.95 (2H, m), 3.60-3.64 (2H, m), 4.05-4.13 (1H, m), 4.35 (2H, s), 6.43 (1H, d, J = 8.3 Hz), 7.30 (2H, d, J = 8.7 Hz), 7.45- 7.54 (2H, m), 7.75 (1H, dt, J = 7.8, 1.4 Hz), 7.85 (1H, t, J = 1.8 Hz), 7.91-7.96 (2H, m)
458([M + H] + )
Aa-13
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.20 (6H, d, J = 6.4 Hz), 1.90-1.96 (2H, m), 2.76-2.86 (6H, m), 3.74-3.78 (2H, m), 3.82 (2H, t, J = 6.0 Hz), 4.06- 4.13 (1H, m), 4.36 (2H, s), 6.36-6.45 (1H, m), 7.30 (2H, d, J = 8.7 Hz), 7.46-7.51 (1H, m), 7.51-7.54 (1H, m), 7.74-7.78 (1H, m), 7.85-7.88 (1H, m), 7.93 (2H, d, J = 8.3 Hz)
498([M + H] + )
Ab-1
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.17 (6H, d, J = 6.9 Hz), 1.44 (2H, br. s.), 1.57-1.61 (4H, m), 2.45 (4H, br. s.), 2.51-2.58 (2H, m), 2.78-2.86 (2H,m), 4.04-4.12 (1H, m), 4.34 (2H, s), 6.31 (1H, d, J = 7.3 Hz), 7.41-7.47 (1H, m), 7.47-7.52 (1H, m), 7.68 (1H, dd, J = 8.3, 2.3 Hz), 7.71-7.76 (1H, m), 7.88 (1H, t, J = 1.6 Hz), 8.02 (1H, d, J = 8.3 Hz), 8.43 (1H, d, J = 2.3 Hz)
483([M + H] + )
Ab-2
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.18 (6H, d, J = 6.9 Hz), 2.52 (4H, br. s.), 2.61 (2H, t, J = 7.6 Hz), 2.84 (2H, t, J = 7.8 Hz), 3.73 (4H, t, J = 4.6 Hz), 4.05- 4.15 (1H, m), 4.36 (2H, s), 6.28 (1H, d, J = 7.3 Hz), 7.44-7.48 (1H, m), 7.50-7.53 (1H, m), 7.70 (1H, dd, J = 8.3, 2.3 Hz), 7.75 (1H, d, J = 7.8 Hz), 7.88 (1H, t, J = 1.6 Hz), 8.05 (1H, d, J = 8.3 Hz), 8.45 (1H, d, J = 1.8 Hz)
485([M + H] + )
[0000]
TABLE 1-3
Ab-3
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.19 (6H, d, J = 6.4 Hz), 1.87-1.98 (2H, m), 2.72-2.89 (8H, m), 3.75 (2H, br. s.), 3.81 (2H, t, J = 6.0 Hz), 4.07-4.14 (1H, m), 4.36 (2H, s), 6.24-6.31 (1H, m), 7.45- 7.49 (1H, m), 7.50-7.55 (1H, m), 7.69-7.73 (1H, m), 7.74-7.78 (1H, m), 7.88-7.91 (1H, m), 8.06 (1H, d, J = 8.3 Hz), 8.44-8.47 (1H, m)
499([M + H] + )
Ab-4
1 H NMR (600 MHz, DMSO-d 6 ) δ (ppm); 1.00 (6H, d, J = 6.4 Hz), 1.89-1.96 (2H, m), 2.11-2.25 (3H, m), 2.33-2.41 (2H, m), 3.02-3.13 (2H, m), 3.19-3.26 (2H, m), 3.74-3.82 (1H, m), 3.87-4.06 (3H, m), 4.39 (2H, s), 4.88-4.97 (1H, m), 7.55-7.63 (1H, m), 7.63-7.74 (3H, m), 7.91-8.02 (2H, m), 8.20- 8.26 (1H, m), 8.45-8.51 (1H, m)
525([M + H] + )
Ab-5
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.19 (6H, d, J = 6.4 Hz), 1.90 (4H, br. s.), 2.50-2.57 (2H, m), 2.78- 2.84 (2H, m), 3.07 (2H, br. s.), 3.52 (2H, d, J = 9.6 Hz), 3.71 (2H, d, J = 10.5 Hz), 4.08-4.14 (1H, m), 4.36 (2H, s), 6.23-6.31 (1H, m), 7.45-7.49 (1H, m), 7.50-7.55 (1H, m), 7.71-7.79 (2H, m), 7.88- 7.91 (1H, m), 8.06 (1H, d, J = 8.3 Hz), 8.46-8.49 (1H, m)
511([M + H] + )
Ac-1
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.11-1.19 (6H, m), 1.39-1.83 (6H, m), 2.43-2.65 (4H, m), 2.73- 2.90 (2H, m), 3.01-3.15 (2H, m), 3.98-4.14 (1H, m), 4.34 (2H, s), 6.27 (1H, d, J = 7.8 Hz), 7.29 (1H, d, J = 8.3 Hz), 7.44-7.51 (1H, m), 7.50-7.55 (1H, m), 7.73 (1H, dt, J = 7.8, 1.8 Hz), 7.82 (1H, t, J = 1.8 Hz), 8.23 (1H, dd, J = 8.3, 2.5 Hz), 9.18 (1H, d, J = 2.3 Hz)
483([M + H] + )
Ac-2
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.21 (6H, d, J = 6.4 Hz), 2.56 (4H, d, J = 3.7 Hz), 2.73-2.86 (2H, m), 2.96-3.11 (2H, m), 3.67-3.80 (4H, m), 4.01- 4.18 (1H, m), 4.37 (2H, s), 6.16-6.30 (1H, m), 7.31 (1H, s), 7.48-7.59 (2H, m), 7.76 (1H, d, J = 7.3 Hz), 7.85 (1H, d, J = 3.7 Hz), 8.15-8.36 (1H, m), 9.23 (1H, d, J = 2.8 Hz)
485([M + H] + )
Ba-1
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.23 (6H, d, J = 6.4 Hz), 1.86-1.98 (4H, m), 2.23-2.38 (2H, m), 2.62-2.76 (2H, m), 3.14-3.37 (4H, m), 3.61-3.72 (2H, m), 3.93 (3H, s), 4.09-4.18 (1H, m), 4.41 (2H, s), 6.54 (1H, d, J = 7.3 Hz), 7.11-7.15 (1H, m), 7.37 (2H, d, J = 8.7 Hz), 7.39-7.43 (2H, m), 7.45-7.50 (1H, m), 8.04 (2H, d, J = 8.7 Hz)
478([M + H] + )
[0000]
TABLE 1-4
Ba-2
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.17 (6H, d, J = 6.4 Hz), 2.80-2.97 (2H, m), 3.12-3.36 (4H, m), 3.50 (2H, br. s.), 3.88 (3H, s), 4.00 (2H, br. s.), 4.04- 4.12 (1H, m), 4.15-4.30 (2H, m), 4.35 (2H, s), 6.41 (1H, d, J = 6.9 Hz), 7.05-7.10 (1H, m), 7.32 (2H, d, J = 8.7), 7.34-7.37 (2H, m), 7.43 (1H, s), 8.01 (2H, d, J = 8.7 Hz)
480([M + H] + )
Ca-1
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.20 (6H, d, J = 6.4 Hz), 1.41-1.51 (2H, m), 1.60-1.71 (4H, m), 2.42-2.66 (6H, m), 2.80-2.94 (2H, m), 4.01 (3H, s), 4.04-4.11 (1H, m), 4.34 (2H, s), 6.65-6.71 (1H, m), 7.21-7.25 (1H, m), 7.31 (2H, d, J = 8.3 Hz), 7.38- 7.42 (1H, m), 7.54-7.58 (1H, m), 7.92 (2H, d, J = 8.3 Hz)
496([M + H] + )
Ca-2
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.20 (6H, d, J = 6.9 Hz), 2.49-2.67 (6H, m), 2.81-2.88 (2H, m), 3.76 (4H, br. s.), 4.01 (3H, s), 4.05-4.11 (1H, m), 4.35 (2H, s), 6.63-6.69 (1H, m), 7.23 (1H, dd, J = 11.0, 8.3 Hz), 7.31 (2H, d, J = 8.7 Hz), 7.38-7.42 (1H, m), 7.54-7.58 (1H, m), 7.93 (2H, d, J = 8.7 Hz)
498([M + H] + )
Ca-3
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.19 (6H, d, J = 6.4 Hz), 1.21-1.28 (1H, m), 1.66 (2H, d, J = 14.2 Hz), 1.90-1.98 (2H, m), 2.03-2.15 (4H, m), 2.53- 2.63 (2H, m), 2.77-2.83 (2H, m), 3.24 (2H, br. s.), 3.99 (3H, s), 4.03-4.10 (2H, m), 4.33 (2H, s), 6.68 (1H, d, J = 7.8 Hz), 7.22 (1H, dd, J = 10.8, 8.5 Hz), 7.30 (2H, d, J = 8.7 Hz), 7.39 (1H, ddd, J = 8.5, 4.1, 2.1 Hz), 7.55 (1H, dd, J = 7.8, 2.3 Hz), 7.87-7.93 (2H, m)
538([M + H] + )
Ca-4
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.16-1.21 (6H, m), 1.78-1.92 (4H, m), 2.33-2.39 (2H, m), 2.56 (2H, t, J = 7.6 Hz), 2.62 (2H, d, J = 11.0 Hz), 2.76 (2H, t, J = 7.3 Hz), 3.97-4.01 (3H, m), 4.07 (1H, dd, J = 14.2, 6.4 Hz), 4.28 (2H, d, J = 2.3 Hz), 4.34 (2H, s), 6.63- 6.70 (1H, m), 7.22 (1H, dd, J = 11.0, 8.3 Hz), 7.30 (2H, d, J = 8.3 Hz), 7.39 (1H, ddd, J = 8.3, 4.1, 1.8 Hz), 7.53-7.57 (1H, m), 7.88-7.93 (2H, m)
524([M + H] + )
Ca-5
1 H NMR (600 MHz, CDCl 3 ) δ (ppm); 1.20 (6H, d, J = 6.9 Hz), 1.86-1.96 (4H, m), 2.51-2.57 (2H, m, 2.79-2.85 (2H, m), 3.10 (2H, br. s.), 3.51-3.56 (2H, m), 3.74 (2H, d, J = 10.5 Hz), 4.01 (3H, s), 4.04- 4.12 (1H, m), 4.35 (2H, s), 6.63-6.70 (1H, m), 7.23 (1H, dd, J = 10.8, 8.5 Hz), 7.32 (2H, d, J = 8.3 Hz), 7.38-7.42 (1H, m), 7.54-7.58 (1H, m), 7.92 (2H, d, J = 8.7 Hz)
524([M + H] + )
[0000]
TABLE 1-5
Cb-1
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.19 (6H, d, J = 6.9 Hz), 1.43-1.50 (2H, m), 1.59-1.65 (4H, m), 2.42-2.51 (4H, m), 2.54-2.60 (2H, m), 2.82-2.87 (2H, m), 3.99 (3H, s), 4.05-4.12 (1H, m), 4.35 (2H, s), 6.48-6.55 (1H, m), 7.21 (1H, dd, J = 11.0, 8.3 Hz), 7.40-7.43 (1H, m), 7.56 (1H, dd, J = 8.0, 2.1 Hz), 7.71 (1H, dd, J = 8.3, 2.3 Hz), 8.03 (1H, d, J = 8.7 Hz), 8.45 (1H, d, J = 2.3 Hz)
497([M + H] + )
Cb-2
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.20 (6H, d, J = 6.4 Hz), 2.53 (4H, br. s.), 2.60-2.65 (2H, m), 2.85 (2H, t, J = 7.6 Hz), 3.70-3.77 (4H, m), 3.99 (3H, s), 4.06-4.13 (1H, m), 4.35 (2H, s), 6.46-6.51 (1H, m), 7.21 (1H, dd, J = 10.8, 8.5 Hz), 7.39-7.44 (1H, m), 7.56 (1H, dd, J = 7.8, 2.3 Hz), 7.71 (1H, dd, J = 8.3, 2.3 Hz), 8.05 (1H, d, J = 8.7 Hz), 8.46 (1H, d, J = 1.8 Hz)
499([M + H] + )
Cb-3
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.18-1.21 (8H, m), 1.88-1.96 (2H, m), 2.72-2.88 (8H, m), 3.72- 3.77 (2H, m), 3.81 (2H, t, J = 6.0 Hz), 3.98-4.00 (3H, m), 4.05-4.13 (1H, m), 4.35 (2H, s), 6.47-6.54 (1H, m), 7.21 (1H, dd, J = 10.8, 8.5 Hz), 7.38-7.44 (1H, m), 7.56 (1H, dd, J = 7.8, 2.3 Hz), 7.71 (1H, dd, J = 8.3, 2.3 Hz), 8.05 (1H, d, J = 8.3 Hz), 8.45 (1H, d, J = 2.3 Hz)
513([M + H] + )
Cb-4
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.19 (6H, d, J = 6.4 Hz), 1.21-1.25 (1H, m), 1.67 (2H, d, J = 14.2 Hz), 1.88-1.98 (2H, m), 2.02-2.15 (4H, m), 2.54- 2.63 (2H, m), 2.77-2.84 (2H, m), 3.21 (2H, br. s.), 3.99 (3H, s), 4.03-4.13 (2H, m), 4.35 (2H, s), 6.46- 6.55 (1H, m), 7.18-7.24 (1H, m), 7.39-7.44 (1H, m), 7.53-7.58 (1H, m), 7.69-7.75 (1H, m), 8.03 (1H, d, J = 8.3 Hz), 8.47 (1H, d, J = 2.3 Hz)
539([M + H] + )
Cb-5
1 H-NMR (600 MHz, CDCl 3 δ (ppm); 1.20 (6H, d, J = 6.4 Hz), 1.85-1.95 (4H, m), 2.51-2.57 (2H, m), 2.78-2.84 (2H, m), 3.07 (2H, br. s.), 3.52 (2H, d, J = 9.2 Hz), 3.70 (2H, d, J = 10.1 Hz), 3.99 (3H, s), 4.05-4.13 (1H, m), 4.35 (2H, s), 6.46-6.53 (1H, m), 7.19-7.24 (1H, m), 7.39-7.44 (1H, m), 7.53- 7.58 (1H, m), 7.72-7.77 (1H, m), 8.05 (1H, d, J = 8.3 Hz), 8.48 (1H, d, J = 2.3 Hz)
525([M + H] + )
Da-1
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.15-1.21 (6H, m), 1.82-2.05 (4H, m), 2.23-2.34 (2H, m), 2.59- 2.68 (2H, m), 3.11-3.18 (2H, m), 3.25-3.31 (2H, m), 3.58-3.65 (2H, m), 4.03-4.11 (1H, m), 4.32 (2H, s), 6.35-6.41 (1H, m), 7.28-7.35 (3H, m), 7.79 (1H, ddd, J = 8.7, 4.1, 2.3 Hz), 7.93-8.00 (3H, m)
500([M + H] + )
[0000]
TABLE 1-6
Da-2
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.18 (6H, d, J = 6.9 Hz), 2.46-2.66 (6H, m), 2.76-2.88 (2H, m), 3.74 (4H, t, J = 4.6 Hz), 4.01-4.12 (1H, m), 4.31 (2H, s), 6.44 (1H, d, J = 7.3 Hz), 7.27-7.34 (3H, m), 7.77- 7.83 (1H, m), 7.90 (2H, d, J = 8.3 Hz), 7.97 (1H, dd, J = 6.9, 2.3 Hz)
502([M + H] + )
Da-3
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.19 (6H, d, J = 6.4 Hz), 2.66 (4H, br. s.), 3.29-3.42 (4H, m), 4.08 (1H, dq, J = 13.7, 6.7 Hz), 4.32 (2H, s), 4.73 (4H, s), 6.41 (1H, d, J = 6.4 Hz), 7.22-7.28 (2H, m), 7.31 (1H, t, J = 8.5 Hz), 7.80 (1H, ddd, J = 8.5, 4.4, 2.3 Hz), 7.91 (2H, d, J = 8.7 Hz), 7.97 (1H, dd, J = 6.9, 2.3 Hz)
514([M + H] + )
Da-4
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.18 (6H, dd, J = 6.6, 1.1 Hz), 1.46-1.54 (2H, m), 1.86-1.96 (2H, m), 2.67-2.73 (2H, m), 2.74-2.86 (4H, m), 3.65- 3.70 (1H, m), 3.71-3.76 (1H, m), 3.77-3.85 (2H, m), 4.02-4.13 (1H, m), 4.29-4.35 (2H, m), 6.46 (1H, br. s.), 7.26-7.33 (2H, m), 7.43-7.48 (1H, m), 7.76-7.83 (1H, m), 7.86-7.94 (2H, m), 7.94-8.00 (1H, m)
516([M + H] + )
Da-5
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.18 (6H, d, J = 6.9 Hz), 1.83-2.04 (4H, m), 2.49-2.55 (2H, m), 2.77-2.83 (2H, m), 3.08 (2H, br. s.), 3.51 (2H, dd, J = 10.5, 1.8 Hz), 3.72 (2H, d, J = 10.1 Hz), 4.02-4.12 (1H, m), 4.31 (2H, s), 6.45 (1H, d, J = 6.9 Hz), 7.27- 7.33 (3H, m), 7.78-7.82 (1H, m), 7.87-7.91 (2H, m), 7.97 (1H, dd, J = 6.9, 2.3 Hz)
528([M + H] + )
Da-6
1 H-NMR (600 MHz, DMSO-d 6 ) δ (ppm); 0.97 (6H, d, J = 6.9 Hz), 1.83-1.92 (2H, m), 2.07-2.16 (2H, m), 2.18-2.26 (2H, m), 2.28-2.34 (2H, m), 3.04 (2H, dd, J = 8.7, 3.7 Hz), 3.09-3.19 (2H, m), 3.70-3.77 (1H, m), 3.81-3.90 (2H, m), 3.96 (1H, d, J = 5.5 Hz), 4.36 (2H, s), 4.90 (1H, d, J = 0.9 Hz), 7.40 (1H, d, J = 7.8 Hz), 7.56-7.66 (1H, m), 7.67-7.73 (1H, m), 7.86-7.96 (2H, m), 8.21 (1H, d, J = 7.8 Hz), 8.28 (1H, s), 9.40 (1H, br. s.)
542([M + H] + )
Db-1
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.10-1.20 (6H, m), 1.45 (2H, br. s.), 1.70-1.80 (2H, m), 2.45 (4H, br. s.), 2.51-2.60 (2H, m), 2.78-2.88 (2H, m), 2.99- 3.09 (2H, m), 3.99-4.14 (1H, m), 4.28-4.37 (2H, m), 6.27-6.38 (1H, m), 7.61-7.74 (2H, m), 7.76- 7.84 (1H, m), 7.97-8.05 (2H, m), 8.43 (1H, s)
501([M + H] + )
[0000]
TABLE 1-7
Db-2
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.15-1.20 (6H, m), 2.51 (4H, br. s.), 2.56-2.64 (2H, m), 2.83 (2H, t, J = 7.8 Hz), 3.72 (4H, t, J = 4.6 Hz), 4.02-4.13 (1H, m), 4.32 (2H, s), 6.30 (1H, d, J = 7.8 Hz), 7.26-7.32 (1H, m), 7.70 (1H, dd, J = 8.7, 2.3 Hz), 7.76-7.85 (1H, m), 7.98-8.07 (2H, m), 8.44 (1H, d, J = 2.3 Hz)
503([M + H] + )
Db-3
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.19 (6H, d, J = 6.4 Hz), 3.11-3.23 (2H, m), 3.27-3.72 (4H, m), 3.78 (2H, d, J = 13.3 Hz), 3.98-4.14 (1H, m), 4.34 (2H, s), 4.68-4.92 (4H, m), 6.40 (1H, d, J = 1.4 Hz), 7.26-7.31 (1H, m), 7.73 (1H, d, J = 6.0 Hz), 7.79- 7.86 (1H, m), 7.86-7.94 (1H, m), 8.02 (1H, d, J = 8.7 Hz), 8.49 (1H, s)
515([M + H] + )
Db-4
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.19 (6H, d, J = 6.4 Hz), 3.11-3.23 (2H, m), 3.27-3.72 (4H, m), 3.78 (2H, d, J = 13.3 Hz), 3.98-4.14 (1H, m), 4.34 (2H, s), 4.68-4.92 (4H, m), 6.40 (1H, d, J = 1.4 Hz), 7.26-7.31 (1H, m), 7.73 (1H, d, J = 6.0 Hz), 7.79- 7.86 (1H, m), 7.86-7.94 (1H, m), 8.02 (1H, d, J = 8.7 Hz), 8.49 (1H, s)
529([M + H] + )
Db-5
1 H-NMR (600 MHz, DMSO-d 6 ) δ (ppm); 0.97 (6H, d, J = 6.4 Hz), 1.88 (2H, s), 2.28 (6H, s), 3.05 (2H, br. s.), 3.18 (2H, br. s.), 3.65-3.79 (1H, m), 3.82-4.08 (2H, m), 4.36 (2H, s), 4.90 (1H, br. s.), 7.62 (1H, d, J = 8.7 Hz), 7.71 (1H, s), 7.82-7.99 (3H, m), 8.14- 8.30 (1H, m), 8.44 (1H, br. s.), 8.98-9.20 (1H, m)
543([M + H] + )
Ea-1
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm): 1.19 (6H, d, J = 6.4 Hz), 1.42-1.66 (6H, m), 2.41-2.52 (4H, m), 2.54-2.60 (2H, m), 2.80-2.87 (2H, m), 4.04-4.12 (1H, m), 4.34 (2H, s), 6.41 (1H, d, J = 7.8 Hz), 7.30 (2H, d, J = 8.7 Hz), 7.67 (1H, t, J = 7.8 Hz), 7.79-7.84 (1H, m), 7.90 (2H, d, J = 8.7 Hz), 8.16-8.21 (2H, m)
473([M + H] + )
Ea-2
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.19 (6H, d, J = 6.9 Hz), 2.53 (4H, br. s.), 2.59-2.64 (2H, m), 2.81- 2.86 (2H, m), 3.74 (4H, t, J = 4.6 Hz), 4.08 (1H, dq, J = 13.8, 6.9 Hz), 4.34 (2H, s), 6.38 (1H, d, J = 7.3 Hz), 7.30 (2H, d, J = 8.7 Hz), 7.65-7.69 (1H, m), 7.80- 7.83 (1H, m), 7.91 (2H, d, J = 8.7 Hz), 8.16-8.20 (2H, m)
475([M + H] + )
[0000]
TABLE 1-8
Ea-3
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.20 (6H, d, J = 6.4 Hz), 2.61-2.69 (4H, m), 3.35 (4H, s), 4.08 (1H, dq, J = 13.7, 6.7 Hz), 4.34 (2H, s), 4.73 (4H, s), 6.38 (1H, d, J = 6.9 Hz), 7.25-7.29 (2H, m), 7.68 (1H, t, J = 7.6 Hz), 7.82 (1H, d, J = 7.8 Hz), 7.91 (2H, d, J = 8.7 Hz), 8.17-8.20 (2H, m)
487([M + H] + )
Ad-17
1 H-NMR (600 MHz, DMSO-d 6 ) δ (ppm); 1.18 (9H, s), 3.07-3.17 (4H, m), 3.32-3.45 (2H, m), 3.51 (2H, d, J = 12.4 Hz), 3.74-3.81 (2H, m), 4.00 (2H, d, J = 10.3 Hz), 4.38 (2H, s), 7.57-7.62 (1H, m), 7.64-7.69 (2H, m), 7.69-7.72 (1H, m), 7.92 (1H, dd, J = 8.7, 2.5 Hz), 7.96-8.02 (2H, m), 8.46 (1H, d, J = 2.1 Hz), 10.73-10.81 (1H, m)
499([M + H]+).
Ad-18
1 H-NMR (600 MHz, DMSO-d 6 ) δ (ppm); 1.18 (9H, s), 2.00-2.07 (2H, m), 2.17-2.25 (2H, m), 3.12-3.19 (2H, m), 3.21-3.28 (2H, m), 3.74 (2H, d, J = 11.1 Hz), 3.99-4.08 (4H, m), 4.38 (2H, s), 7.57-7.62 (1H, m), 7.64-7.73 (3H, m), 7.93-8.03 (3H, m), 8.46- 8.51 (1H, m), 10.42 (1H, br. s.)
525([M + H]+).
Ba-3
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.18 (6H, d, J = 6.4 Hz), 1.85-1.94 (4H, m), 2.50-2.56 (2H, m), 2.78-2.83 (2H, m), 3.09 (2H, br. s.), 3.53 (2H, d, J = 10.1 Hz), 3.73 (2H, d, J = 10.1 Hz), 3.89 (3H, s), 4.08 (1H, dq, J = 13.8, 6.9 Hz), 4.36 (2H, s), 6.54 (1H, d, J = 6.9 Hz), 7.08 (1H, dd, J = 6.9, 2.3 Hz), 7.30 (2H, d, J = 8.3 Hz), 7.35-7.39 (2H, m), 7.41-7.45 (1H, m), 7.93 (2H, d, J = 8.7 Hz)
506([M + H]+).
Bd-1
1 H-NMR (600 MHz, DMSO-d 6 ) δ (ppm); 1.19 (9H, s), 3.13 (4H, m, J = 8.7 Hz), 3.30-3.46 (3H, m), 3.48- 3.54 (2H, m), 3.72-3.79 (2H, m), 3.81 (3H, s), 4.01 (1H, m, J = 2.1 Hz), 4.34 (2H, s), 7.14-7.17 (1H, m), 7.19-7.25 (2H, m), 7.45-7.49 (1H, m), 7.92 (1H, dd, J = 8.7, 2.5 Hz), 7.95 (1H, s), 7.99 (1H, d, J = 8.3 Hz), 8.46 (1H, d, J = 2.1 Hz), 10.62 (1H, br. s.)
495([M + H]+).
Bd-2
1 H-NMR (600 MHz, DMSO-d 6 ) δ (ppm); 1.19 (9H, s), 2.01-2.07 (2H, m), 2.18-2.25 (2H, m), 3.10-3.16 (2H, m), 3.22-3.39 (2H, m), 3.75 (2H, d, J = 11.1 Hz), 3.81 (3H, s), 3.97 (2H, d, J = 12.4 Hz), 4.03- 4.08 (2H, m), 4.34 (2H, s), 7.16 (1H, dd, J = 8.3, 2.1 Hz), 7.19-7.24 (2H, m), 7.47 (1H, t, J = 8.1 Hz), 7.92- 7.96 (2H, m), 7.96-8.00 (1H, m), 8.46-8.51 (1H, m), 10.12 (1H, br. s.)
521([M + H]+).
Synthesis of Example Ad-1
N-Tert-Butyl-2-[3-(3-chlorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]acetamide
[0662]
[0663] A mixture of the compound (36 mg) prepared in Reference Example P-P1, tert-butylamine (0.086 mL), HATU (0.046 g), DIEA (0.028 mL), and DMF (1.00 mL) was stirred at room temperature overnight. The mixture was separated between a saturated aqueous sodium bicarbonate solution (20 mL) and ethyl acetate (20 mL), and the aqueous layer was extracted with ethyl acetate (20 mL×3). The combined organic layer was filtered through a phase separator, and the filtrate was concentrated under reduced pressure. The residue was purified by silica gel column chromatography (SNAP Cartridge HP-Sil: 10 g, mobile phase: CHCl 3 /MeOH=100/0 to 96/4 (v/v)). The resulting solid was washed with n-hexane and was collected by filtration to yield the title compound (9 mg, colorless solid).
[0664] MS (ESI pos.) m/z: 498 ([M+H] + ).
[0665] 1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.37 (9H, s), 2.50-2.69 (6H, m), 2.81-2.88 (2H, m), 3.73-3.79 (4H, m), 4.30 (2H, s), 6.30-6.33 (1H, m), 7.27-7.31 (2H, m), 7.45-7.53 (2H, m), 7.73-7.76 (1H, m), 7.81-7.83 (1H, m), 7.91-7.95 (2H, m).
[0666] The following compounds were synthesized as in Example Ad-1
Example Ad-2
2-[3-(3-Chlorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(1,1,1-trifluoropropan-2-yl)acetamide (Synthesis from Reference Example P-P1 and 1,1,1-trifluoropropane-2-amine)
[0667]
[0668] MS (ESI pos.) m/z: 538 ([M+H] + ).
[0669] 1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.37 (3H, d, J=6.9 Hz), 2.49-2.57 (4H, m), 2.62 (2H, d, J=8.3 Hz), 2.82-2.86 (2H, m), 3.75 (4H, t, J=4.6 Hz), 4.43 (2H, s), 4.66-4.74 (1H, m), 7.04-7.09 (1H, m), 7.28-7.32 (2H, m), 7.46-7.51 (1H, m), 7.51-7.55 (1H, m), 7.66-7.69 (1H, m), 7.80-7.83 (1H, m), 7.89-7.93 (2H, m).
Example Ad-3
2-[3-(3-Chlorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(1-hydroxy-2-methylpropan-2-yl)acetamide (Synthesis from Reference Example P-P1 and 2-amino-2-methylpropan-1-ol)
[0670]
[0671] MS (ESI pos.) m/z: 514 ([M+H] + ).
[0672] 1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.33 (6H, s), 2.49-2.56 (4H, m), 2.58-2.64 (2H, m), 2.81-2.86 (2H, m), 3.62 (2H, s), 3.75 (4H, t, J=4.6 Hz), 4.35 (2H, s), 6.57-6.60 (1H, m), 7.27-7.31 (2H, m), 7.46-7.50 (1H, m), 7.51-7.55 (1H, m), 7.68-7.72 (1H, m), 7.78-7.81 (1H, m), 7.89-7.93 (2H, m).
Example Ad-4
2-[3-(3-Chlorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-cyclobutylacetamide (Synthesis from Reference Example P-P1 and cyclobutanamine)
[0673]
[0674] MS (ESI pos.) m/z: 496 ([M+H] + ).
[0675] 1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.65-2.02 (4H, m), 2.31-2.40 (2H, m), 2.50-2.57 (4H, m), 2.59-2.64 (2H, m), 2.81-2.87 (2H, m), 3.75 (4H, t, J=4.6 Hz), 3.98-4.43 (3H, m), 6.87 (1H, d, J=7.3 Hz), 7.28-7.32 (2H, m), 7.45-7.54 (2H, m), 7.71-7.76 (1H, m), 7.84-7.86 (1H, m), 7.90-7.94 (2H, m).
Example Ad-5
2-[3-(3-Chlorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(oxetan-3-yl)acetamide (Synthesis from Reference Example P-P1 and oxetane-3-amine)
[0676]
[0677] MS (ESI pos.) m/z: 498 ([M+H] + ).
[0678] 1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 2.49-2.57 (4H, m), 2.60-2.64 (2H, m), 2.81-2.87 (2H, m), 3.75 (4H, t, J=4.4 Hz), 4.41 (2H, s), 4.56 (2H, t, J=6.6 Hz), 4.92 (2H, t, J=7.3 Hz), 5.03-5.09 (1H, m), 7.29-7.33 (2H, m), 7.47-7.50 (1H, m), 7.51-7.56 (2H, m), 7.69-7.72 (1H, m), 7.82-7.85 (1H, m), 7.89-7.93 (2H, m).
Example Ad-6
2-[3-(3-Chlorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(cyclopropylmethyl)acetamide (Synthesis from Reference Example P-P1 and 1-cyclopropylmethanamine)
[0679]
[0680] MS (ESI pos.) m/z: 496 ([M+H] + ).
[0681] 1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 0.20-0.25 (2H, m), 0.50-0.55 (2H, m), 0.94-1.01 (1H, m), 2.49-2.57 (4H, m), 2.60-2.64 (2H, m), 2.81-2.87 (2H, m), 3.17 (2H, dd, J=7.1, 5.7 Hz), 3.75 (4H, t, J=4.4 Hz), 4.40 (2H, s), 6.67-6.75 (1H, m), 7.28-7.32 (2H, m), 7.45-7.55 (2H, m), 7.73-7.77 (1H, m), 7.84-7.88 (1H, m), 7.90-7.95 (2H, m).
Example Ad-20
2-[3-(3-Chlorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(1-hydroxypropan-2-yl)acetamide (Synthesis from Reference Example P-P1 and DL-alaninol)
[0682]
[0683] MS (ESI pos.) m/z: 500 ([M+H] + ).
[0684] 1 H-NMR (600 MHz, DMSO-d 6 ) δ (ppm); 0.97 (3H, d, J=6.6 Hz), 2.40-2.46 (4H, m), 2.51-2.55 (2H, m), 2.74-2.80 (2H, m), 3.16-3.22 (1H, m), 3.26-3.31 (1H, m), 3.54-3.61 (4H, m), 3.67-3.76 (1H, m), 4.42 (2H, s), 4.71 (1H, t, J=5.6 Hz), 7.32-7.39 (2H, m), 7.55-7.61 (1H, m), 7.63-7.69 (2H, m), 7.71-7.75 (1H, m), 7.83-7.89 (2H, m), 8.17 (1H, d, J=8.3 Hz).
Synthesis of Example Ad-7
2-[3-(3-Chlorophenyl)-1-{3-fluoro-4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide
[0685]
[0686] In a nitrogen gas flow, a suspension of the compound (80 mg) prepared in Reference Example P-Q2, Reference Example P-R1-1 (82 mg), copper iodide (52 mg), tripotassium phosphate (115 mg), and trans-(1R,2R)—N,N′-bismethyl-1,2-cyclohexanediamine (0.04 mL) in 1,4-dioxane (4 mL) was stirred at an outside temperature of 80° C. for 2 days. After cooling, 20% aqueous ammonia was added thereto, followed by extraction with toluene (containing 10% EtOAc). The organic layer was dried over Na 2 SO 4 . The desiccant was removed by filtration, and the filtrate was concentrated under reduced pressure. The residue was purified by silica gel column chromatography (SNAP Cartridge KP-NH: 28 g, mobile phase: n-hexane/CHCl 3 =80/20 to 0/100 (v/v)). The resulting compound was washed with a solvent mixture (n-hexane/EtOAc=6/1 (v/v)), and the solid was collected by filtration to yield the title compound (3 mg, colorless powder).
[0687] 1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.19 (6H, d, J=6.6 Hz), 2.53 (4H, br. s.), 2.58-2.63 (2H, m), 2.82-2.88 (2H, m), 3.74 (4H, t, J=4.3 Hz), 4.06-4.12 (1H, m), 4.34 (2H, s), 6.27 (1H, d, J=5.8 Hz), 7.21-7.32 (1H, m), 7.48 (1H, d, J=7.4 Hz), 7.51-7.54 (1H, m), 7.74 (1H, d, J=7.4 Hz), 7.76-7.80 (2H, m), 7.84 (1H, t, J=1.9 Hz).
[0688] MS (ESI pos.) m/z: 502 ([M+H] + ).
[0689] The following compounds were synthesized as in Example Ad-7:
[0690] Example Ad-8: 2-[3-(3-Chlorophenyl)-1-{3-fluoro-4-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-Q2 and Reference Example P-R1-2),
[0691] Example Ad-9: 2-[3-(3-Chlorophenyl)-1-{3-methoxy-4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-Q2 and Reference Example P-R2-1),
[0692] Example Ad-10: 2-[3-(3-Chlorophenyl)-1-{3-methoxy-4-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-Q2 and Reference Example P-R2-2),
[0693] Example Ad-11: 2-[3-(3-Chlorophenyl)-1-{2-fluoro-4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-Q2 and Reference Example P-R3-1),
[0694] Example Ad-12: 2-[3-(3-Chlorophenyl)-1-{2-methoxy-4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-Q2 and Reference Example P-R4-1),
[0695] Example Ad-13: 2-[3-(3-Chlorophenyl)-1-{4-[2-(morpholin-4-yl)propyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-Q2 and Reference Example P-S1),
[0696] Example Ad-14: 2-[3-(3-Chlorophenyl)-1-{4-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)propyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-Q2 and Reference Example P-R5-2),
[0697] Example Ad-15: 2-[3-(3-Chlorophenyl)-1-{5-[2-(morpholin-4-yl)propyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-Q2 and Reference Example P-R6-1),
[0698] Example Ad-16: 2-[3-(3-Chlorophenyl)-1-{5-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)propyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-Q2 and Reference Example P-R6-2),
[0699] Example Ia-1: 2-(3-[3-(Methylsulfonyl)phenyl]-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl)-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-Q1 and 4-[2-(4-bromophenyl)ethyl]morpholine),
[0700] Example Bd-3: N-Tert-Butyl-2-[3-(3-methoxyphenyl)-1-{4-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)propyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]acetamide (Synthesis from Reference Example P-Q4 and Reference Example P-R5-2),
[0701] Example Bd-4: N-Tert-Butyl-2-[3-(3-methoxyphenyl)-1-{5-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)propyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]acetamide (Synthesis from Reference Example P-Q4 and Reference Example P-R6-2),
[0702] Example Cd-2: 2-[3-(4-Fluoro-3-methoxyphenyl)-1-{4-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)propyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-Q3 and Reference Example P-R5-2),
[0703] Example Cd-3: 2-[3-(4-Fluoro-3-methoxyphenyl)-1-{5-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)propyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-Q3 and Reference Example P-R6-2),
[0704] Example Cd-4: 2-[3-(4-Fluoro-3-methoxyphenyl)-1-{4-[(4-methylpiperazin-1-yl)methyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-Q3 and 1-[(4-bromophenyl)methyl]-4-methylpiperazine),
[0705] Example Ja-1: 2-[3-(6-Methoxypyridin-2-yl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-Q5 and 4-[2-(4-bromophenyl)ethyl]morpholine), and
[0706] Example Ja-2: 2-[3-(6-Methoxypyridin-2-yl)-1-{4-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide (Synthesis from Reference Example P-Q5 and Reference Example P-R7-1).
[0707] The results of 1 H-NMR and MS of Examples Ad-8 to Ad-16, Ia-1, Bd-3, Bd-4, Cd-2 to Cd-4, Ja-1, and Ja-2 are shown in Tables 2-1 to 2-3.
[0000]
TABLE 2-1
MS (ESI pos.)
Example
Structure
1 H NMR
m/z
Ad-8
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.19 (6H, d, J = 6.6 Hz), 1.85-1.94 (4H, m), 2.51 (2H, t, J = 7.6 Hz), 2.82 (2H, t, J = 7.6 Hz), 3.09 (2H, br. s.), 3.52 (2H, d, J = 9.5 Hz), 3.71 (2H, d, J = 10.3 Hz), 4.09 (1H, dq, J = 13.9, 6.8 Hz), 4.34 (2H, s), 6.28 (1H, d, J = 6.6 Hz), 7.28-7.33 (1H, m), 7.46-7.50 (1H, m), 7.51- 7.54 (1H, m), 7.73-7.79 (3H, m), 7.84 (1H, t, J = 1.7 Hz)
528([M + H]+).
Ad-9
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.19 (6H, d, J = 6.6 Hz), 2.50-2.60 (6H, m), 2.80-2.86 (2H, m), 3.75 (4H, t, J = 4.3 Hz), 3.89 (3H, s), 4.06-4.13 (1H, m), 4.34 (2H, s), 6.34 (1H, d, J = 6.6 Hz), 7.21 (1H, d, J = 7.8 Hz), 7.46-7.49 (1H, m), 7.51-7.55 (2H, m), 7.57 (1H, d, J = 2.1 Hz), 7.75 (1H, dt, J = 7.5, 1.4 Hz), 7.85 (1H, t, J = 1.7 Hz)
514([M + H]+).
Ad-10
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.19 (6H, d, J = 6.6 Hz), 1.83-1.95 (4H, m), 2.45-2.51 (2H, m), 2.77-2.84 (2H, m), 3.13 (2H, br. s.), 3.53 (2H, d, J = 9.9 Hz), 3.75 (2H, d, J = 10.3 Hz), 3.89 (3H, s), 4.09 (1H, dq, J = 13.4, 6.7 Hz), 4.34 (2H, s), 6.34 (1H, d, J = 6.6 Hz), 7.22 (1H, d, J = 8.3 Hz), 7.46-7.50 (1H, m), 7.50-7.55 (2H, m), 7.57 (1H, s), 7.75 (1H, d, J = 7.8 Hz), 7.85 (1H, s)
540([M + H]+).
Ad-11
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.18 (6H, d, J = 6.2 Hz), 2.52 (4H, br. s.), 2.59-2.64 (2H, m), 2.82- 2.87 (2H, m), 3.74 (4H, t, J = 4.5 Hz), 4.04-4.13 (1H, m), 4.35 (2H, s), 6.47 (1H, d, J = 6.6 Hz), 7.09- 7.14 (2H, m), 7.43-7.53 (3H, m), 7.76 (1H, dt, J = 7.5, 1.4 Hz), 7.85 (1H, t, J = 1.9 Hz)
502([M + H]+).
Ad-12
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.18 (6H, d, J = 6.6 Hz), 2.53 (4H, br. s.), 2.59-2.65 (2H, m), 2.82- 2.87 (2H, m), 3.72-3.78 (4H, m), 3.86 (3H, s), 4.06-4.12 (1H, m), 4.36 (2H, s), 6.70 (1H, d, J = 6.6 Hz), 6.89-6.92 (2H, m), 7.34 (1H, d, J = 8.7 Hz), 7.43- 7.51 (2H, m), 7.76 (1H, dt, J = 7.4, 1.4 Hz), 7.87 (1H, t, J = 1.7 Hz)
514([M + H]+).
Ad-13
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 0.97 (3H, d, J = 6.6 Hz), 1.19 (6H, d, J = 6.6 Hz), 2.46 (1H, dd, J = 13.4, 9.3 Hz), 2.58-2.66 (4H, m), 2.75-2.82 (1H, m), 3.01 (1H, dd, J = 13.2, 5.0 Hz), 3.73 (4H, t, J = 4.3 Hz), 4.05-4.13 (1H, m), 4.35 (2H, s), 6.40 (1H, d, J = 6.6 Hz), 7.24-7.28 (2H, m), 7.45-7.49 (1H, m), 7.50-7.53 (1H, m), 7.75 (1H, dt, J = 7.7, 1.3 Hz), 7.86 (1H, t, J = 1.7 Hz), 7.92 (2H, d, J = 8.7 Hz)
498([M + H]+).
[0000]
TABLE 2-2
Ad-14
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 0.93 (3H, d, J = 6.2 Hz), 1.20 (6H, d, J = 6.6 Hz), 1.77-1.86 (1H, m), 1.88-2.00 (3H, m), 2.46 (1H, dd, J = 13.4, 8.9 Hz), 2.52-2.59 (1H, m), 3.00 (1H, dd, J = 13.4, 3.5 Hz), 3.32-3.37 (1H, m), 3.43-3.48 (1H, m), 3.53- 3.59 (2H, m), 3.78 (2H, dd, J = 10.3, 4.5 Hz), 4.06- 4.14 (1H, m), 4.36 (2H, s), 6.36-6.43 (1H, m), 7.22- 7.30 (2H, m), 7.46-7.51 (1H, m), 7.51-7.55 (1H, m), 7.74-7.78 (1H, m), 7.85-7.88 (1H, m), 7.93 (2H, d, J = 8.3 Hz)
524([M + H]+).
Ad-15
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.00 (3H, d, J = 6.6 Hz), 1.18 (6H, d, J = 6.6 Hz), 2.51-2.58 (3H, m), 2.60-2.66 (2H, m), 2.75-2.82 (1H, m), 2.93 (1H, dd, J = 13.6, 6.2 Hz), 3.66-3.74 (4H, m), 4.07- 4.13 (1H, m), 4.36 (2H, s), 6.26 (1H, d, J = 6.2 Hz), 7.44-7.48 (1H, m), 7.50-7.53 (1H, m), 7.67 (1H, dd, J = 8.3, 2.5 Hz), 7.75 (1H, dd, J = 8.9, 1.4 Hz), 7.89 (1H, t, J = 1.7 Hz), 8.05 (1H, d, J = 8.7 Hz), 8.42 (1H, d, J = 2.1 Hz)
499([M + H]+).
Ad-16
1 H-NMR (800 MHz, CDCl 3 ) δ (ppm); 0.91 (3H, d, J = 5.8 Hz), 1.18 (6H, d, J = 6.6 Hz), 1.75-1.83 (1H, m), 1.88-1.97 (3H, m), 2.56-2.64 (2H, m), 2.84- 2.90 (1H, m), 3.28 (1H, d, J = 5.4 Hz), 3.41 (1H, br. s.), 3.51-3.58 (2H, m), 3.70-3.78 (2H, m), 4.06- 4.14 (1H, m), 4.36 (2H, s), 6.26 (1H, d, J = 7.4 Hz), 7.47 (1H, d, J = 7.8 Hz), 7.50-7.53 (1H, m), 7.70 (1H, dd, J = 8.5, 2.3 Hz), 7.73-7.77 (1H, m), 7.89 (1H, t, J = 1.7 Hz), 8.05 (1H, d, J = 8.3 Hz), 8.43 (1H, d, J = 2.1 Hz
525([M + H]+).
Ia-1
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.19 (6H, d, J = 6.6 Hz), 2.53 (4 H, br. s.), 2.59-2.65 (2H, m), 2.81- 2.87 (2H, m), 3.16 (3H, s), 3.75 (4H, t, J = 4.3 Hz), 4.04-4.13 (1H, m), 4.35 (2H, s), 6.41 (1H, d, J = 7.0 Hz), 7.31 (2H, d, J = 8.7 Hz), 7.77 (1H, t, J = 7.8 Hz), 7.93 (2H, d, J = 8.3 Hz), 8.12 (1H, d, J = 7.8 Hz), 8.22 (1H, d, J = 7.4 Hz), 8.43 (1H, s)
528([M + H]+).
Bd-3
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 0.94 (3H, d, J = 5.8 Hz), 1.37 (9H, s), 1.77-1.87 (1H, m), 1.88- 2.00 (3H, m), 2.42-2.49 (1H, m), 2.52-2.60 (1H, m), 2.97-3.03 (1H, m), 3.32-3.37 (1H, m), 3.43- 3.48 (1H, m), 3.53-3.59 (2H, m), 3.74-3.81 (2H, m), 3.89 (3H, s), 4.32 (2H, s), 6.46 (1H, br. s.), 7.07- 7.11 (1H, m), 7.22-7.29 (2H, m), 7.34-7.36 (1H, m), 7.38 (1H, d, J = 7.4 Hz), 7.42-7.47 (1H, m), 7.95 (2H, d, J = 8.3 Hz)
534([M + H]+).
Bd-4
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 0.92 (3H, d, J = 5.8 Hz), 1.37 (9H, s), 1.75-1.84 (1H, m), 1.89- 1.97 (3H, m), 2.56-2.64 (2H, m), 2.84-2.92 (1H, m), 3.27-3.32 (1H, m), 3.39-3.45 (1H, m), 3.52- 3.60 (2H, m), 3.70-3.80 (2H, m), 3.88 (3H, s), 4.32 (2H, s), 6.27-6.34 (1H, m), 7.06-7.11 (1H, m), 7.34-7.37 (1H, m), 7.37-7.45 (2H, m), 7.68-7.72 (1H, m), 8.07 (1H, d, J = 8.3 Hz), 8.44 (1H, d, J = 2.1 Hz)
535([M + H]+).
[0000]
TABLE 2-3
Cd-2
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 0.94 (3H, d, J = 6.2 Hz), 1.20 (6H, d, J = 6.6 Hz), 1.78-1.87 (1H, m), 1.88-1.99 (3H, m), 2.43-2.50 (1H, m), 2.53- 2.61 (1H, m), 2.97-3.03 (1H, m), 3.32-3.37 (1H, m), 3.43-3.48 (1H, m), 3.53-3.59 (2H, m), 3.77 (2H, dd, J = 10.7, 5.0 Hz), 4.01 (3H, s), 4.05-4.12 (1H, m), 4.35 (2H, s), 6.62-6.69 (1H, m), 7.23 (1H, dd, J = 10.7, 8.3 Hz), 7.25-7.29 (2H, m), 7.40 (1H, ddd, J = 8.4, 4.2, 2.3 Hz), 7.56 (1H, dd, J = 7.8, 2.1 Hz), 7.93 (2H, d, J = 8.3 Hz)
538([M + H]+).
Cd-3
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 0.92 (3H, d, J = 5.8 Hz), 1.20 (6H, d, J = 6.6 Hz), 1.74-1.85 (1H, m), 1.88-1.98 (3H, m), 2.56-2.67 (2H, m), 2.84- 2.92 (1H, m), 3.26-3.32 (1H, m), 3.39-3.44 (1H, m), 3.51-3.60 (2H, m), 3.70-3.79 (2H, m), 3.99 (3H, s), 4.06-4.13 (1H, m), 4.35 (2H, s), 6.44-6.52 (1H, m), 7.21 (1H, dd, J = 10.7, 8.3 Hz), 7.39-7.44 (1H, m), 7.56 (1H, dd, J = 7.8, 2.1 Hz), 7.69-7.74 (1H, m), 8.05 (1H, d, J = 8.3 Hz), 8.44 (1H, d, J = 2.1 Hz)
539([M + H]+).
Cd-4
1 H-NMR (600 MHz, DMSO-d 6 ) δ (ppm); 0.97-1.02 (6H, m), 2.14 (3H, s), 2.26-2.43 (8H, m), 3.47 (2H, s), 3.74-3.82 (1H, m), 3.89 (3H, s), 4.38 (2H, s),7.24- 7.29 (1H, m), 7.37-7.43 (3H, m), 7.46-7.49 (1H, m), 7.88-7.93 (2H, m), 8.16-8.22 (1H, m)
497([M + H]+).
Ja-1
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.08 (6H, d, J = 6.6 Hz), 2.47-2.69 (6H, m), 2.81-2.91 (2H, m), 3.71-3.81 (4H, m), 3.98 (3H, s), 4.01-4.10 (1H, m), 5.03 (2H, s), 5.62-5.71 (1H, m), 6.81-6.88 (1H, m), 7.31 (2H, d, J = 8.7 Hz), 7.67-7.74 (1H, m), 7.75-7.81 (1H, m), 7.99 (2H, d, J = 8.7 Hz)
481([M + H]+).
Ja-2
1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.08 (6H, d, J = 6.6 Hz), 1.82-2.00 (4H, m), 2.47-2.61 (2H, m), 2.75-2.88 (2H, m), 3.03-3.16 (2H, m), 3.50-3.58 (2H, m), 3.68-3.81 (2H, m), 3.98 (3H, s), 4.01- 4.10 (1H, m), 5.03 (2H, s), 5.64-5.71 (1H, m), 6.79- 6.89 (1H, m), 7.32 (2H, d, J = 8.7 Hz), 7.68-7.75 (1H, m), 7.75-7.80 (1H, m), 7.98 (2H, d, J = 8.3 Hz)
507([M + H]+).
Synthesis of Example Fa-1
2-[3-(3-Fluorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide
[0708]
[0709] K 2 CO 3 (150 mg) and 2-bromo-N-(propan-2-yl)acetamide (147 mg) were added to a suspension of the compound (200 mg) prepared in Reference Example P-N1 in DMF (4.0 mL), followed by stirring at room temperature for 14.5 hours. Water and CHCl 3 were added to the reaction solution, and then were separated between water and CHCl 3 , and the aqueous layer was extracted with CHCl 3 . The combined organic layer was dried over MgSO 4 . The desiccant was removed by filtration. The filtrate was concentrated under reduced pressure. The residue was purified by silica gel column chromatography twice (SNAP Cartridge HP-SiL: 25 g, mobile phase: CHCl 3 /MeOH/NH 4 OH=99/1/0.1 to 95/5/0.5 (v/v/v) and SNAP Cartridge HP-SiL: 50 g, mobile phase: CHCl 3 /MeOH/NH 4 OH=99/1/0.1 to 95/5/0.5 (v/v/v)). The resulting fraction was concentrated and was stirred in n-hexane/EtOAc=6/1 (v/v, 5 mL) at room temperature for 2 hours. The precipitated product was collected by filtration to yield the title compound (138 mg, colorless solid).
[0710] MS (ESI pos.) m/z: 468 ([M+H] + ).
[0711] 1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.18 (6H, d, J=6.4 Hz), 2.53 (4H, br. s.), 2.59-2.64 (2H, m), 2.81-2.86 (2H, m), 3.75 (4H, t, J=4.8 Hz), 4.09 (1H, dq, J=14.2, 6.6 Hz), 4.36 (2H, s), 6.41 (1H, d, J=6.4 Hz), 7.22-7.27 (1H, m), 7.30 (2H, d, J=8.7 Hz), 7.52 (1H, td, J=8.0, 5.5 Hz), 7.60 (1H, dt, J=9.2, 2.1 Hz), 7.63-7.66 (1H, m), 7.91-7.95 (2H, m).
Synthesis of Example Ga-1
2-(1-{4-[2-(Morpholin-4-yl)ethyl]phenyl}-5-oxo-3-phenyl-1,5-dihydro-4H-1,2,4-triazol-4-yl)-N-(propan-2-yl)acetamide
[0712]
[0713] A mixture of the compound (100 mg) prepared in Example Aa-1, 10% Pd—C (0.020 g), triethylamine (0.035 mL), and MeOH (2 mL) was stirred in a hydrogen atmosphere overnight. The insoluble matter was removed through Celite (registered trademark). The filtrate was concentrated under reduced pressure to yield the title compound (89 mg, colorless solid).
[0714] MS (ESI pos.) m/z: 450 ([M+H] + ).
[0715] 1 H-NMR (600 MHz, DMSO-d6) δ (ppm); 0.99 (6H, d, J=6.9 Hz), 2.43 (4H, br. s.), 2.51-2.56 (2H, m), 2.70-2.81 (2H, m), 3.52-3.65 (4H, m), 3.70-3.85 (1H, m), 4.35 (2H, s), 7.35 (2H, d, J=8.7 Hz), 7.48-7.61 (3H, m), 7.64-7.72 (2H, m), 7.82-7.95 (2H, m), 8.08-8.22 (1H, m).
Synthesis of Example Ha-1
2-[3-(2-Bromo-5-chlorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide
[0716]
[0717] 2-Bromo-N-(propan-2-yl)acetamide (470 mg) was added to a suspension of the compound (1.10 g) prepared in Reference Example P-Q1 and anhydrous K 2 CO 3 (656 mg) in DMF (22 mL), followed by stirring at room temperature for 16.5 hours. Water and CHCl 3 were added to the reaction solution, and then were separated between water and CHCl 3 , and the aqueous layer was extracted with CHCl 3 . The combined organic layer was dried over MgSO 4 , and the desiccant was removed by filtration. The filtrate was concentrated under reduced pressure. The resulting crude product was purified by silica gel column chromatography (SNAP Cartridge HP-SiL: 50 g, mobile phase: CHCl 3 /MeOH/NH 4 OH=99/1/0.1 to 95/5/0.5 (v/v/v)) twice. The resulting solid was stirred in a solvent mixture (15 mL, EtOAc/n-hexane=1/6 (v/v)) at room temperature, was then collected by filtration, and was dried to yield the title compound (749 mg, colorless solid).
[0718] MS (ESI pos.) m/z: 562, 564 ([M+H] + ).
[0719] 1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.11 (6H, d, J=6.6 Hz), 2.53 (4H, br. s.), 2.58-2.63 (2H, m), 2.80-2.85 (2H, m), 3.74 (4H, t, J=4.5 Hz), 3.95-4.03 (1H, m), 4.20 (2H, s), 5.93 (1H, d, J=7.4 Hz), 7.28 (2H, d, J=8.7 Hz), 7.40 (1H, dd, J=8.7, 2.5 Hz), 7.61 (1H, d, J=2.5 Hz), 7.62 (1H, d, J=8.7 Hz), 7.91 (2H, d, J=8.7 Hz).
Example Aa-15
2-[3-(3-Chlorophenyl)-1-{4-[2-(morpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide hydrochloride
[0720]
[0721] A solution of 4 M HCl in EtOAc was added to the compound (550 mg) prepared in Example Aa-1, followed by stirring at room temperature overnight. The solvent was distilled off under reduced pressure, and the residue was azeotroped with EtOAc twice. The residue was washed with Et 2 O. The solid was collected by filtration to yield the title compound (575 mg, colorless solid).
[0722] 1 H-NMR (500 MHz, DMSO-d6) δ (ppm); 1.00 (6H, d, J=6.5 Hz), 3.03-3.16 (4H, m), 3.34-3.41 (2H, m), 3.45-3.55 (2H, m), 3.71-3.82 (3H, m), 3.97-4.04 (2H, m), 4.39 (2H, s), 7.42 (2H, d, J=8.6 Hz), 7.57-7.62 (1H, m), 7.64-7.70 (2H, m), 7.72-7.75 (1H, m), 7.96 (2H, d, J=8.2 Hz), 8.22-8.28 (1H, m), 10.52-10.64 (1H, m).
Synthesis of Example Ad-19-1
(−)-2-[3-(3-Chlorophenyl)-1-{5-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide and Example Ad-19-2: (+)-2-[3-(3-chlorophenyl)-1-{5-[2-(3-oxa-8-azabicyclo[3.2.1]oct-8-yl)ethyl]pyridin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide
[0723]
[0724] Racemic resolution of the compound (50 mg) prepared in Example Ad-16 was performed.
[0725] Fractionation Conditions
[0726] Solvent: n-hexane/EtOH=100/0 to 85/15 (v/v)
[0727] Column: CHIRALPAK AD
[0728] Flow rate: 5 mL/min
[0729] The compound (5×10 mg/EtOH 1 mL) prepared in Example Ad-16 was applied to the column. Each fraction was collected by a fraction collector (time mode) to yield the title compound: Ad-19-1 (peak at a shorter retention time, 11 mg, colorless amorphous compound) and the title compound: Ad-19-2 (peak at a longer retention time, 10 mg, light yellow oily compound).
[0730] Example Ad-19-1: [α] D 27 =−2.26° (c=0.2, MeOH)
[0731] Retention Time: 13.486 min
[0732] MS (ESI pos.) m/z: 525 ([M+H] + ).
[0733] 1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 0.92 (3H, d, J=6.2 Hz), 1.19 (6H, d, J=6.6 Hz), 1.75-1.84 (1H, m), 1.93 (3H, s), 2.56-2.65 (2H, m), 2.84-2.92 (1H, m), 3.27-3.32 (1H, m), 3.39-3.45 (1H, m), 3.53-3.59 (2H, m), 3.70-3.79 (2H, m), 4.07-4.15 (1H, m), 4.37 (2H, s), 6.23-6.30 (1H, m), 7.45-7.50 (1H, m), 7.50-7.55 (1H, m), 7.68-7.73 (1H, m), 7.74-7.78 (1H, m), 7.90 (1H, s), 8.06 (1H, d, J=8.3 Hz), 8.43-8.46 (1H, m).
Example Ad-19-2: [α] D 28 =+1.94° (c=0.2, MeOH)
[0734] Retention Time: 16.008 min
[0735] MS (ESI pos.) m/z: 525 ([M+H] + ).
[0736] 1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 0.91 (3H, d, J=5.8 Hz), 1.19 (6H, d, J=6.6 Hz), 1.80 (1H, dd, J=11.1, 6.2 Hz), 1.88-1.98 (3H, m), 2.54-2.66 (2H, m), 2.84-2.92 (1H, m), 3.30 (1H, d, J=5.8 Hz), 3.42 (1H, br. s.), 3.52-3.60 (2H, m), 3.69-3.80 (2H, m), 4.11 (1H, dd, J=13.6, 6.6 Hz), 4.37 (2H, s), 6.29 (1H, d, J=7.4 Hz), 7.44-7.49 (1H, m), 7.50-7.55 (1H, m), 7.70 (1H, dd, J=8.3, 2.1 Hz), 7.76 (1H, d, J=7.4 Hz), 7.90 (1H, s), 8.06 (1H, d, J=8.7 Hz), 8.44 (1H, d, J=2.1 Hz).
Synthesis of Example Ad-21
2-[3-(3-Chlorophenyl)-1-[4-(2-aminoethyl)phenyl]-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide
[0737]
[0738] A solution of 4 M HCl in 1,4-dioxane (0.80 mL) was added to a mixture of the compound (82 mg) prepared in Reference Example P-U1 and 1,4-dioxane (2 mL), followed by stirring at room temperature for 16 hours. The solvent was distilled off under reduced pressure. The residue was purified by reverse-phase column chromatography. The resulting crude product was washed with EtOAc/n-hexane (1/4) to yield the title compound (37 mg, colorless solid).
[0739] MS (ESI pos.) m/z: 414 ([M+H] + ).
[0740] 1 H-NMR (600 MHz, DMSO-d 6 ) δ (ppm); 1.00 (6H, d, J=6.6 Hz), 2.63-2.70 (2H, m), 2.76-2.81 (2H, m), 3.74-3.82 (1H, m), 4.38 (2H, s), 7.32 (2H, d, J=8.7 Hz), 7.56-7.61 (1H, m), 7.63-7.69 (2H, m), 7.72-7.74 (1H, m), 7.83-7.89 (2H, m), 8.22 (1H, d, J=7.4 Hz).
Synthesis of Example Cd-1
2-[3-(4-Fluoro-3-methoxyphenyl)-1-{5-[2-(morpholin-4-yl)ethyl]pyrimidin-2-yl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide
[0741]
[0742] The mesyl form of the compound (35 mg) prepared in Reference Example P-T1 was prepared as in Reference Example P-I1.
[0743] The title compound (15 mg, colorless solid) was prepared from the resulting mesyl form as in Example Aa-1.
[0744] MS (ESI pos.) m/z: 500 ([M+H] + ).
[0745] 1 H-NMR (600 MHz, CDCl 3 ) δ (ppm); 1.20 (6H, d, J=6.6 Hz), 2.51 (4H, br. s.), 2.63 (2H, s), 2.82 (2H, s), 3.67-3.76 (4H, m), 4.00 (3H, s), 4.05-4.14 (1H, m), 4.35 (2H, s), 6.48-6.59 (1H, m), 7.19-7.25 (1H, m), 7.42-7.48 (1H, m), 7.57-7.62 (1H, m), 8.75 (2H, s).
[0746] The following compounds were synthesized using the compound prepared in Reference Example P-Q3, as in Example Cd-1:
[0747] Example Ca-6: 2-[3-(4-Fluoro-3-methoxyphenyl)-1-{4-[2-(7-oxa-2-azaspiro[3.5]non-2-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide,
[0748] Example Ca-7: 2-[1-{4-[2-(3,6-Dihydropyridin-1(2H)-yl)ethyl]phenyl}-3-(4-fluoro-3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide,
[0749] Example Ca-8: 2-[3-(4-Fluoro-3-methoxyphenyl)-5-oxo-1-{4-[2-(thiomorpholin-4-yl)ethyl]phenyl}-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide,
[0750] Example Ca-9: 2-[3-(4-Fluoro-3-methoxyphenyl)-1-{4-[2-(4-methylpiperidin-1-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide,
[0751] Example Ca-10: 2-[1-{4-[2-(4-Cyanopiperidin-1-yl)ethyl]phenyl}-3-(4-fluoro-3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide,
[0752] Example Ca-11: 2-[3-(4-Fluoro-3-methoxyphenyl)-1-{4-[2-(3-methoxypiperidin-1-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide,
[0753] Example Ca-12: 2-[3-(4-Fluoro-3-methoxyphenyl)-5-oxo-1-{4-[2-(4-propylpiperidin-1-yl)ethyl]phenyl}-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-1)acetamide,
[0754] Example Ca-13: 1-[2-(4-{3-(4-Fluoro-3-methoxyphenyl)-5-oxo-4-[2-oxo-2-(propan-2-ylamino)ethyl]-4,5-dihydro-1H-1,2,4-triazol-1-yl}phenyl)ethyl]piperidine 4-carboxamide,
[0755] Example Ca-14: 2-[1-(4-{2-[4-(Dimethylamino)piperidin-1-yl]ethyl}phenyl)-3-(4-fluoro-3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide,
[0756] Example Ca-15: 2-[3-(4-Fluoro-3-methoxyphenyl)-1-{4-[2-(octahydroisoquinolin-2(1H)-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide,
[0757] Example Ca-16: 2-[3-(4-Fluoro-3-methoxyphenyl)-1-{4-[2-(4-fluoropiperidin-1-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide trifluoroacetate,
[0758] Example Ca-17: 2-[1-(4-{2-[4-(Acetylamino)piperidin-1-yl]ethyl}phenyl)-3-(4-fluoro-3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide,
[0759] Example Ca-18: 2-[1-{4-[2-(4,4-Difluoropiperidin-1-yl)ethyl]phenyl}-3-(4-fluoro-3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide trifluoroacetate,
[0760] Example Ca-19: 2-[3-(4-Fluoro-3-methoxyphenyl)-5-oxo-1-(4-{2-[4-(trifluoromethyl)piperidin-1-yl]ethyl}phenyl)-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide trifluoroacetate,
[0761] Example Ca-20: 2-[1-(4-{2-[(2R,6S)-2,6-Dimethylmorpholin-4-yl]ethyl}phenyl)-3-(4-fluoro-3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide,
[0762] Example Ca-21: 2-[1-{4-[2-(3,5-Dimethylmorpholin-4-yl)ethyl]phenyl}-3-(4-fluoro-3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide trifluoroacetate,
[0763] Example Ca-22: 2-[3-(4-Fluoro-3-methoxyphenyl)-1-{4-[2-(3-methylmorpholin-4-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide,
[0764] Example Ca-23: 2-[1-{4-[2-(3-Ethylmorpholin-4-yl)ethyl]phenyl}-3-(4-fluoro-3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide,
[0765] Example Ca-24: 2-[3-(4-Fluoro-3-methoxyphenyl)-5-oxo-1-{4-[2-(pyrrolidin-1-yl)ethyl]phenyl}-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide formate,
[0766] Example Ca-25: 2-[3-(4-Fluoro-3-methoxyphenyl)-1-{4-[2-(4-methylpiperazin-1-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide trifluoroacetate,
[0767] Example Ca-26: 2-[1-{4-[2-(4-Acetylpiperazin-1-yl)ethyl]phenyl}-3-(4-fluoro-3-methoxyphenyl)-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide trifluoroacetate, and
[0768] Example Ca-27: 2-[3-(4-Fluoro-3-methoxyphenyl)-1-{4-[2-(4-hydroxy4-methylpiperidin-1-yl)ethyl]phenyl}-5-oxo-1,5-dihydro-4H-1,2,4-triazol-4-yl]-N-(propan-2-yl)acetamide trifluoroacetate.
[0769] The retention times of LCMS (Conditions 2-1 or 2-2) and the results of MS of Examples Ca-6 to Ca-27 are shown in Tables 3-1 to 3-3.
[0000]
TABLE 3-1
LC-MS
Retention
MS (ESI pos.)
Example
Structure
Salt
conditions
time (min)
m/z ([M + H]+)
Ca-6
Free
2-1
0.519
538
Ca-7
Free
2-1
0.529
494
Ca-8
Free
2-1
0.529
514
Ca-9
Free
2-1
0.578
510
Ca-10
Free
2-1
0.518
521
Ca-11
Free
2-1
0.537
526
Ca-12
Free
2-1
0.07
538
Ca-13
Free
2-1
0.475
539
Ca-14
Free
2-2
0.648
539
[0000]
TABLE 3-2
Ca-15
Free
2-1
0.662
550
Ca-16
CF3CO2H
2-1
0.536
514
Ca-17
Free
2-1
0.483
553
Ca-18
CF3CO2H
2-1
0.556
532
Ca-19
CF3CO2H
2-1
0.596
564
Ca-20
Free
2-1
0.551
526
Ca-21
CF3CO2H
2-1
0.532
526
Ca-22
Free
2-1
0.511
512
Ca-23
Free
2-1
0.547
526
Ca-24
HCO2H
2-1
0.516
482
[0000]
TABLE 3-3
Ca-25
CF3CO2H
2-1
0.391
511
Ca-26
CF3CO2H
2-1
0.481
539
Ca-27
CF3CO2H
2-1
0.503
526
Test Example 1
Binding Test for V1b Receptor
[0770] Human V1b receptor was transiently expressed in 293FT cells (Invitrogen). The cells were collected and were homogenated in a 15 mmol/L tris-hydrochloric acid buffer (pH 7.4, containing 2 mmol/L magnesium chloride, 0.3 mmol/L ethylenediaminetetracetic acid, and 1 mmol/L glycol ether diaminetetraacetic acid). The resulting homogenate was centrifuged at 50,000×g at 4° C. for 20 minutes. The precipitate was resuspended in a 75 mmol/L tris-hydrochloric acid buffer (pH 7.4, containing 12.5 mmol/L magnesium chloride, 0.3 mmol/L ethylenediaminetetracetic acid, 1 mmol/L glycol ether diamine tetraacetic acid, and 250 mmol/L sucrose) to give a crude membrane preparation, which was stored at −80° C. until the binding test. In the binding test, the crude membrane preparation was diluted with a 50 mmol/L tris-hydrochloric acid buffer (pH 7.4, containing 10 mmol/L magnesium chloride and 0.1% bovine serum albumin), and test compound was serially diluted with DMSO. The diluted crude membrane preparation was incubated with each test compound (final concentration of 0.01 nmol/L to 1 μmol/L) and [ 3 H]AVP (final concentration: 0.4 to 1 nmol/L) at room temperature for 60 minutes. After the incubation, the mixture was suction filtered through a GF/C filter pretreated with 0.3% polyethyleneimine. The GF/C filter was dried, and a scintillator was added thereto. The radioactivity remaining on the filter was measured using TopCount (PerkinElmer Inc.). The radioactivity in the presence of 10 μmol/L of unlabeled AVP was defined as 0%, and the radioactivity in the absence of unlabeled AVP was defined as 100%. A dose-response curve was plotted from radioactivities in the presence of a test compound at various concentrations, and the 50% inhibitory concentration (IC 50 value) of the compound was calculated. The IC 50 values of the compounds of the present invention were in the range of about 1 to 1000 nM. Table 4 shows the IC 50 values of typical compounds.
[0000]
TABLE 4
V1b binding
Example
IC 50 value
No.
(nmol/L)
Aa-1
8.6
Aa-6
56
Aa-7
34
Aa-8
4.1
Aa-9
18
Aa-10
4.7
Aa-11
37
Aa-13
20
Ab-2
41
Ab-4
20
Ab-5
8.6
Ac-2
79
Ad-1
2.5
Ad-2
15
Ad-3
55
Ad-4
102
Ad-5
97
Ad-6
62
Ba-2
19
Ca-1
26
Ca-2
10
Ca-3
6.0
Ca-5
4.4
Cb-2
17
Cb-4
8.6
Cb-5
16
Da-1
17
Da-2
4.3
Da-3
32
Da-4
12
Da-5
2.5
Da-6
4.4
Db-1
16
Db-2
7.1
Db-3
10
Db-4
2.9
Ea-2
48
Fa-1
46
Ga-1
114
Ad-7
3.8
Ad-8
1.5
Ad-9
2.3
Ad-10
1.3
Ad-13
2.9
Ad-14
0.54
Ad-15
5.1
Ad-16
0.92
Ad-17
3.5
Ad-18
2.6
Ba-3
9.4
Bd-1
4.1
Bd-2
3.6
Ia-1
46
Ad-19-1
0.59
Ad-19-2
17
Ad-20
96
Ad-21
365
Bd-3
0.21
Bd-4
0.44
Ca-6
10~100
Ca-7
10~100
Ca-8
<10
Ca-9
10~100
Ca-10
100~1000
Ca-11
10~100
Ca-12
100~1000
Ca-13
100~1000
Ca-14
100~1000
Ca-15
10~100
Ca-16
10~100
Ca-17
100~1000
Ca-18
10~100
Ca-19
100~1000
Ca-20
10~100
Ca-21
10~100
Ca-22
10~100
Ca-23
10~100
Ca-24
10~100
Ca-25
100~1000
Ca-26
100~1000
Ca-27
100~1000
Cd-1
166
Cd-2
0.51
Cd-3
0.55
Cd-4
863
Ja-1
16
Ja-2
20
Test Example 2
Measurement of V1b Receptor Antagonistic Activity
[0771] CHO cells (ATCC) stably expressing human V1b receptor were cultured in Ham's F-12 medium (containing 10% FBS and 0.5 mg/mL Geneticin). The cells were seeded the day before the test at 20,000 cells/well in a 96-well poly-D-lysine coated black plate. On the day of the test, the culture medium was removed, and a loading solution (1×HBSS, 10 mmol/L HEPES, 0.1% bovine serum albumin, 1.25 mmol/L Probenecid, 0.02% Pluronic F-127, 1.5 μmol/L Fluo-4-AM, pH 7.4) was added to each well, followed by incubation in a CO 2 incubator for 1 hour. After the incubation, the loading solution was removed. A test solution (1×HBSS, 10 mmol/L HEPES, 0.1% bovine serum albumin, 1.25 mmol/L Probenecid, pH 7.4) containing any one of test compounds was added to wells, followed by incubation in a CO 2 incubator for 30 minutes. The test compound was serially diluted with DMSO so as to be assayed at a final concentration of 0.1 nmol/L to 1 μmol/L. After the incubation, measurement of fluorescence intensity levels and addition of AVP were performed with Functional Drug Screening System (FDSS, Hamamatsu Photonics K.K.). AVP was added to each well at a final concentration of 2.5 nmol/L. At this concentration, AVP shows 70 to 80% of the maximum activity. The fluorescence level in the well not containing any test compound and AVP was defined as 0%, and the fluorescence level in the well not containing any test compound but containing AVP was defined as 100%. A dose-response curve was plotted from fluorescence levels after the addition of AVP in the presence of a test compound at various concentrations, and the 50% inhibitory concentration (IC 50 value) of the compound was calculated. Table 5 shows the results.
[0000]
TABLE 5
Example
IC 50 value
No.
(nmol/L)
Aa-1
9.3
Aa-8
23
Aa-10
20
Ab-2
13
Ab-5
29
Ba-2
30
Ca-2
11
Ca-3
16
Cb-2
26
Da-2
6.3
Da-5
6
Da-6
12
INDUSTRIAL APPLICABILITY
[0772] The present invention can provide a therapeutic or preventive agent for, for example, mood disorder, anxiety disorder, schizophrenia, Alzheimer's disease, Parkinson's disease, Huntington's chorea, eating disorder, hypertension, gastrointestinal disease, drug addiction, epilepsy, cerebral infarction, cerebral ischemia, cerebral edema, head injury, inflammation, immune-related disease, or alopecia.
|
The present invention provides a 1,2,4-triazolone derivative represented by Formula (1A) having an antagonistic activity on the arginine-vasopressin 1b receptor or a pharmaceutically acceptable salt thereof and provides a pharmaceutical composition comprising the compound or the salt as an active ingredient, in particular, a therapeutic or preventive agent exhibiting favorable pharmacokinetics in a disease such as mood disorder, anxiety disorder, schizophrenia, Alzheimer's disease, Parkinson's disease, Huntington's chorea, eating disorder, hypertension, gastrointestinal disease, drug addiction, epilepsy, cerebral infarction, cerebral ischemia, cerebral edema, head injury, inflammation, immune-related disease, or alopecia.
| 2
|
BACKGROUND OF THE INVENTION
This invention relates to nuclear reactors and is primarily directed to liquid metal cooled nuclear reactors.
One known kind of liquid metal cooled nuclear reactor comprises a nuclear reactor core submerged in a pool of liquid sodium contained by a primary vessel within a concrete vault. The core is supported on a diagrid and enclosed by a shroud or core tank and coolant is circulated from outside the core tank by a pump upwardly through the reactor core thence to a heat exchanger from which the coolant is discharged back to the region of the pool which is outside the core tank. The temperature of the pool outside the core tank is approximately 400° C. whilst that inside the core tank is approximately 600° C.
To reduce heat transfer from the inner to the outer region of the pool and to protect the wall of the core tank from the stress effects of such a large temperature differential it is necessary to provide thermal insulation for the inner wall, that is, the hot wall, of the tank. In the known kind of liquid metal cooled nuclear reactor the insulation has been of the passive kind, that is, cladding of the kind which has a low heat transfer characteristic and has taken such form as a gas filled quilted envelope made from thin stainless steel material. However, such insulation is unreliable and requires testing for gas tightness by complex techniques. In a recently proposed construction of liquid metal nuclear reactor passive insulation for the wall of the core tank comprises a cladding layer of closely packed and inter-sealed stainless steel blocks and a stainless steel membrane spaced from the layer of blocks. The membrane is provided with a network of intersecting corrugations to accommodate thermal expansion of the membrane but it is feared that the complex stresses induced at the knots of the orthogonal corrugations will give rise to unreliability.
It is an object of the present invention to develop insulation means for the core tank of a liquid metal cooled nuclear reactor wherein the liquid metal coolant plays a more active part in the insulation and thereby reduces the complexity of manufacture and improves the reliability of the insulation.
SUMMARY OF THE INVENTION
According to the invention, in a liquid metal cooled nuclear reactor comprising a primary vessel containing a pool of liquid metal and a nuclear reactor core submerged in the pool of liquid metal and enclosed by a core tank there is means for enveloping the inner wall surface of the core tank with liquid metal drawn from the pool region outside of the core tank and for flowing the liquid metal thence radially inwardly towards the reactor core. The invention provides that the inner wall surface of the core tank is cooled by contact with relatively cool liquid metal and that the subsequent radially inward flow of liquid metal repels the outward transfer of heat to the inner wall surface of the core tank.
The means for enveloping the inner wall surface of the core tank with liquid metal drawn from the pool region outside of the core tank and for flowing the liquid metal thence radially inwardly may comprise a continuous membrane spaced from the inner wall surface of the core tank thereby defining a compartment bounded by the inner wall surface of the core tank and the membrane, the membrane having a plurality of distributed perforations, and a pump having an inlet port submerged in the pool of liquid metal outside of the core tank and an outlet port disposed for discharging liquid metal into the compartment. However, in a preferred construction there is a plurality of spaced membranes having distributed perforations and defining a radial series of compartments through which liquid metal from the discharge port can flow sequentially. The membranes may have a network of intersecting corrugations to accommodate thermal expansion, the perforations being slits provided at the intersections of the corrugations but in a preferred construction the corrugations of a first group of parallel corrugations are intermittently interrupted to avoid the possibility of complex stresses being induced at the knots. A constructional example of liquid metal cooled nuclear reactor embodying the invention is described with reference to the accompanying drawings wherein,
FIG. 1 is a fragmentary side view in section,
FIG. 2 is a perspective view of a detail, and
FIG. 3 is a sectional view of the construction.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In the nuclear reactor construction shown in FIG. 3 a fast breeder nuclear reactor core 101 is submerged in a pool 102 of liquid sodium contained within a primary vessel 103. The vessel 103 is housed in a concrete containment vault 104 having a cover 105 from which the primary vessel 103 depends. The reactor core is carried by a diagrid 106 which is supported from the cover 105 and the reactor core is housed within a shroud or core tank 107. The cover has numerous penetrations for ancillary equipment such as heat exchangers 108 and circulators 109 and has a central rotating shield 110. The rotating shield 110 comprises an outer rotatable member having an inner rotatable member mounted eccentrically in it, there being penetrations in the shield for control mechanisms and to provide access to fuel assemblies in the core. In use, coolant is circulated from the pool region outside of the core tank 107 through the core 101 by way of the diagrid and thence through the core tank 107 back to the pool region outside of the core tank by way of the heat exchangers 108. The primary vessel 103 is spaced from the wall of the concrete vault and thermal insulation is interposed between vessel and vault wall. The temperature of the sodium in the outer region of the pool is approximately 400° C. and the temperature of the sodium within the core tank is approximately 600° C. so thermal insulation 111 is provided for the inner wall that is, the hot wall, of the core tank.
Referring now to FIG. 1, there is shown therein a fragment of the core tank 107 having a base designated 1. The level of the liquid metal in the outer part of the primary vessel 103 is indicated by the reference numeral 3 and the level within the core tank 107 is indicated by reference numeral 4, the level 4 being higher than the level 3 due to the pressure drop in the reactor cooling system, whereby sodium pumped through the core passes from the core tank to the primary heat exchangers 108 before being returned to the outer region of the pool which feeds the inlets of the pumps. Thus the sodium in the core tank 107 having just passed through the core, which is the best source of the power producing system, is hotter than that on the outside of the core tank. The insulation 111 takes the form of a plurality of similar membranes, conveniently of stainless steel, three being shown in the illustrated example designated respectively 5, 6 and 7. The first membrane 5 is spaced from the wall of the core tank 107 to provide a space or compartment 8, the second membrane 6 is spaced from the membrane 5 to provide a space or compartment 9, the latter being of smaller width than compartment 8, and the outer membrane 7 is spaced from the membrane 6 similarly to the spacing between membranes 5 and 6 to provide a space or compartment 10. The core is cylindrical, the core tank 107 is also cylindrical, and the membranes are similarly shaped, thereby providing annular compartments 8, 9 and 10. Other shapes of core, core tank and membranes are of course possible but cylindrical is found to be the most convenient and is almost invariably employed.
The membranes 5, 6 and 7 are mounted on the wall of the core tank 107 and spaced apart by means of fixing studs 11, three only at a single level being shown for the sake of clarity, it being appreciated they are provided at several levels as expedient. The wall thickness of the membranes 5, 6 and 7 are relatively small compared with the thickness of the core tank wall (1 mm compared with 20 mm in a typical example). It is preferable to impart some flexibility to the membranes by providing a network of corrugations conveniently intersecting at right angles and arranged vertically and horizontally. The vertical corrugations on the outer membrane 7 are designated 12 and the horizontal corrugations 13. At every position at which these corrugations cross, a perforation through the respective membrane is provided for intercommunication between the compartments, and the perforations conveniently consist in slits in one of the corrugations (see FIG. 2). The slits designated 14 FIGS. 1 and 2 are in the horizontal corrugations 13. In a modification, shown in dot-and-dash lines in FIG. 2, each of the interrupted corrugations (the vertical corrugations 12 in FIGS. 1 and 2) is so formed that a flap 15 extends over the highest point of the slits 14 in a hooding manner so as to interrupt radially outward flow of fluid through the slits 14 and divert the flow laterally with flow direction components more parallel to the membrane surfaces (and in several such directions) than radial.
In order to promote movement of cool sodium through the compartments 8, 9 and 10, a sodium pump, preferably electromagnetic, illustrated diagrammatically in FIG. 2 and designated 16, is provided with an inlet 17 dipping into the cool sodium in the tank, and an outlet 18 over (as shown) or through the core tank wall to feed cool sodium to compartment 8. The levels of the sodium in compartments 8, 9 and 10 are designated 19, 20 and 21 respectively. The level difference across a membrane represents the pressure difference required to drive sodium through the slits 14. Sodium passes through the slits 14 at every level and with several flow directional components as aforesaid, and as illustrated by the flow direction arrows at some of the slits 14 in FIG. 1 to pass to compartment 9 and to compartment 10, finally joining the hot sodium in the core tank, and being more or less at the same temperature when it does, by reason of its having taken heat from the membranes and the sodium contained in the compartments between them. Thus very little of the heat passing through diaphragm 7 reaches the core tank 107, the majority of the heat being taken back into the core tank by sodium flowing through the membranes.
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Thermal insulation for a core tank of a fast breeder nuclear reactor comprises a plurality of spaced membranes defining a series of concentric chambers lining the tank. Liquid metal is pumped from the cooler regions of a pool of coolant into the first chamber from which it flows successively through the remaining chambers towards the reactor core.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to an apparatus and method for packing gravel within the bore of a subterranean well.
2. Description of the Prior Art
Of considerable magnitude in the production of hydrocarbons such as oil and gas from a producing well is the problem of sand flow into the well bore from unconsolidated formation. Production of sand with the flow of hydrocarbons will cause the well bore to gradually fill up with minute sand particles until production perforations in the casing and, oftentimes, the end of production tubing inserted therein are covered, resulting in a significant reduction in fluid production. In many instances, sand production will cause the well to die.
In addition to reduction of fluid production, flow of sand also may cause severe damage to equipment such as pumps, chokes and the like. In flowing wells, fluid velocity may be sufficient to scavenge sand within the well bore and produce it with the fluid hydrocarbon, resulting in holes being cut in the tubing and flow lines.
One well known means of controlling flow of sand into the well bore is the placement of gravel on the exterior of a slotted liner to filter sand produced with the oil or gas and thus prevent its entry into production tubing. The slotted liner or screen must be designed to prevent entry of the gravel itself into the production tubing.
The reverse circulation method of packing gravel provides for pumping the gravel down the well in the annulus between the production tubing and the well casing. The gravel is deposited on the outer periphery of the screen assembly while the fluid returns to the top of the well through the production tubing. A pressure buildup is noted at the surface and fluid pumping stopped when the gravel covers the screen. After gravel settlement, the tubing is disconnected from the screen assembly and pulled out of the hole.
Although other fluids have been used, treated and filtered production or nearby well or surface water is preferably used in most gravel packing processes during the cleaning and washing procedure. The water is treated to remove contaminants such as cement particles, scale, and other foreign material generally resulting from the circulation of water in the well bore. Because the volume in the annulus between the production tubing and the well casing may be as much as eight to 10 times greater than the volume of the production tubing, considerably more water must be used and thus treated and filtered if clean fluid is to be used in a reverse circulation process or method than is used in conventional wash down methods.
In order to provide a gravel pack apparatus which is more efficient than prior art apparatuses and, primarily, to drastically reduce the amount of fluid which must be used during a gravel packing process, crossover equipment has been developed for use with screen assemblies and high performance packers. Such equipment now has made it feasible to gravel pack using only a fraction of the volume of fluid heretofore utilized because the fluid is maintained within the tubing and is circulated only within the treatment zone which is isolated by the packing element of the packer.
Although such an apparatus has provided many advantages over the use of conventional prior art techniques, heretofore its use has been confining because it has not been able to be successfully utilized in high pressure wells which require the use of high density fluids, such as highly weighted muds instead of water. Heretofore, if such an apparatus were utilized in conjunction with the mud system, the screen as well as the gravel pack would become plugged, resulting in a severe limitation of hydrocarbon production therethrough.
It is, therefore, an object of the present invention to provide an apparatus and method for gravel packing utilizing concentric strings of tubing wherein the zone being gravel packed is completely isolated from the well control fluid (mud) during the gravel pack operation and may remain isolated from it, if desired, after completion of the gravel pack operation.
It is also an object of the present invention to provide an apparatus and a method which utilizes a crossover assembly with concentric strings of tubing to eliminate the necessity of pumping gravel in a high pressure well down the tubing-to-tubing annulus.
It is a further object of the present invention to provide an apparatus and method whereby flow paths into, through, and around a gravel pack screen can be altered and regulated by longitudinal manipulation of an internal tubing string within an outer tubing string.
It is a further object of the present invention to provide an apparatus and method for gravel packing wherein high pressures may be utilized during acidizing and squeezing of gravel into the formation.
Other objects of the present invention will be readily apparent from a reading of the Figures, the specification below, and the claims.
SUMMARY OF THE INVENTION
The present apparatus for packing gravel within a well isolates the zone to be gravel packed from well fluid normally used to contain the well pressure. The apparatus utilizes two concentric tubing strings. The outer tubing string is connected or may be releasably connected to a packer which is set within the well casing with the liner assembly being attached to the packer and positioned adjacent to perforations within the well casing. The liner assembly comprises a production screen preferably long enough to cover or straddle substantially all casing perforations to be gravel packed. The inner tubing string carries a crossover assembly selectively positionable within the packer and liner assembly such that flow paths are established for washing the screen, squeezing acid into the formation, gravel packing the production zone, and, if desired, thereafter pumping mud down one of the tubing strings to kill the well. The invention also incorporates a method utilizing the apparatus as above described for selectively directing the flushing and gravel packing fluids through the tubing strings and into and from the annulus around the liner assembly, as well as the interior of the liner assembly.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a longitudinally schematic drawing of a packer carrying a liner assembly, the packer being in sealed position above the production zone within the casing.
FIG. 2 is a similar drawing showing an outer tubular string sealingly engaged and detachably connected to the packer.
FIG. 3 is a similar drawing showing the crossover assembly carried by an inner tubular string with the crossover assembly sealingly engaged within the packer and extending into the liner assembly in position for displacing mud from inside the screen prior to gravel packing, the flow path being indicated by arrows.
FIG. 4 is a similar drawing showing the crossover assembly in lowered position for squeezing of acid within the production zone.
FIG. 5 is a similar drawing showing the crossover assembly in position for gravel packing the production zone.
FIG. 6 is a similar drawing showing the production zone completely gravel packed and the crossover assembly in its fully raised position for pumping of mud to kill the well.
FIG. 7 is a similar drawing with the crossover assembly and the inner tubular string removed from the well and the production of fluid hydrocarbons from the zone being, as indicated by the arrows, through the production screen, the interior of the liner assembly, and through the second tubular string thereabove.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The apparatus disclosed in the drawings is used within a well bore W extending through a formation producing zone Z, a casing C having been suitably cemented or otherwise secured in place within the well bore. The casing has perforations P through which fluids from the producing zone can flow to the interior of the casing. A suitable bridge plug B is disclosed as having been set in the well casing a predetermined distance below the perforations, which serves to prevent fluid from the zone from flowing downwardly beyond the bridge plug, and which also acts as a locator for appropriately positioning a liner assembly 5 embodying one or more perforated portions or screens 9 with respect to the casing perforations.
The upper end of the liner assembly is secured to a suitable well packer 1. The particular packer or packer mechanism 1 utilized in the present invention may vary considerably in design, construction and operation. The packer will provide an interior surface or bore which serves as a sealing surface for the crossover tool described below. Preferably, the packer mechanism is designed to receive a latching mechanism at its upper end for utilization in connection of the outer tubular string to the packing mechanism. The packer also is adapted to be lowered in the well casing C and anchored in a packed-off condition therewithin against longitudinal movement in both upward and downward directions in a known manner. Suitable for use in the present invention are Model DA and FA packers manufactured and sold by Baker Oil Tools, Inc., and shown on pages 396 and 397, respectively, of the 1974-1975 Catalog of Baker Oil Tools, Inc.
The liner assembly 5 includes a series of circumferentially extending ports 6 for communication of the interior 10 of the liner assembly 5 with the annular area A between the liner assembly 5 and the casing C below the packer 1. At a longitudinal distance below the series of ports 6 is an internally extending seal receptacle 7 having a reduced internal diameter for receipt of companion seal members carried on the crossover assembly.
Below the seal receptacle 7 on the liner assembly 5 is a longitudinally extending perforated or screen member 8 for detecting completion of the gravel packing step as described below. Separated from the perforated or screen section 8 by a tubular member 12 is a second perforated or screen member 9 which straddles the perforations P within the production zone Z. The screens 8 and 9 permit communication of fluid between the interior 10 of the liner assembly 5 and the annular area A, but prevents particulate matter from entering the interior 10. Below the screen member 9 and terminating the liner assembly 5 at its lower end is a bull plug 11 which is seated on the bottom of the well or, as shown in the Figures, on a reference point, such as a bridge plug B.
Referring particularly to FIG. 3, a crossover assembly 20 is carried by an inner tubing string 25 which is inserted in the well within the first or outer tubing string 4. The crossover assembly 20 consists of an outer tubular member 29 long enough to extend from the top of the packer to below the screen member 9 and an inner tubular member 30 extending from the top of the crossover assembly to the vicinity of the ports 6 in the liner assembly 5. The interior of the inner tubular member 30 is open at its upper end to the interior of the inner tubing string 25. Its lower end 28 is closed except that a passageway or port 27 is provided through its side near the lower end which also extends through the adjacent side of the outer tubular member 29.
Elastomeric seal members 24 are mounted on the exterior of the outer tubular member 29 to effect selective sealing engagement within the bore 1a of the packer and the bore 7b of the receptacle 7. Ports 26 through the outer tubular member 29 are positioned between the uppermost seal member 24a and the second seal member 24b to provide a fluid passage between the exterior of the crossover assembly at this point, the annulus 31a between the inner and outer tubular members and thence to the lower end 34 of the outer tubular member. Thus when in a first position the lowermost seal 24 of the crossover assembly 20 is engaged with the wall 7b of the receptacle 7. (See FIG. 5) the passageway or port 27 in conjunction with port 6 in liner assembly 5 will provide fluid communication between the interior 32 of the crossover assembly 20 and the annulus A between the liner assembly 5 and the casing C.
Fluid can be pumped down the inner tubular string 25, through the ports 27 and 6 into the area A on the outside of the screen, through the screen 9 into the lower end of the crossover assembly 20 and upwardly through interior areas 31 and 31a and the outer tubular string 4 (shown in FIG. 5), with reverse circulation possible at any time. When the inner tubular member 25 is raised to a second position so that the lower seal members 24 on the crossover assembly 20 are engaged within the bore 1a of the packer 1, the port 27 will be above the packer and fluid may be pumped down the inner tubular string 25, through the port 27 and upwardly to the surface through the outer tubular string 4 (shown in FIG. 6) with reverse circulation possible at any time.
Engagement of an abutment 22 formed by an enlargement of the crossover assembly 20 at its upper end with an internal shoulder in the anchored seal member 23a positions the crossover assembly in a third position as shown in FIG. 4. In this position ports 26 are sealed off in bore 1a of the packer 1 by seals 24a and 24b and no communication can take place between fluid in the annulus formed by the inner and outer tubing strings and fluid below the packer, but fluid can be pumped into the formation through the inner tubing string.
In a fourth position (FIG. 3) the crossover assembly can be raised until the lowermost seal member is slightly above the receptacle 7 whereby fluid may be pumped down the inner tubular string 25, through port 27, thence downwardly within the liner assembly 5 through the open receptacle 7 then upwardly through the open end 34 of the crossover assembly 20 and to the top of the well through the annulus between the inner and outer tubular strings.
OPERATION
In order to establish a base to support the gravel pack, a bridge plug B may be set below the lowermost end of the perforations P.
The packer or packing mechanism 1 with the seal receptacle 2 thereon and the liner assembly 5 therebelow is set at a predetermined depth in the well within the annular area A prior to initiation of the gravel packing operation. The setting mechanism is withdrawn and returned to the well surface. After the packing mechanism 1 has been set, the outer tubing string 4 is run in the well and is sealingly stabbed and latched into the seal receptacle 2, the latch members 21 of the outer tubular string 4 compatably engaging the threads 3 of the receptacle 2, the sealing engagement of the outer tubular string 4 and the receptacle 2 being assured by the circumferentially extending seal 40 carried by the outer tubular string 4 engaging the inner smooth wall 2a of the receptacle
After the outer tubular string 4 has been engaged within the receptacle 2, the inner tubular string 25 is inserted at the top of the well through the outer tubular string 4, the inner tubular string 25 having affixed at its lower end the crossover assembly 20. The crossover assembly 20 carried by the tubular member 25 is lowered in the well until the abutment 22 contacts the shoulder 23. Thereafter, the inner tubular member 25 is raised a known and predetermined distance such that the lower seal members 24 carried by the first or outer tubular member 29 of the crossover assembly 20 are engaged along the inner wall 7b of the receptacle 7 of the liner assembly 5, with at least one of the series of seals 24 also being engaged within bore 1a of the packer mechanism 1. In this first or initial position, the port 26 of the crossover assembly 20 provides fluid communication to the top of the well and between the annular area of the outer and inner tubular strings 4 and 25 and the interior 31 of the tubular member 23 of the crossover assembly 20. Additionally, the first positioning of the crossover assembly 20 also permits the port 27 to provide fluid communication to the top of the well and between the interior 32 of the second or inner tubular member 30 and the interior of the liner assembly 5 above the receptacle 7 as well as the annular area A on the exterior of the liner assembly 5 by means of the port 6 on the liner assembly 5. The entire apparatus now is in condition for initiation of the gravel packing procedure.
As an initial step, the interior of the liner assembly 5 may be cleaned by first removing the lower seals 24 from engagement within the receptacle 7 by raising the inner tubing string 25. Thereafter, a flushing fluid is pumped from the top of the well through the inner tubular string 25 and the inner tubular member 30 of the crossover assembly 20, exiting the assembly 20 by means of port 27. The fluid continues downward circulation through the interior of the liner assembly 5 and re-enters the crossover assembly 20 by means of open end 34, thence through the interior areas 31 and 31a and thereafter to the top of the well through the outer tubular string 4.
Thereafter, the inner tubing string 25 is lowered until the lower seals 24 are sealingly engaged within the receptacle 7. The flushing fluid is pumped from the top of the well through the annulus between the outer and inner tubular strings, entering the crossover assembly 20 through the port 26, thence downwardly through the crossover assembly out the open end 34 thereof and through the lower perforations of the liner assembly to the well bore, thence upwardly in the well liner assembly annulus and through the port 27 and the inner member of the crossover assembly to the top of the well. The flow path of this displacement and cleaning step is the reverse of that shown by the arrows in FIG. 5. While the crossover assembly is in the position as above described, an acidic solution is pumped down one of the tubing strings and around the screens 8 and 9 and washed back and forth to clean the screen perforations.
Upon completion of the step as described above, the inner tubular string 25 is lowered in the well until the shoulder 23 engages the abutment 22 at the top of the crossover assembly 20. When the crossover assembly 20 is in this position, the port 26 on the outer tubular member 29 will be within the bore 1a of the packer 1 and fluid will be prevented from traveling through said port because of the sealing engagement of upper and lower seal members 24a and 24b within the bore 1a of the packer member 1.
Although the crossover assembly 20 has been lowered further within the liner assembly 5, the receptacle 7 still will engage at least one of the lower seals 24 on the outer tubular member 29 to prevent communication of fluid in the interior 10 of the liner assembly 5 below the receptacle 7 with fluid in the interior of the liner above it.
With the crossover assembly 20 positioned as described above, and as shown in FIG. 4, pressure is applied to the tubing strings and an acidic solution is squeezed into the perforations P. The acidic solution is pumped through the internal tubular string 25, exiting the crossover assembly 20 through the port 27, thence through the liner assembly 5 to the annular area A by means of ports 6. The flow path for this step is shown by the arrows in FIG. 4.
An alternative step in lieu of the foregoing may be achieved by leaving the crossover assembly 20 as shown in FIG. 3 while applying pressure to the tubing strings 25 and 4.
After cleaning the perforations P in one of the manners described above, the crossover assembly 20 is moved to a position within the liner assembly 5, as shown in FIG. 5. Thereafter, gravel carried by a suitable fluid is pumped down the inner tubular string 25 through the second or inner tubular member 30 of the crossover assembly 20, thence outwardly through ports 27 and ports 6. The gravel is deposited on the exterior of the liner assembly 5 adjacent to the perforations P and the perforated or screen member 9 while the fluid flows inwardly through the perforated or screened section 9 to the interior 10 of the liner assembly 5 and through the crossover assembly 20 through the open end 34, exiting the crossover assembly 20 through the ports 26 above the packer 1, thence to the top of the well through the outer tubular string 4. The pumping of gravel is continued and pressure is exerted within the inner tubular string 25 by closing a valve (not shown) on the outer string at the surface which will shut off the return path for the fluid. High pressure may then be applied to the inner string in order to force the gravel laden fluid into the formation so that gravel will fill the perforations and be tightly packed in any cavity behind them. Thereafter circulation is reestablished by opening the valve at the surface and gravel packing is continued until the annulus A is filled with gravel particles and until an increase in back pressure indicates that the tell tale perforated or screen member 8 has been covered with gravel.
Upon notation at the well surface of an increase in back pressure, the inner tubular string 25 and the crossover assembly 20 are raised until the lower seals 24 on the outer tubular member 29 of the crossover assembly 20 are withdrawn from the receptacle 7. Flushing fluid then can be circulated downwardly through the outer tubing 4 to clean the interior of the liner assembly 5 and is followed by enough gel solution to fill the interior of the liner assembly. The inner tubing string 25 may be moved to the position shown in FIG. 6 and the well killed with mud prior to removal from the well of the inner tubing string 25 and the crossover assembly 20 thereon. The hydrocarbons in the zone Z are produced through the perforations P, the screen or perforated member 9, thence upwardly through the interior 10 of the liner assembly 5 through the outer string 4 to the top of the well.
In lieu of killing the well, the crossover assembly 20 and the inner tubular string 25 may be removed from the well subsequent to completion of the gravel pack step (as shown in FIG. 5) by use of a snubbing unit with a blanking plug (not shown) being placed in the inner tubular string 25 adjacent to the top of the crossover assembly 20. The well is produced as described above and as shown in FIG. 7.
Although the invention has been described in terms of specified embodiments which are set forth in detail, it should be understood that this is by illustration only and that the invention is not necessarily limited thereto, since alternative embodiments and operating techniques will become apparent to those skilled in the art in view of the disclosure. Accordingly, modifications are contemplated which can be made without departing from the spirit of the described invention.
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A packer with a liner assembly depending from it is packed off and anchored in well casing so that a screen portion of the liner assembly straddles casing perforations within a producing formation. An outer tubing string is lowered through the well casing and engaged with the packer to isolate the formation from well fluids above the packer and to provide a passage to the surface for the formation fluids.
A member having crossover fluid passages and external seals engageable with internal seal surfaces in the liner and packer is lowered through the outer tubing string into the liner and packer on an inner string. Fluid passages between the two strings, and between the two strings and the interior and exterior of the liner to control the flow of circulating, washing or acidizing fluids and for placement of gravel on the outside of the liner are selectively opened or closed by manipulation of the inner string.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The invention relates generally to the design of packer devices.
[0003] 2. Description of the Related Art
[0004] Anti-extrusion backup rings are used to prevent or reduce extrusion of deformable elastomeric packer elements for packer devices in wellbores. Other backup rings partially encase an end portion of the elastomeric packer element and are therefore, expanded radially outwardly as the packer element expands radially during setting. Backup rings of this type are discussed in U.S. Pat. No. 8,083,001 issued to Conner et al. which is owned by the assignee of the present invention and is herein incorporated by reference.
SUMMARY OF THE INVENTION
[0005] The invention provides packer devices having one or more anti-extrusion backup rings that are expanded radially outwardly by the radial expansion of a setting mechanism that lies proximate the elastomeric packer element that is being protected against extrusion. In certain embodiments, the setting mechanism is a slip assembly that has a radially expandable slip element. In particular embodiments, the slip assembly is set by axial movement of the slip element over a setting cone. In a described embodiment, the anti-extrusion backup ring has an interior portion that extends along the end wall of the packer element and an exterior portion that is substantially perpendicular to the interior portion. In the described embodiment, the exterior portion overlies a portion of the slip element. The slip element urges the backup ring into mechanical or intimate contact with a surrounding tubular when the slip element is set against the surrounding tubular. Outward radial expansion of the slip element will urge the exterior portion of the backup ring radially outwardly. In a described embodiment, the exterior portion of the backup ring is urged into contact with the surrounding tubular by the slip element. When so set, the backup ring prevents or reduces axial extrusion of the packer element past the backup ring in the direction of the slip assembly.
[0006] In another described embodiment, the backup ring takes the form of an annular spring that radially surrounds the cone of the slip assembly. During setting of the packer device, the slip element urges the spring into a wedged position between the cone and the surrounding tubular so that the wedged spring acts as backup ring to prevent extrusion of the packer element.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The advantages and further aspects of the invention will be readily appreciated by those of ordinary skill in the art as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings in which like reference characters designate like or similar elements throughout the several figures of the drawing and wherein:
[0008] FIG. 1 is a one-quarter side cross-sectional view of an unset exemplary packer device having an anti-extrusion backup ring in accordance with the present invention.
[0009] FIG. 2 is a one-quarter side cross-sectional view of the packer device of FIG. 1 , now in a set position.
[0010] FIG. 3 is a one-quarter side cross-sectional view of an unset packer device having an exemplary alternative anti-extrusion backup ring in accordance with the present invention.
[0011] FIG. 4 is a one-quarter side cross-sectional view of the packer device of FIG. 3 , now in a set position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0012] FIG. 1 illustrates an exemplary compression-set packer device 10 that includes an interior cylindrical mandrel 12 that defines an interior flowbore 14 having central axis 16 along its length. As the general construction and operation of a compression-set packer device is well known, it will not be discussed in detail here.
[0013] A compressible, or compression-set, packer element 18 radially surrounds the mandrel 12 . The packer element 18 is preferably formed of a deformable elastomer, as is known in the art. An anti-extrusion backup ring 20 is located adjacent the packer element 18 . The backup ring 20 has an interior portion 22 that extends radially outwardly from the mandrel 12 and along the end wall 24 of the packer element 18 . The backup ring 20 also has an exterior portion 26 that, in the depicted embodiment, is substantially perpendicular to the interior portion 22 . In particular embodiments, the backup ring 20 is formed of metal. A suitable metal for this application is annealed 8620 steel. In other particular embodiments, the backup ring 20 is formed of a non-metallic material such as carbon epoxy and other composites. In preferred embodiments, the backup ring 20 has a rigidity that allows it to be deployed with a setting force that is usual and customary for setting of the packer element 18 . In particular embodiments, the setting force would be in the range of 5,000-15,000 lbs. In accordance with other embodiments, the backup ring 20 could be a non-metallic petal-style backup ring that is not flexible, but has a designated break point.
[0014] In accordance with other particular embodiments of the present invention, the exterior portion 26 of the backup ring 20 is slotted so that the backup ring 20 is of the petal variety. Also in certain embodiments, this petal-style ring is formed of non-metallic material.
[0015] A slip assembly, generally shown at 28 , radially surrounds the mandrel 12 and includes a cone 30 that is axially slidable upon the mandrel 12 . The cone 30 presents a ramped outer radial setting surface 32 . The slip assembly 28 also includes a slip element 34 . The slip element 34 is typically radially segmented, but need not be so. The slip element 34 preferably has teeth 36 to create a biting engagement with a surrounding tubular member 38 when set. The slip element 34 presents a radially inwardly-facing slanted surface 40 that is complimentary to the surface 32 of the cone 30 . The slip element 34 is located so that the slanted surface 40 is in contact with the surface 32 of the cone 30 . It is noted that, in the unset position, shown in FIG. 1 , an end portion 42 of the slip element 34 is disposed radially within the exterior portion 26 of the backup ring 20 .
[0016] A ring 44 also radially surrounds the mandrel 12 and is affixed to the mandrel 12 by threaded or bonded connection 46 . The ring 44 contacts the slip element 34 .
[0017] In order to set the packer device 10 , the components surrounding the mandrel 12 are axially compressed against the ring 44 as is known in the art. As FIG. 2 illustrates, the packer element 18 will expand radially outwardly and into sealing contact with the surrounding tubular 38 . As the cone 30 is moved axially toward the ring 44 , the slip element 34 is moved radially outwardly due to sliding movement of the slip element 34 upon the ramped surface 32 of the cone 30 . The slip element 34 is moved radially outwardly until its teeth 36 bitingly engage the surrounding tubular 38 .
[0018] The radial outward movement of the slip element 34 also energizes the backup ring 20 . The interior portion 24 of the backup ring 20 is urged against the packer element 18 . The exterior portion 26 of the backup ring 20 is also preferably brought into contact with the surrounding tubular 38 by the slip element 34 . The backup ring 20 now functions as an anti-extrusion barrier which will prevent extrusion of the packer element 18 axially toward the slip assembly 28 . Although only a single backup ring 20 is depicted associated with a single axial end wall 24 of the packer element 18 , it should be understood that a similar to backup ring and setting arrangement could be used for the opposite axial end of the packer element 18 .
[0019] It will be understood that the invention provides an arrangement for preventing axial extrusion of a packer element that is set within a surrounding tubular. This arrangement includes the anti-extrusion backup ring 20 as well as the setting mechanism that is provided in certain embodiments by the slip assembly 28 .
[0020] In addition, it should be understood that the invention provides methods for establishing an anti-extrusion backup seal for a packer element 18 in a packer device 10 to be set within a surrounding tubular 38 . In accordance with these methods, an anti-extrusion backup ring 20 is placed proximate an end wall 24 of the packer element 18 . The backup ring 20 is then energized to prevent extrusion by a setting mechanism other than the packer element 18 . In particular embodiments, the setting mechanism is a slip assembly 28 and energizes the backup ring 20 by urging a slip element 34 radially outwardly to cause the backup ring 20 to be urged against the packer element 18 . In certain embodiments, the slip element 34 urges a portion of the backup ring 20 into engagement with the surrounding tubular 38 .
[0021] The inventors have found that the arrangements and methods of the present invention provide for positive energizing of the backup ring 20 . Since the slip element 34 is formed of a rigid material or assemblage of rigid materials, it will provide for a rigid anchoring of the backup ring 20 against the surrounding tubular 38 .
[0022] FIGS. 3 and 4 illustrate an alternative compression-set packer device 50 having a packer element 18 that radially surrounds mandrel 12 . The packer device 50 is constructed and operates in the manner as the packer device 10 described previously except where indicated otherwise. The inclined outer surface 32 of cone 30 preferably includes an annular recess 52 . An annular spring 54 is disposed on the outer surface 32 of the cone 30 . Preferably, the spring 54 resides within the recess 52 . In one embodiment, the spring 54 is formed of a non-metallic ceramic material, such as carbon fiber reinforced PEEK (polyether ether ketone). Suitable annular springs for use as the spring 54 are available commercially from a number of manufacturers, including Automated Dynamics of Schenectady, N.Y.
[0023] When the packer device 50 is moved from the unset position ( FIG. 3 ) to the set position ( FIG. 4 ) by compression, the end portion 42 of the slip element 34 will contact the spring 54 and urge it over the cone 30 . The spring 54 is then wedged between the cone 30 and the surrounding tubular 38 so that the spring 54 functions as an anti-extrusion backup member that will prevent extrusion of the packer element 18 axially within the surrounding tubular 38 . It is noted that the spring 54 may deform (flatten) cross-sectionally as it is wedged.
[0024] The foregoing description is directed to particular embodiments of the present invention for the purpose of illustration and explanation. It will be apparent, however, to those skilled in the art that many modifications and changes to the embodiment set forth above are possible without departing from the scope and the spirit of the invention.
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Arrangements and packer devices having anti-extrusion backup rings that are expanded radially outwardly by a setting mechanism that lies proximate the elastomeric packer element that is being protected against extrusion. The setting mechanism can be a slip assembly that has a radially expandable slip element.
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This is a division of prior application Ser. No. 09/921,243 filed Aug. 2, 2001, now U.S. Pat. No. 6,904,103.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a receiving device and an integrated circuit for reception.
2. Description of the Related Art
Digital audio radio services in the U.S. are called “DARS”, and in DARS, satellite waves and terrestrial waves are used in combination so that even a receiver mounted in a mobile unit such as vehicle can reliably receive the radio waves.
More specifically, in the DARS, a 2.3 GHz band is used, and as shown in part B of FIG. 6 , two services are broadcast. Currently, each of the services uses a frequency band of 12.5 MHz. As is also shown in part A of FIG. 6 , one service is formed of two ensembles A and B, and each of these ensembles A and B provides 50 channels of programs contents. Therefore, one service provides programs of 100 channels.
The ensemble A is broadcast with individual signals A 1 , A 2 , and A 3 , and the ensemble B is broadcast with individual signals B 1 , B 2 , and B 3 . That is, the contents of the signals A 1 , A 2 , and A 3 are the same, and the contents of the signals B 1 , B 2 , and B 3 are the same. Therefore, if any one of the signals A 1 , A 2 , and A 3 can be received, the program of the ensemble A can be listened to, and in a similar manner, if any one of the signals B 1 , B 2 , and B 3 can be received, the program of the ensemble B can be listened to.
As is also shown in part A of FIG. 6 , the signals A 1 to A 3 and B 1 to B 3 are arranged as the signals A 1 , A 2 , A 3 , B 3 , B 2 , and B 1 in order of frequency, and the signals A 1 , A 2 , and A 3 , and the signals B 3 , B 2 , and B 1 are symmetrically placed about a center frequency fC between the signal A 3 and the signal B 3 .
The signals A 1 , A 2 , B 1 , and B 2 are QPSK (Quadrature Phase Shift Keying) signals. The signals A 1 and B 1 are transmitted from a broadcasting satellite BS 1 over the Western U.S., and the signals A 2 and B 2 are transmitted from a broadcasting satellite BS 2 over the Eastern U.S. (strictly speaking, the satellites BS 1 and BS 2 are positioned along the Equator at longitudes corresponding to the Western U.S. and the Eastern U.S.). Also, the signals A 3 and B 3 are OFDM (Orthogonal Frequency Division Multiplex) signals and are transmitted from an antenna on the ground.
Therefore, since the signals A 1 , A 2 , B 1 , and B 2 are satellite waves, and a diversity effect can be obtained by the satellites BS 1 and BS 2 , a broadcast can be listened to over the entire U.S. Also, when there is a high-rise building, radio waves are sometimes blocked, but this is compensated for by the signals A 3 and B 3 of the terrestrial waves. Therefore, even when the receiving conditions of radio waves of a receiver mounted in a vehicle greatly change as the vehicle travels, it is possible to satisfactorily receive a broadcast.
In DARS, since the signals A 1 to A 3 and B 1 to B 3 are broadcast by frequency division in the above-described manner, a receiver therefor is constructed as shown in, for example, FIG. 7 . In the following description, for brevity of explanation, as shown in FIG. 8A , the signals A 1 and A 2 are collectively denoted as A 12 , and the signals B 1 and B 2 are collectively denoted as B 12 .
More specifically, in FIG. 7 , the signals A 12 , A 3 , B 12 , and B 3 are received by an antenna 11 , and the received signals A 12 to B 3 are supplied to a first mixer circuit 14 via a band-pass filter 12 and a high-frequency amplifier 13 . Furthermore, a first local oscillation signal SLO is supplied from a first local oscillation circuit 15 to the first mixer circuit 14 , whereby the signals A 12 to B 3 are frequency-converted into first intermediate frequency signals.
When the ensemble A is to be listened to (when the signals A 1 to A 3 are subjects to be received), as indicated by the solid line in FIG. 8A , the first local oscillation signal SLO is set to a predetermined frequency fL which is lower than those of the signals A 12 and A 3 . Therefore, as shown in FIG. 8B , the signal A 12 is frequency-converted into a first intermediate frequency signal SIF 12 (at intermediate frequency fIF 12 ), the signal A 3 is frequency-converted into a first intermediate frequency signal SIF 3 (at intermediate frequency fIF 3 ), and the signals B 12 and B 3 are frequency-converted into first intermediate frequency signals SIF 45 and SIF 6 , respectively.
When the image rejection characteristics are taken into consideration, the first intermediate frequencies fIF 12 and fIF 3 cannot be decreased too much, and since a frequency band of 2.3 GHz is used in a broadcast, the first intermediate frequencies fIF 12 and fIF 3 are set to 100 MHz or higher. For example, the following are set:
fIF 12 is approximately 113 MHz, and fIF 3 is approximately 116 MHz
Also, when the ensemble B is to be listened to (when the signals B 1 to B 3 are subjects to be received), as indicated by the broken line in FIG. 8A , the first local oscillation signal SLO is set to a predetermined frequency fH which is higher than those of the signals B 12 and B 3 . Therefore, as shown in FIG. 8C , the signal B 12 is frequency-converted into a first intermediate frequency signal SIF 12 (at intermediate frequency fIF 12 ), the signal B 3 is frequency-converted into a first intermediate frequency signal SIF 3 (at intermediate frequency fIF 3 ), and the signals A 12 and A 3 are frequency-converted into first intermediate frequency signals SIF 45 and SIF 6 , respectively.
Therefore, when any one of the ensembles A and B is to be listened to, the intermediate frequency signals SIF 12 to SIF 6 are supplied to a band-pass filter 21 L for a first intermediate-frequency filter, whereby an intermediate frequency signal SIF 12 is extracted. Then, this signal is supplied to a second mixer circuit 22 L, a second local oscillation signal having a predetermined frequency is provided from a second local oscillation circuit 23 , and this signal is supplied to the mixer circuit 22 L, whereby the signal SIF 12 is frequency-converted into a second intermediate frequency signal. Then, this signal is supplied to a demodulation circuit 25 L via a variable gain amplifier 24 L for AGC (Automatic Gain Control), whereby a digital audio signal of the target program is demodulated, and this signal is supplied to a selecting/combining circuit 26 .
Also, the signals SIF 12 to SIF 6 from the first mixer circuit 14 is supplied to a band-pass filter 21 H for a first intermediate frequency filter, whereby the intermediate frequency signal SIF 3 is extracted. Then, this signal is supplied to a second mixer circuit 22 H, and furthermore, a second local oscillation signal from the second local oscillation circuit 23 is supplied to the mixer circuit 22 H, whereby the signal SIF 3 is frequency-converted into a second intermediate frequency signal. Then, this signal is supplied to a demodulation circuit 25 H via a variable gain amplifier 24 H for AGC, whereby a digital audio signal of the target program is demodulated, and this signal is supplied to the selecting/combining circuit 26 .
Then, in the selecting/combining circuit 26 , the signal from the demodulation circuit 25 L and the signal from the demodulation circuit 25 H are selected or combined, and is output at an output terminal 27 .
Therefore, as a result of switching the frequency of the first local oscillation signal SLO to a frequency fL or a frequency fH, a digital signal of the ensemble A or a digital signal of the ensemble B is output at the terminal 27 .
Then, at that time, when the ensemble A is received, since the digital signal demodulated from the received signal A 12 and the digital signal demodulated from the received signal A 3 are selected or combined, and is taken out at the terminal 27 , a digital signal having a small amount of error can be obtained regardless of the receiving conditions. Furthermore, also when the ensemble B is received, a digital signal having a small amount of error can be obtained regardless of the receiving conditions for the same reasons.
However, in the above-described receiver, when the ensemble is switched from the ensemble A to the ensemble B, it is necessary to change the frequency of the first local oscillation signal SLO from the frequency fL to the frequency fH. That is, as is also clear from FIGS. 8A to 8C , it is necessary to change the frequency of the first local oscillation signal SLO to a frequency larger than the occupied bandwidth 12.5 MHz of the services of the signals A 1 to A 3 and B 1 to B 3 . Also, the same applies to a case in which the ensemble is changed from the ensemble B to the ensemble A.
The amount of change of this frequency is equal to or more than 10% of the frequencies fL and fH. Moreover, when the first local oscillation circuit 15 is formed by a PLL (Phase-Locked Loop), it is necessary to allow for some margin with respect to the range of change of the oscillation frequency of the VCO (Voltage Controlled Oscillator) of the PLL. For this reason, it is necessary to increase the range of change of the oscillation frequency of the VCO by making the resonance device of the VCO changeable. As a result, the construction becomes complex, and the phase noise characteristics of the local oscillation signal SLO deteriorate, causing the error rate of the digital signal to become worse.
Also, as long as the first local oscillation circuit 15 is formed by a PLL, it takes time to change the frequency, and the ensemble cannot be received during that change.
In addition, the first intermediate frequencies fIF 12 and fIF 3 are increased to 100 MHz or higher in the above-described manner, and as shown in FIGS. 8B and 8C , it is necessary for the filters 21 L and 21 H to extract the first intermediate frequency signals SIF 12 and SIF 3 from within the crowded signals. As a result, the filters 21 L and 21 H are formed by an SAW (Surface Acoustic Wave) filter. For this reason, the cost increases, and when the circuit is formed into an IC (integrated circuit), the SAW filter must be provided externally. Furthermore, this becomes an obstacle to the reduction in size of the receiver.
Also, when the demodulation of the demodulation circuits 25 L and 25 H is to be performed by a digital process, an intermediate frequency signal supplied to the demodulation circuits 25 L and 25 H must be formed into a frequency at which a digital process is possible. For this purpose, as is also shown in FIG. 7 , for the receiving method, a double conversion method must be used, the construction becomes complex, and the number of parts is increased.
SUMMARY OF THE INVENTION
The present invention aims to solve such problems as those described above.
Accordingly, an object of the present invention is to provide a receiving device comprising: a receiving circuit for receiving a first signal and a second signal which are transmitted at mutually different frequencies; a circuit for forming-first and second local oscillation signals, whose frequencies are both the center frequency between the first signal and the second signal, and whose phases differ by 90° from each other; a first mixer circuit for frequency-converting the received signal received by the receiving circuit into a first intermediate frequency signal in accordance with the first local oscillation signal; a second mixer circuit for frequency-converting the received signal received by the receiving circuit into a second intermediate frequency signal in accordance with the second local oscillation signal; a first phase-shift circuit to which the first intermediate frequency signal is supplied; a second phase-shift circuit to which the second intermediate frequency signal is supplied, in which the amount of the phase shift differs by 90° from that of the first phase-shift circuit; and an addition/subtraction circuit for performing one of addition and subtraction between the output signal of the first phase-shift circuit and the output signal of the second phase-shift circuit, wherein, by switching the process in the addition/subtraction circuit to the addition or the subtraction, the intermediate frequency signal corresponding to the first signal or the intermediate frequency signal corresponding to the second signal is selectively extracted from the addition/subtraction circuit.
Therefore, while the local oscillation frequency is being fixed, the first signal or the second signal is selected.
In particular, a receiving device is provided which is suitable for a case in which each of the first and second signals is formed of a signal of a plurality of programs, and the signals of individual programs are transmission programs which are arranged according to frequency symmetrically with respect to the center frequency.
More specifically, when the ensemble is to be switched, since the frequency of the local oscillation signal does not need to be changed, the local oscillation circuit does not become complex. Also, the deterioration of the phase noise characteristics of the local oscillation signal, and the deterioration of the error rate of the digital signal do not occur. Furthermore, when the ensemble is to be switched, the switching can be performed easily at high speed, and the problem where the ensemble cannot be received during the switching, like when the local oscillation frequency is to be changed, does not occur.
Another object of the present invention is to provide a reception integrated circuit which is suitable for constructing the above-described receiving device. According to the integrated circuit of the present invention, in addition to the above-described features, the intermediate-frequency filter can be formed by an active filter, and can be integrally formed into a one-chip IC with other circuits. This is effective in reducing the cost and the size of the receiver. Furthermore, even when demodulation is to be performed by a digital process, a single conversion may be used for the receiving method, the construction becomes simple, and the number of parts is decreased.
The above and further objects, aspects and novel features of the invention will become more fully apparent from the following detailed description when read in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram showing an embodiment of the present invention;
FIGS. 2A , 2 B, and 2 C are frequency spectrum diagrams illustrating the present invention;
FIG. 3 is a block diagram showing another embodiment of the present invention;
FIG. 4 is a circuit diagram showing a part of the other embodiment of the present invention;
FIG. 5 is a circuit diagram showing a part of the other embodiment of the present invention;
FIG. 6 is a frequency spectrum diagram illustrating DARS;
FIG. 7 is a block-diagram showing the present invention; and
FIGS. 8A , 8 B, and 8 C are frequency spectrum diagrams illustrating the circuit of FIG. 7 .
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 shows an example of a DARS receiving circuit according to the present invention, in which a portion 30 surrounded by a one-dot chain line is formed into a one-chip IC. Signals A 1 to A 3 , and B 1 to B 3 are received by an antenna 51 , and the received signals A 1 to B 3 are supplied to mixer circuits 32 I and 32 Q via a band-pass filter 52 , which is formed of, for example, an SAW filter and which has a passing bandwidth of 12.5 MHz and furthermore via a high-frequency amplifier 31 .
In a local oscillation circuit 33 , as shown in FIG. 2A , an oscillation signal SLO having a frequency equal to the center frequency fC between the signal A 3 and the signal B 3 is formed, this signal SLO is supplied to a phase processing circuit 34 , whereby two local oscillation signals SLI and SLQ, whose phases differ by 90° from each other, with the frequency being kept at the value fC, are formed, and these signals SLI and SLQ are supplied to the mixer circuits 32 I and 32 Q, respectively.
In the following description, for brevity of explanation, it is assumed that, as shown in FIG. 2A , the signal SA represents each of the signals A 1 to A 3 , and the signal SB represents each of the signals B 1 to B 3 . That is, it is assumed that SA=A 1 , SA=A 2 , or SA=A 3 , and that SB=B 1 , SB=B 2 , or SB=B 3 . Then, it is arranged that:
SA=EA ·sin ω At
SB=EB ·sin ω Bt
where EA is the amplitude of the signal SA, EB is the amplitude of the signal SB, ωA is the angular frequency of the signal SA, and ωB is the angular frequency of the signal SB.
Also, it is arranged that:
SLI=EL ·sin ω Ct
SLQ=EL ·cos ω Ct
where EL is the amplitude of the signals SLI and SLQ, and ωC=2πfC.
Then, from the mixer circuits 32 I and 32 Q, signals SIFI and SIFQ as described below are extracted:
SIFI = ( SA + SB ) × SLI = EA · sin ω At × EL · sin ω Ct + EB · sin ω Bt × EL · sin ω Ct = α { cos ( ω A - ω C ) t - cos ( ω A + ω C ) t } + β { cos ( ω B - ω C ) t - cos ( ω B + ω C ) t } SIFQ = ( SA + SB ) × SLQ = EA · sin ω At × EL · cos ω Ct + EB · sin ω Bt × EL · cos ω Ct = α { sin ( ω A + ω C ) t + sin ( ω A - ω C ) t } + β { sin ( ω B + ω C ) t + sin ( ω B - ω C ) t }
where α=EA·EL/2, and β=EB·EL/2
As will be described later, of the signals SIFI and SIFQ, the signal components of angular frequencies (ωA−ωC) and (ωB−ωC) are used as the intermediate frequency signals, and the signal components of angular frequencies (ωA+ωC) and (ωB+ωC) are removed by the intermediate frequency filter. Therefore, for the sake of simplicity, if the signal components of angular frequencies (ωA+ωC) and (ωB+ωC) to be removed are ignored, the above equations become:
SIFI =α·cos(ω A−ωC ) t +β·cos(ω B−ωC ) t
SIFQ =α·sin(ω A−ωC ) t +β·sin(ω B−ωC ) t
Here, if it is arranged that ωA=ωC−Δω with regard to the signal SA, since, as is also shown in FIG. 2A , the signal SA and the signal SB are symmetrically distributed about the frequency fC, the following equation holds:
ω B=ωC+Δω
Then, if these equations are substituted in the equations for the signals SIFI and SIFQ, the following equations are obtained:
SIFI = α · cos ( ω C - Δ ω - ω C ) t + β · cos ( ω C + Δ ω - ω C ) t = α · cos ( - Δ ω ) t + β · cos Δ ω t = α · cos Δ ω t + β · cos Δ ω t SIFQ = α · sin ( ω C - Δ ω - ω C ) t + β · sin ( ω C + Δ ω - ω C ) t = α · sin ( - Δ ω ) t + β · sin Δ ω t = - α · sin Δ ω t + β · sin Δ ω t
These signals SIFI and SIFQ are then supplied to phase-shift circuits 35 I and 35 Q. The phase-shift circuits 35 I and 35 Q are formed by an active filter in which, for example, a capacitor, a resistor, and an operational amplifier are used. The phase-shift circuit 35 I phase-shifts the signal SIFI by a value φ (φ is an arbitrary value), and the phase-shift circuit 35 Q phase-shifts the signal SIFQ by a value (φ+90°).
In this manner, the phase-shift circuits 35 I and 35 Q cause the signal SIFQ to lead the signal SIFI by 90°, and the following equations hold:
SIFI = α · cos Δ ω t + β · cos Δ ω t SIFQ = - α · sin ( Δ ω t + 90 ° ) + β · sin ( Δ ω t + 90 ° ) = - α · cos Δ ω t + β · cos Δ ω t
Therefore, between the signal SIFI and the signal SIFQ, the signal components α·cos Δωt are at the opposite phase from each other, and the signal components β·cos Δωt are in phase.
These signals SIFI and SIFQ are then supplied to an addition/subtraction circuit 36 , and a control signal SSW is supplied from a terminal 37 to the addition/subtraction circuit 36 . This control signal SSW controls the operation of the addition/subtraction circuit 36 in such a way that when the program of the ensemble A is to be listened to, the addition/subtraction circuit 36 acts as a subtraction circuit, and when the program of the ensemble B is to be listened to, the addition/subtraction circuit 36 acts as an addition circuit.
Therefore, a signal SIF such as that described below is extracted from the addition/subtraction circuit 36 in such a manner as to correspond to the control signal SSW. That is, during subtraction, the following is extracted:
SIF = SIFI - SIFQ = 2 α · cos Δ ω t = EL · EA · cos Δ ω t ,
and during addition, the following is extracted:
SIF = SIFI + SIFQ = 2 β · cos Δ ω t = EL · EB · cos Δ ω t
Here, the signal SIF=EL·EA·cos Δωt which is obtained during subtraction is, as is also shown in FIG. 2B , the same intermediate frequency signal when the signal SA is received. The signals SIF 1 to SIF 3 contained in this signal SIF are the intermediate frequency signals of the signals A 1 to A 3 . Also, the signal SIF=EL·EB·cos Δωt which is obtained during addition is, as is also shown in FIG. 2C , the same intermediate frequency signal when the signal SB is received. The signals SIF 1 to SIF 3 contained in this signal SIF are the intermediate frequency signals of the signals B 1 to B 3 .
Therefore, this signal SIF is supplied to a band-pass filter 41 H for an intermediate-frequency filter having passing characteristics such as those indicated by the broken line in, for example, FIGS. 2B and 2C , whereby an intermediate frequency signal SIF 3 of a terrestrial-wave signal A 3 or B 3 is extracted. At this time, the intermediate frequency signals SIF 1 and SIF 2 and the above-mentioned signal components of angular frequencies (ωA+ωC) and (ωB+ωC) are removed by the band-pass filter 41 H.
Then, this intermediate frequency signal SIF 3 is supplied to a demodulation circuit 43 H via a variable gain amplifier 42 H for AGC, whereby a digital audio signal of the target program is demodulated, and this signal is supplied to a selecting/combining circuit 44 .
Also, the signal SIF from the addition/subtraction circuit 36 is supplied to a band-pass filter 41 L for an intermediate-frequency filter having passing characteristics such as those indicated by the broken line in, for example, FIGS. 2B and 2C , whereby intermediate frequency signals SIF 2 and SIF 1 of the satellite-wave signals A 1 and A 2 , or B 1 and B 2 are extracted. At this time, the intermediate frequency signal SIF 3 and the above-mentioned signal components of angular frequencies (ωA+ωC) and (ωB+ωC) are removed by the filter 41 L.
Then, these intermediate frequency signals SIF 2 and SIF 1 are supplied to a demodulation circuit 43 L via a variable gain amplifier 42 L for AGC, whereby a digital audio signal of the target program is demodulated, and this signal is supplied to the selecting/combining circuit 44 .
Then, in the selecting/combining circuit 44 , the digital signal from the demodulation circuit 43 H and the digital signal from the demodulation circuit 43 L are selected or combined according to the received status of the signals A 1 to B 3 , and is extracted at an output terminal 45 . Of course, when it is desired to give priority to a receiving environment of a mobile unit in which the receiver is mounted and to satellite-wave reception, the AGC voltage obtained from the level detection circuit 46 L may be supplied as a gain control signal.
At this time, parts of the intermediate frequency signals from the demodulation circuits 43 H and 43 L are supplied to level detection circuits 46 H and 46 L, whereby AGC voltages are formed, and these AGC voltages are supplied, as gain control signals, to the amplifiers 42 H and 42 L, whereby AGC is performed.
In addition, although the level variation of the satellite wave is relatively small, the level variation of the terrestrial wave is relatively large. Therefore, for the high-frequency amplifier 31 , a variable gain amplifier is used, and the AGC voltage obtained from the level detection circuit 46 H is supplied, as a gain control signal, to the amplifier 31 , whereby AGC is performed.
In this manner, according to the receiving circuit of FIG. 1 , a broadcast by DARS can be received, and in a case where the ensemble is switched between the ensemble A and the ensemble B, the frequency fC of the local oscillation signals SLI and SLQ does not need to be changed. Consequently, the local oscillation circuit 33 may be formed in a standard construction and does not become complex. Also, since the phase noise characteristics of the local oscillation signals SLI and SLQ are not decreased, the error rate of the digital signal does not become worse.
In addition, when the ensemble is to be switched, the addition/subtraction circuit 36 need only be switched to an addition operation or a subtraction operation. Consequently, the switching can be performed at high speed, and the problem of not being able to receive the ensemble during switching time does not occur.
As is also clear from FIGS. 2B and 2C , since the upper-limit frequency of the occupied bandwidth of the intermediate frequency signal SIF is equal to a half of the bandwidth of one ensemble, and the center frequencies of the filters 41 H and 41 L become approximately 1.3 MHz and 4.4 MHz, it is possible to form each of the filters 41 H and 41 L by an active filter. Therefore, it is possible to form the entirety into a one-chip IC as an IC 30 , excluding a band-pass filter 52 at the antenna input stage, and this is effective in reducing the costs and the size of the receiver.
In addition, since the intermediate frequency of the intermediate frequency signals SIF 3 to SIF 1 is as low as several MHz, even when the demodulation of the demodulation circuits 43 H and 43 L is performed by a digital process, as shown in, for example, FIG. 1 , for the receiving method, a single conversion may be used, the construction becomes simple, and the number of parts is decreased.
In the receiving circuit shown in FIG. 3 , a case is shown in which, by inverting or non-inverting the phase of the local oscillation signal SLQ when the ensemble A is received and when the ensemble B is received, the signals SIFI and SIFQ are always added together.
More specifically, in the receiving circuit in FIG. 3 , the control signal SSW is supplied as a phase control signal to the phase processing circuit 34 , so that the phase of the local oscillation signal SLQ is controlled such that:
SLQ=+EL·cos ωCt . . . when the ensemble B is received, and
SLQ=−EL·cos ωCt . . . when the ensemble A is received.
The phase of the local oscillation signal SLI is fixed, as described above:
SLI=EL ·sin ω Ct
In place of the addition/subtraction circuit 36 in FIG. 1 , an addition circuit 38 is provided, and the signals SIFI and SIFQ output from the phase-shift circuits 35 I and 35 Q are supplied to the addition circuit 38 .
According to such a construction, in the case of SLQ=+EL·cos ωCt, in the addition circuit 38 , the signal SIFI and the signal SIFQ are added together. Therefore, as is described with reference to the receiving circuit of FIG. 1 , the signal SIF extracted from the addition circuit 38 becomes as follows:
SIF = SIFI + SIFQ = EL · EB · cos Δ ω t
Therefore, it is possible to listen to the program of the ensemble B.
On the other hand, in the case of SLQ=−EL·cos ωCt, the output signal of the phase-shift circuit 35 Q becomes the signal −SIFQ. Therefore, since, in the addition circuit 38 , subtraction between the signal SIFI and the signal SIFQ is performed, as is described with reference to the receiving circuit of FIG. 1 , the signal SIF extracted from the addition circuit 38 becomes:
SIF = SIFI - SIFQ = EL · EA · cos Δ ω t
Therefore, it is possible to listen to the program of the ensemble A.
In this way, also in the receiving circuit of FIG. 3 , a DARS broadcast can be received. In particular, according to the receiving circuit of FIG. 3 , in a case where the ensemble is switched between the ensemble A and the ensemble B, it is only necessary to invert or non-invert the phase of the local oscillation signal SLQ by the phase processing circuit 34 . Therefore, the ensemble can be switched quickly. Also, since the phase-shift circuits 35 I and 35 Q and the addition circuit 38 can be formed by a poly-phase filter, the phase characteristics of the signal SIFI and the signal SIFQ can be improved.
In FIG. 4 , a case is shown in which the phase of the intermediate frequency signal SIFI is constant regardless of the ensemble which is received, but the phase of the intermediate frequency signal SIFQ is inverted or non-inverted between when the ensemble A is to be received and when the ensemble B is to be received.
More specifically, the mixer circuit 32 Q is formed as a double balanced-type by transistors Q 321 to Q 327 . The received signals A 1 to A 3 and B 1 to B 3 are extracted as a balanced type from the amplifier 31 and are supplied to transistors Q 322 and Q 323 . Furthermore, the local oscillation signal SLQ is extracted as a balanced type from the phase processing circuit 34 and is supplied to transistors Q 324 , Q 327 , Q 325 , and Q 326 .
Consequently, the intermediate frequency signal SIFQ is extracted as a balanced type from the mixer circuit 32 Q. That is, for example, the intermediate frequency signal +SIFQ is extracted from the transistors Q 324 and Q 326 , and the intermediate frequency signal −SIFQ is extracted from the transistors Q 325 and Q 327 .
Then, these intermediate frequency signal ±SIFQ are supplied to a switching circuit 39 . This switching circuit 39 is formed as a balanced type by transistors Q 391 to Q 397 , and the intermediate frequency signals ±SIFQ which are supplied thereto are supplied to a phase-shift circuit 36 Q in accordance with the control signal SSW with the phase kept as it is or with the phase being inverted.
More specifically, based on the control signal SSW, when the transistor Q 395 is on and transistor Q 396 is off, the transistors Q 392 and Q 393 are turned on, and the transistors Q 391 and Q 394 are turned off. Therefore, the intermediate frequency signal +SIFQ extracted from the transistors Q 324 and Q 326 is supplied to one of the balance input terminals of the phase-shift circuit 36 Q via the transistor Q 392 . Also, the intermediate frequency signal −SIFQ extracted from the transistors Q 325 and Q 327 is supplied to the other one of the balance input terminals of the phase-shift circuit 36 Q via the transistor Q 393 .
However, based on the control signal SSW, when the transistor Q 396 is on and the transistor Q 395 is off, the transistors Q 391 and Q 394 are turned on, and the transistors Q 392 and Q 393 are turned off. Therefore, the intermediate frequency signal +SIFQ extracted from the transistors Q 324 and Q 326 is supplied to the other one of the balance input terminals of the phase-shift circuit 36 Q via the transistor Q 391 . Also, the intermediate frequency signal −SIFQ extracted from the transistors Q 325 and Q 327 is supplied to one of the balance input terminals of the phase-shift circuit 36 Q via the transistor Q 394 .
Therefore, since the phase of the intermediate frequency signal SIFQ supplied to the phase-shift circuit 36 Q is inverted or non-inverted in accordance with the control signal SSW, the intermediate frequency signal SIF of the ensemble A or the ensemble B is output from the addition circuit 38 . In this case, since the phase of the intermediate frequency signal SIFQ need only be inverted or non-inverted by the switching circuit 39 , it is possible to quickly switch the ensemble.
Although the phase of the intermediate frequency signal SIFI is kept fixed, the intermediate frequency signal SIFI output from the mixer circuit 32 I may be supplied to a phase-shift circuit 36 I via a switching circuit having the same construction as that of the switching circuit 39 , and the switching circuit may be kept fixed.
FIG. 5 shows a circuit 34 Q of a portion which switches the phase of the local oscillation signal SLQ within the phase processing circuit 34 in FIG. 3 . That is, the mixer circuit 32 Q is formed as a double balance-type as described in FIG. 4 , and the received signals A 1 to A 3 and B 1 to B 3 are extracted as a balanced type and are supplied to the transistors Q 322 and Q 323 .
Furthermore, the switching circuit 34 Q is formed as a double balanced-type by the transistors Q 341 to Q 347 . The local oscillation signal +SLQ of one of the phases is supplied to the transistors Q 345 and Q 346 , and the local oscillation signal −SLQ of the other phases is supplied to the transistors Q 344 and Q 347 . Also, the balanced-type control signal SSW is supplied to the transistors Q 342 and Q 343 .
Then, based on the control signal SSW, when the transistor Q 342 is on and the transistor Q 343 is off, the transistors Q 344 and Q 345 are turned on, and the transistors Q 346 and Q 347 are turned off. Therefore, the local oscillation signal +SLQ is supplied to the transistors Q 324 to Q 327 via the transistor Q 345 and further via the emitter-follower transistor Q 349 . Also, the local oscillation signal −SLQ is supplied to the transistors Q 325 and Q 326 via the transistor Q 344 and further via the emitter-follower transistor Q 348 .
However, based on the control signal SSW, when the transistor Q 343 is on and the transistor Q 342 is off, the transistors Q 346 and Q 347 are turned on, and the transistors Q 344 and Q 345 are turned off. Therefore, the local oscillation signal +SLQ is supplied to the transistors Q 325 and Q 326 via the transistor Q 346 and further via the transistor Q 348 . Also, the local oscillation signal −SLQ is supplied to the transistors Q 324 and Q 327 via the transistor Q 347 and further via the transistor Q 349 .
Therefore, since the phase of the local oscillation signal SLQ supplied to the mixer circuit 32 Q is made to lead or reversed in accordance with the control signal SSW, the intermediate frequency signal SIF of the ensemble A or the ensemble B is output from the addition circuit 38 . Also in this case, since the phase of the local oscillation signal SLQ need only be inverted or non-inverted by the switching circuit 34 Q, the ensemble can be switched quickly.
Many different embodiments of the present invention may be constructed without departing from the spirit and scope of the present invention. It should be understood that the present invention is not limited to the specific embodiments described in this specification. To the contrary, the present invention is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the invention as hereafter claimed. The scope of the following claims is to be accorded the broadest interpretation so as to encompass all such modifications, equivalent structures and functions.
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In order to improve various characteristics of a receiving circuit for digital radio services, circuits are provided for forming two local oscillation signals, whose frequencies are both the center frequency between a first ensemble and a second ensemble, and whose phases differ by 90° from each other. Furthermore, there are provided mixer circuits for frequency-converting the received signal into intermediate frequency signals in accordance with the local oscillation signals, phase-shift circuits to which the intermediate frequency signals are supplied, and an addition/subtraction circuit for performing one of addition and subtraction of the outputs of the phase-shift circuits. In addition, there are provided intermediate frequency filters to which the output signal of the addition/subtraction circuit is supplied and demodulation circuits to which the output signals of the intermediate frequency filters are supplied. By switching the process in the addition/subtraction circuit to addition or subtraction, the signals of the first ensemble and the second ensemble are selectively extracted from the demodulation circuits.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
This invention relates to surface treatments for textiles and paper products for imparting resistance to impregnation by liquid to the treated materials, and in particular is directed to gas plasma treatments for that purpose.
2. State of the Prior Art
The production of high quality textiles or paper calls for efficient methods for imparting soil-resistance to the textile or paper materials. Polymer surface coatings have been used to this end. Currently practiced methods of coating a paper surface with such a film involve at least seven distinct stages:
synthesis of a monomer;
polymerization of the monomer with formation of intermediate or end polymer;
preparation of a film forming solution;
cleaning of the surface or application of a bonding agent to the surface;
application of the coating;
drying of the coating;
solidification of the coating.
The basic disadvantages of these methods include the large number of stages involved in the process as well as unevenness and excessive thickness of the resultant coating, which leads to a change in the appearance of the treated material.
Japanese patent 63-75002 describes treatment in an impulse or pulsed discharge in an atmosphere comprising the gases CH 4 , C 2 H 6 or C 4 H 10 for increasing the durability and thermal stability of ferromagnetic layers of magnetic tapes. This method cannot be applied to fabrics because the film formed during the process changes the appearance of the treated surface.
Another prior method of achieving film plasma polymerization, described in U.S. Pat. No. 4,188,426, includes treatment in a glow discharge of per-fluoro-cyclo-butane or hexafluoroethane to reduce the friction coefficient and to improve the surface hydrophobia of organic and inorganic substrates (e.g. polyethylene films, metals). This method also cannot be applied to fabrics because the film formed during the process changes the appearance of the treated surface. In addition, the use of fluoro containing monomers is contraindicated by ecological considerations.
A known method of water and oil repellent finishing of textiles, described in USSR Patent 1,158,634, includes plasma treatment in a glow discharge in an atmosphere of inorganic gases, followed by treatment with a fluoro containing acrylic monomer in gas phase. The first stage of the process can cause additional destruction of archival documents when the documents interact with the gas that creates the plasma. The second stage forms too rough a film.
Another prior method of plasma formation of a thin film on the surface of polymer material, described in Japanese Patent 62-132940, includes:
1. plasma treatment in a glow discharge in an atmosphere of H 2 ,CO,N 2 ,O 2 gases;
2. plasma polymerization; and
3. treatment in hydrogen plasma.
The first stage is used to improve adhesion of the film surface for the subsequent polymerization stage. This first stage lasts from 20 sec to 30 minutes of time and can cause additional destruction of archive documents when the documents interact with the gas that creates the plasma.
A prior method described in USSR patent 642550 for treatment of rubber articles includes, treatment in a glow discharge; immersion in an emulsion of polytetra-fluoro-ethylene; and treatment by glow discharge. The application of fluoro-containing monomers is an ecologically detrimental feature of this method.
Japan patent 62-260836 describes a surface plasma polymerization treatment of glass or synthetic sponges, including treatment in a glow discharge in an atmosphere of nitroethane or nitropropane. This method cannot be applied fabrics or paper because the film formed by the process changes the appearance of the treated surface. Also, use of nitro-compounds is ecologically undesirable.
Patents of Japan 62-132940; EPW--Japan, 0177364; Japan, 61-221236; Japan; and USSR 1158634 describe pretreatment of materials in a plasma of inorganic gas for 40 sec. to 20 minutes to purify and activate surfaces for subsequent processing. As a result, polymer films deposited by a subsequent polymerization stage adhere better to the treated material surfaces. However, in some instances satisfactory treatment results require discharge power levels which are harmful or destructive to the material being treated.
A prior method of depositing a thin surface film by a plasma polymerization process (Japanese patent 62-132940) includes treatment in a glow discharge of H 2 , CO, N 2 or O 2 at p=0.05-5 Torr, t=30 sec--20 min, power 5-50 KWt; then a plasma polymerization stage, followed by plasma treatment in hydrogen. The film obtained by this method is characterized by improved durability, but changes the appearance of the treated surface and physico-mechanical properties of materials.
Japanese patent 61-22136 discloses a method of surface preparation before coating of polyolefine articles which includes the steps of treatment by a fluoro-organic solvent, staining in a glow discharge of oxygen, and coating. The film obtained by this method is characterized by improved strength to peeling and water resistance. Use of fluoro-containing solvent however is an ecologically undesirable feature of this method.
What is needed is a method for imparting liquid resistant surface properties to fabrics and paper products which do not alter the appearance nor physically damage the treated material, which involves a minimum of processing of the item, which can be safely used on various materials, which is not ecologically damaging, and which is simple and dependable.
SUMMARY OF THE INVENTION
The present invention is an improved method for applying a durable water and oil-repellent finish to textile fabrics, fibers and paper materials. The finish obtained includes a thin polymer coating formed by plasma polymerization on the surface of the material. The polymer coating does not alter the appearance nor the physical and mechanical properties of the treated materials.
The novel method includes a first, surface preparation and activation stage before the second or plasma polymerization stage. The surface of the subject material is first treated in a low temperature plasma of an inorganic gas, preferably oxygen gas. The concentration of active components in the plasma is increased by addition of water vapor at a concentration is between 0.05 and 0.5% to the oxygen gas, resulting in superior activation and preparation of the surfaces with shortened treatment times as compared to treatment with dry gas. This makes the activation process more economical and commercially attractive.
According to this improved method, textile fabrics and paper products are exposed to a low temperature plasma of methane gas at a pressure of between 0.01 and 10 Torr, input power generator frequency of 1-40 MHz at a specific discharge power of 0.003 to 3.0 Wt/cm 3 , for 30 sec to 3600 sec The materials may be first exposed to a low pressure oxygen plasma before exposure to the methane gas plasma. Water vapor to a concentration of between 0.05 to 0.5% may be added to the oxygen plasma. Exposure to the oxygen plasma takes place at a pressure of 0.01 to 10 Torr, with input power generator frequency of 1 to 40 MHz at specific discharge power of 0.003 to 3.0 Wt/cm 3 , for a treatment time ranging from 3.0 sec to 60 sec.
The presently preferred method for imparting water and oil repellent surface properties to materials including textile fabrics and paper products comprises the steps of first exposing the materials to a low pressure oxygen plasma including water vapor at a concentration of between 0.05 to 0.5%, at a pressure of 0.01-10 Torr, input power generator frequency of 1 to 40 MHz with specific discharge power of 0.003 to 3.0 Wt/cm 3 , for a treatment time ranging from 3.0 sec to 60 sec; and then exposing the materials to a low temperature plasma of methane gas at a pressure of between 0.01 and 10 Torr, input power generator frequency of 1 to 40 MHz at a specific discharge power of 0.003 to 3.0 Wt/cm 3 for 30 sec to 3600 sec.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic illustration of a low pressure gas plasma chamber for use in material treatment according to the improved processes of this invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
The novel method includes a first, surface preparation and activation stage and a second, plasma polymerization stage.
The surface of the subject material is first treated in a low temperature oxygen plasma. Atomic oxygen, ozone and other highly reactive particles are formed in an oxygen plasma. The concentration of these components determines the speed and depth of the surface activation and treatment process. The addition of water vapor has been found to intensify the surface activation process in inorganic gas plasmas when water vapor concentration is between 0.05 and 0.5%. A further increase in water vapor concentration however is counterproductive as it hinders the surface activation process and can lead to extinction of the glow discharge.
Addition of water vapor in concentrations of 0.05-0.5% during the pretreatment stage has been found to achieve activation of the surfaces of the subject material, before polymerization, at a lower specific power of the gas discharge and in a shorter time than with dry gas. In addition, after polymerization, the wetting angle is increased and surface energy of the treated material is decreased, and stronger bonding of the polymer film occurs, so that the polymer films do not separate from the substrate material even following prolonged immersion in water.
The plasma polymerization generally includes processes occurring in the gaseous phase (i.e., in the plasma volume), and processes taking place on the surface being treated. In electrical glow discharges generated under low pressure, the main activation process involves collisions of free electrons accompanied by dissociation of the monomer:
CH.sub.4 +e→CH.sub.3 +H+e
CH.sub.4 +e→CH.sub.2 +H.sub.2 +e
and by ionization of the formed free radicals:
CH.sub.3 +e→CH.sub.3 +2e
CH.sub.3 +e→CH.sub.2 +2e
Under low pressure conditions the main recombination process involves surface phenomena. Energy is released in the course of recombination, including kinetic energy of the ions and the ionization energy of the same. The energy released leads to the formation of so-called growth centers on the surface being treated:
surface e+CH.sub.3.sup.+ →CH.sub.3 +growth center
Formation of polymer film on the surface can be described by the following reactions:
Growth center+CH.sub.3 →polymer
Growth center+CH.sub.2 →polymer+growth center
Formation of the polymer can be understood to include formation of the building blocks in the gas phase, and completion of polymer formation on the surface being treated.
Use of methane as the sole starting monomer in the plasma polymerization stage leads to formation of a polymer film consisting of considerably branched carbon chains, which results in advantageous surface film properties. It is important to this type of treatment that the new surface characteristics obtained be stable over long periods of time. Films formed by methane plasma polymerization are characterized by high adhesion to the substrate. This is attributed to the absence of reaction capable groups in methane, which results in the plasma polymerization proceeding at a relatively slow rate. Films formed by methane plasma polymerization are further characterized by low permeability to air and water, and strong hydrophobic properties. For a 1000 Angstrom film thickness, the permeability is 7.57×10 -13 cm 3 /cm 2 sek.cm.h.c. That is significantly lower than the permeability of polymer films obtained by conventional methods (polyethylene--9×10 -9 ; polyvinilchloride--5×10 -11 ).
The gas plasmas used in this treatment process are generated in a low pressure glow discharge. A main characteristic of this type of plasma is its non-isotermicity: Te>>Ti=Tg, where
Te--temperature of electrons,
Ti--temperature of ions,
Tg--temperature of gas.
Typically: Te=30,000K; ; Tg=375K
The apparatus employed for the low pressure plasma treatment is schematically illustrated in FIG. 1 of the attached drawing. The plasma treatment is as follows. Material to be processed, indicated by the numeral 1, is placed in a vacuum chamber 2. Three gas bottles 4, separately containing the gases used in the process, are connected through suitable valves and conduits to the chamber 2. The chamber 2 is evacuated by means of vacuum pump 3 until the interior pressure of chamber 2 reaches 0.01 Torr. The vacuum system then is flushed with oxygen gas from one of bottles 4, and the chamber is again evacuated. Oxygen gas and water vapor are then fed, in metered amounts, into the system to a pressure from 0.01 to 10.00 Torr. Two cylindrical electrodes 6 are mounted to the exterior of the chamber 2 in axially spaced apart relationship. A high frequency electrical power generator 5 connected between the electrodes 6 lights a plasma generating glow discharge in the chamber 2 between the electrodes. The preferred specific power of the discharge is between 0.003 to 3 Wt/cm 3 , and the discharge is sustained for 3 to 60 seconds. Power to the electrodes is then turned off. The chamber 2 is evacuated to a pressure of 0.01 Torr, and the vacuum system is flushed with methane from another of bottles 4. Methane gas is then fed to chamber 2 to a pressure of 0.01 tp 10 Torr. Power is again applied to the electrodes 6 to light the glow discharge. The specific power of the discharge is between 0.003 to 3 Wt/cm 3 , and the discharge is sustained for 30 to 3600 seconds. Both power generator and vacuum pump are then turned off, the chamber 2 is brought to atmospheric pressure, and the treated material 1 is removed from the chamber by opening end closure 7. The cylindrical electrodes may be replaced by electrode plates diametrically opposed on the exterior of the cylindrical chamber 2.
Fabrics and paper treated by this process acquire water and oil repellent properties. It was found that the absorption time for water drops placed on a treated surface is greater than its evaporation time on that surface. The degree of surface activation of treated fabrics can be evaluated by measurement of capillary absorption of the samples, as set forth in Tables 1-3.
Comparison of three types of paper before and after plasma-chemical treatment showed that the strength characteristics of the samples are practically unaffected by the thin polymer layer deposited on their surface. The strength characteristics of treated samples were found substantially unchanged after thermal and ultraviolet aging of the samples. Deformation characteristics of initial and treated paper samples were found to be practically the same. Consequently, application of a thin polymer layer does not affect strength and deformation characteristics of the paper substrate, but leads, however, to virtual loss of capillary absorption of the treated material.
EXAMPLE 1
A 150×150 mm sample of woolen fabric with specific density 495 g/mm is placed in the discharge chamber 2 with external cylindrical electrodes 6. Air is extracted to a pressure of 0.01 Torr. Oxygen with water vapor added to a concentration of 0.1% is fed into the chamber to a pressure of 0.5 Torr. A glow discharge is ignited by supplying high frequency voltage (13.56 MHz) to the electrodes 6 with a specific power discharge of 0.15 Wt/cm 3 . The discharge is extinguished after 30 sec, and gas is evacuated from the chamber to a pressure of 0.01 Torr. This is followed by the introduction of methane into the system a pressure of 0.5 Torr. The glow discharge is again ignited by supplying high frequency voltage (13.56 MHz) to the electrodes with a specific power discharge of 0.15 Wt/cm 3 . The discharge is extinguished after 450 sec.; vacuum pumping is stopped, air is admitted into the system and the sample 1 is taken out of the discharge unit. The sample is then subjected to testing after treatment. The wetting angle measurements were performed within 10 min. after finishing the plasma polymerization treatment.
The oil repellent score of the sample after treatment was measured as 120. A drop of water placed on the sample did not spread after several hours, and gradually evaporated. The sample elongation before break in the wet state of the treated sample was 23.2%, increased from 19% for the dry untreated sample and 21% for the treated sample. Water column resistance increased from 0 to 190 cm after treatment. In other words, the untreated initial sample wets with water and oil practically at once. The treated sample shows water and oil repellent properties.
Separation of the polymer film from the sample material did not occur after the sample was boiled in water for one hour. The mechanical strength and deformation properties of the sample remained unchanged.
EXAMPLE 2
A sample of sulfite paper (containing sizing agents: high-resin glue--0.5%, alumina--0.5%; cooling filler--25%) was placed in the discharge unit 2 with external cylindrical electrodes 6, but specific power of electrical discharge was adjusted to 0.75 Wt/cm 3 (for both stage 1 and 2 of the treatment process, and treatment by plasma polymerization proceeded for 360 sec as in Example 1.
The following properties of the sample were determined in accordance with methods known and accepted in the paper industry:
tensile strength and stretching;
tear resistance;
deformation in wet state;
whiteness of spherical photometer.
Paper durability was estimated according to the stability of its strength characteristics following thermal (@T=100+3 deg. C.) aging for 30 days and exposure to ultra violet radiation on both sides under a UV lamp for 60 min.
Comparison of strength and deformation characteristics of treated paper samples (before and after thermal and UV aging) showed that these characteristics are substantially unaffected by the thin polymer layer, which however leads to virtual loss of capillary absorption of the treated material. Capillary absorption of the untreated sample was 36 mm/10 min. The treated sample had no absorption. The wetting angle of the treated sample was 115 degrees. After the sample was kept in the water for one month neither separation of the film nor change of sample properties occurred.
EXAMPLE 3
A sample of woolen fabric with density 540 g/m 2 was placed in the discharge unit 2 with parallel electrodes diametrically opposed on the chamber exterior, and treated under conditions the indicated in example 2, but the specific power of the electrical discharge was adjusted to 1.5 Wt/cm 3 (for both stage 1 and 2 of the process). The pretreatment or activation stage 1 proceeded for 3 sec. and the polymerization stage 2 proceeded for 120 sec.
The longitudinal elongation before break of a 50×100 mm sample when dry increased, as a result of treatment, from 9.5% (untreated sample) to 11.0%, and from 15.2 (untreated sample) to 16.4% when wet.
Water resistance of the untreated sample was 260 cm in water. Water resistance of the sample treated in plasma was 420 cm in water. A drop of water placed on the sample did not spread over the surface after several hours, gradually evaporating. The oil repellent score was 120. The colors of fabric did not fade after exposure to ultraviolet radiation.
EXAMPLE 4
A sample of newsprint paper (containing sulfate unbleached cellulose--25%, white pulp mass--75%, filler--not more than 5%) was placed in the discharge unit 2 with external cylindrical electrodes 6, and treated under the conditions indicated in example 2, but the frequency of electrical discharge was adjusted to 6.25 MHz.
Mechanical properties of the treated sample were not degraded after thermal and UV aging. Time of absorption of a water drop for the untreated sample was 3 sec. The treated sample showed no capillary absorption. The absorption time for water is greater than its evaporation time on the treated surface. The wetting (contact) angle of water was 110 degrees. After thermal and UV aging these characteristics were unchanged. These surface characteristics of the treated sample do not deteriorate, and the polymer coating on the treated surface does not separate from the sample after immersion of the sample in water.
TABLE 1______________________________________EFFECT OF WATER VAPOR CONCENTRATION ONINTENSITY OF SURFACE ACTIVATION UNDERFIXED TREATMENT CONDITIONS CapillarySpecific Power Time of Treat- AbsorptionWt/cm3 ment Sec (H.sub.2 O) % mm/10 min______________________________________0 initial 0 0 210.3 60 0 240.3 60 0.05 260.3 60 0.1 280.3 60 0.15 300.3 60 0.2 310.3 60 0.3 300.3 60 0.4 270.3 60 0.5 250.3 60 0.6 21______________________________________ The added water vapor activates the plasma process and increases the capillary absorption of the treated sample compared to results obtained b existing methods. As seen from the table, the maximum activation was obtained at (H.sub.2 O) = 0.2 to 0.25% concentration.
TABLE 2______________________________________EFFECT OF TREATMENT TIME ON SURFACEACTIVATION AT MOST EFFICIENT CONCENTRATIONOF WATER VAPOR AND FIXED SPECIFIC POWER CapillarySpecific Time of Absorption at CapillaryPower Treatment (H.sub.2 O) = 0.0 AbsorptionWt/cm3 Sec. mm/10 min (H.sub.2 O), % mm/10 min______________________________________0 initial 0 21 0 210.15 10 21.5 0.2 22.50.15 20 22 0.2 24.50.15 30 22.5 0.2 260.15 40 23 0.2 280.15 50 23.5 0.2 290.15 60 24 0.2 30______________________________________
TABLE 3______________________________________EFFECT OF SPECIFIC POWER OR SURFACEACTIVATION AT MOST EFFICIENTCONCENTRATION OF WATER VAPORAND FIXED TREATMENT TIME CapillarySpecific Time of Absorption CapillaryPower Treatment mm/10 min AbsorptionWt/cm3 Sec at (H.sub.2 O) = 0.0 (H.sub.2 O), % mm/10 min______________________________________0 0 21 0 21initial 0.003 10 21 2.0 230.5 10 21 2.0 251.0 10 22 2.0 26.51.5 10 23 2.0 282.0 10 24 2.0 292.5 10 25 2.0 303.0 10 26 2.0 30.5______________________________________ Addition of water vapor in .05-.5% concentration allows surface activatio before polymerization at a lower specific power and in a shorter time tha activation with dry gas. This makes the activation process more economical.
TABLE 4______________________________________EFFECT OF POLYMERIZATION TREATMENT TIMEON PROPERTIES OF PAPER Time of Capillary ContractSpecific Polymeri- Absorp- Angle ofPower zation tion Water,Wt/cm3 sec. mm/10 min Degrees______________________________________Sulphate 0 0 37 --Paper initial 0.5 15 15 74 0.5 20 5 83 0.5 30 0 106 0.5 60 0 112 0.5 3600 0 108 0.5 3600 0 0.5 3700 0 115______________________________________
TABLE 5______________________________________EFFECT OF SPECIFIC POWER DURING POLYMER-IZATION STAGE ON PROPERTIES OF PAPER ContactTime of Specific Capillary Angle ofPolymeriza- Power Absorption Watertion Sec. Wt/cm3 mm/10 min Degrees______________________________________Newsprint 0 initial 0 49 -- 600 0.002 24 68 600 0.0025 7 85 600 0.003 0 95 600 0.5 0 97 600 1.0 0 103 600 2.0 0 107 600 3.0 0 112 600 3.0 0 109 600 3.5 0 113______________________________________
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An improved method for imparting water and oil repellent surface properties to fabrics or paper includes pretreatment in a low pressure oxygen plasma in the presence of water vapor followed by plasma polymerization of methane in a high frequency glow discharge carried out in the same treatment chamber. The resultant polymer film formed on the material surface resists separation from the treated material even after prolonged immersion in water. The method is characterized by use of low cost and readily available starting monomer, by use of a single treatment unit for all stages of the process, reduced energy requirements and treatment time, and improved results over conventional processes.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims foreign priority benefits under 35 U.S.C. §119(a)-(d) to GB 0919393.9 filed Nov. 5, 2009, which is hereby incorporated by reference in its entirety.
BACKGROUND
[0002] 1. Technical Field
[0003] This disclosure relates to cooling systems for a motor vehicle having an internal combustion engine.
[0004] 2. Background Art
[0005] As internal combustion engines become more fuel efficient, less waste heat is produced and consequently, the time taken to reach an optimum running temperature increases. This protracted time has a deleterious effect on fuel economy and engine wear.
[0006] Hence, a cooling system which reduces the time taken for a cold engine to reach its optimum running temperature would be desirable.
SUMMARY
[0007] Accordingly, in a first embodiment, the present disclosure comprises a cooling system for a motor vehicle having an internal combustion engine, said cooling system including a pump for supplying coolant to the engine, an outflow conduit for connecting the pump outlet to the engine, and a return circuit for connecting the engine to the pump inlet, wherein the return circuit comprises three branches, a first branch including a first valve, a second branch including a radiator and thermostat, and a third branch including a heater matrix, a degas tank and a second valve.
[0008] The second branch of the return circuit may further include an engine oil cooler.
[0009] The first and second valves may be controlled electronically and the cooling system includes a control unit for controlling the valves in response to an input from at least one of the following onboard vehicle devices; an engine coolant temperature sensor, an ambient air temperature sensor, a timer, a cabin heating demand sensor, an engine operating condition sensor.
[0010] The engine operating condition sensor may be, for example, a sensor which detects engine speed, engine load, throttle position or mass air flow into the engine.
[0011] To prevent damage to the pump if malfunction of the control unit were to occur, the first valve has its default position set to the closed position and the second valve to has its default position set to the open position.
[0012] In accordance with a second embodiment, the present disclosure includes a method of operating a cooling system for a motor vehicle having an internal combustion engine, wherein the cooling system includes a pump for supplying coolant to the engine, an outflow conduit for connecting the pump outlet to the engine, and a return circuit for connecting the engine to the pump inlet, the return circuit comprising three branches, a first branch including a first valve, a second branch including a radiator and thermostat, and a third branch including a heater matrix, a degas tank and a second valve. The method includes: opening both first and second valves for a period long enough to flush air from the system when the engine is started cold. Then, both valves are closed. At least one engine operating condition and engine coolant temperature are monitored. The first valve is closed if one engine operating condition exceeds a pre-set level; and the second valve is opened if engine coolant temperature exceeds a threshold value.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a schematic block diagram of a cooling system in accordance with a preferred embodiment of the disclosure,
[0014] FIG. 2 is a chart illustrating an operating regime of a first valve which is included in the system of FIG. 1 , and
[0015] FIG. 3 is a chart illustrating an operating regime of a second value which is included in the system of FIG. 1 .
DETAILED DESCRIPTION
[0016] As those of ordinary skill in the art will understand, various features of the embodiments illustrated and described with reference to any one of the Figures may be combined with features illustrated in one or more other Figures to produce alternative embodiments that are not explicitly illustrated or described. The combinations of features illustrated provide representative embodiments for typical applications. However, various combinations and modifications of the features consistent with the teachings of the present disclosure may be desired for particular applications or implementations. Those of ordinary skill in the art may recognize similar applications or implementations consistent with the present disclosure, e.g., ones in which components are arranged in a slightly different order than shown in the embodiments in the Figures. Those of ordinary skill in the art will recognize that the teachings of the present disclosure may be applied to other applications or implementations.
[0017] With reference to FIG. 1 , a water pump 1 supplies coolant to an internal combustion engine 2 via a conduit 3 which connects the pump outlet to the engine 2 .
[0018] Coolant returns to the inlet side of the pump 2 via a return circuit which comprises three branches. A first branch 4 includes an electronically controllable bypass valve 5 . A second branch 6 includes a radiator 7 and thermostat 8 . A third branch 9 includes a heater matrix 10 , an engine oil cooler 11 and electronically-controllable heater/degas valve 12 and a degas tank 13 connected via a side branch 14 upstream of the heater/degas valve 12 and downstream of the oil cooler 11 and heater matrix 10 .
[0019] A temperature sensor 15 is provided on the engine 2 for monitoring the temperature of the coolant at the point at which it leaves the engine 2 .
[0020] An electronic control unit (ECU) 16 is electrically connected with the bypass valve 5 and the heater/degas valve 12 and controls opening and closing of each valve 5 , 12 . The ECU 16 receives inputs from a timer 17 , an ambient air temperature sensor 18 , an engine speed sensor 19 and a cabin heater demand sensor 20 . A conduit 21 links the engine 2 directly with the degas tank 13 . Alternatively engine speed sensor 19 may be an engine load sensor, a throttle position sensor, or a mass airflow sensor.
[0021] Operation of the system of FIG. 1 is described with particular reference to FIGS. 2 and 3 in which FIG. 2 shows operation of valve 5 , a first valve, and FIG. 3 shows operation of valve 12 , a second valve, according to one example embodiment. The specific ranges in speed and temperature shown in the table and the numbers provided herein are non-limiting and merely serve to provide one example.
[0022] During operation, the ECU 16 constantly monitors engine coolant temperature, engine speed, ambient air temperature and cabin heat demand (as requested by the occupants of the vehicle) and is also responsive to a signal from the timer 17 . In response to these various inputs, the ECU 16 opens or closes each of the valves 5 , 12 in accordance with a pre-set operating regime.
[0023] For a few seconds immediately following a cold start of the engine 2 , both valves 5 , 12 are opened. This measure serves to flush out air that might be in the system. After ten seconds (in this example) have elapsed, as measured by the timer 17 , both valves are closed. Provided that engine speed remains relatively low, both valves 5 , 12 remain closed. With both valves 5 , 12 closed and the thermostat 8 also closed, there is virtually no circulation of coolant through the engine 2 and so the engine warms up quickly. However, if engine speed reaches a threshold value, say 2300 rpm in this example, then the bypass valve 5 is opened to prevent cavitation occurring in the pump 1 . If the engine speed continues to increase, say beyond 3000 rpm them the heater/degas valve 12 is also opened to ensure that no pump damage can occur.
[0024] If engine rpm remains within the lower limit, then both valves 5 , 12 remain closed until the engine coolant temperature reaches an intermediate (medium) value, say 60 degrees Celsius, whereupon the bypass valve 5 is opened. This allows some coolant flow through the engine while the thermostat 8 remains shut.
[0025] The heater/degas valve remains closed until engine coolant temperature rises further to around 80 degrees Celsius, say, unless ambient air temperature is very low or the occupants demand some cabin heating in which case it is opened sooner.
[0026] Throughout the engine coolant temperature range from around 80 degrees Celsius to the point at which the thermostat opens, say 103 degrees Celsius, both valves 5 , 12 are open, irrespective of engine speed. Hence (warm) coolant is supplied to the heater matrix and to the oil cooler for warming the cabin of the vehicle and for maintaining engine oil at an optimum temperature.
[0027] Once this threshold temperature of 103 degrees Celsius is exceeded and the thermostat 8 is open, the bypass valve 5 is closed allowing full flow of coolant through the radiator 7 .
[0028] If the engine 2 is switched off and the restarted when still hot, the bypass valve 5 is closed and the heater/degas valve is opened.
[0029] The default (unpowered) position of the bypass valve 5 is closed and the default (unpowered) position of the heater/degas valve 12 is open. Hence if the ECU 16 fails, the valves 5 , 12 allow coolant to flow such that no damage to the pump 1 or a hot engine 2 can occur.
[0030] While the best mode has been described in detail, those familiar with the art will recognize various alternative designs and embodiments within the scope of the following claims. Where one or more embodiments have been described as providing advantages or being preferred over other embodiments and/or over prior art in regard to one or more desired characteristics, one of ordinary skill in the art will recognize that compromises may be made among various features to achieve desired system attributes, which may depend on the specific application or implementation. These attributes include, but are not limited to: cost, strength, durability, life cycle cost, marketability, appearance, packaging, size, serviceability, weight, manufacturability, ease of assembly, etc. The embodiments described as being less desirable relative to other embodiments with respect to one or more characteristics are not outside the scope of the disclosure as claimed.
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A cooling system for a vehicle having an internal combustion engine permits rapid warm-up of the engine by the use of two electrically-operated valves in addition to a conventional thermostat. A bypass valve and a heater valve both remain closed at low coolant temperatures and engine speeds, thereby inhibiting coolant flow through the engine. A control unit opens the bypass valve to prevent cavitation in the water pump if engine speed and/or load exceeds a certain value. The heater valve is opened when a threshold engine coolant temperature is reached permitting warming of the heater matrix.
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This is a division of application Ser. No. 621,980, filed Oct. 14, 1975 U.S. Pat. No. 4,026,894.
BACKGROUND OF THE INVENTION
A recently introduced drug, 2-[4-(2-furoyl)-1-piperazine-1-yl]-4-amino-6,7-dimethoxyquinazoline, commonly identified by the generic name prazosin, is a hypotensive drug producing peripheral arterial dilation. This drug is represented by the formula: ##STR1## This drug however, as reported in The Lancet, May 10, 1975, at page 1095, exhibits significant toxicity and can cause a profound fall in blood pressure. Sudden collapse with loss of consciousness for periods ranging from a few minutes to one hour following use of this drug have been reported. (The Lancet and British Medical Journal, June 28, 1975, pages 727, 728) The drug prazosin also has a very low solubility and it is therefore postulated that the problem of toxicity sometimes resulting upon oral administration of this drug may be caused by erratic absorption.
SUMMARY OF THE INVENTION
This invention relates to compounds selected from the class consisting of 2[4(tetrahydro-2-furoyl)-piperazino]-4-amino-6,7-dimethoxyquinazoline and 2-[4(tetrahydropyran-2-carbonyl)piperazinyl]-4-amino-6,7-dimethoxyquinazoline, and pharmaceutically acceptable acid addition salts thereof, represented by the following formulas, respectively. ##STR2##
The compounds of this invention are useful as antihypertensive agents. They have a solubility of from 100 to about 900 times greater than that of prazosin and are considerably less toxic. Because of their considerable water solubility, these compounds can be administered intravenously, particularly for emergency purposes, and should be absorbed uniformly by all patients. Further, they can be administered in time release form, as well as parenterally, including intravenously.
DETAILED DESCRIPTION
The compounds of the present invention are prepared according to the following reaction scheme: ##STR3##
In the reactions illustrated above, the compound of formula II is made by hydrogenating the known compound N-(2-furoyl) piperazine to give N(tetrahydro-2-furoyl) piperazine. This compound is reacted with 4-amino-2-chloro-6,7-dimethoxyquinazoline to give the active drug 2-[4-tetrahydro-2-furoyl)piperazinyl]-4-amino-6,7-dimethoxyquinazoline.
To prepare the compound of formula III, the 3,4-dihydro-2H-pyran-2 carboxylic acid sodium salt is hydrogenated to the tetrahydro-pyran-2-carboxylic acid. This compound converted to the acid chloride with oxalyl chloride and is then treated with N-benzyl piperazine. The resultant N-benzyl-N'-(tetrahydropyran-2-carbonyl)piperazine is hydrogenated to give N-(tetrahydro-pyran-2-carbonyl)piperazine. This compound is reacted with the known compound 4-amino-2-chloro-6,7-dimethoxyquinazoline to give the active drug 2-[4-(tetrahydro-pyran-2-carbonyl)piperazinyl]-4-amino-6,7-dimethoxyquinazoline.
The compounds of this invention are useful as antihypertensive agents. The compounds are effective at dosages generally from 0.01 to 100 milligrams daily.
EXAMPLE I
N-(2-Furoyl)Piperazine (1)
This compound and its preparation has been described in Great Britain Pat. Nos. 1,390,014 and 1,390,015.
194 g. (1Mole) piperazine hexahydrate was dissolved in 250 ml. H 2 O. The solution was acidified to pH 4.5 with 6 HCl. 130.5 g. furoyl chloride (1 Mole) was added along with 10% NaOH solution at such a rate that the pH was maintained at 4.5. After 1 hour, the solution was made basic (pH = 8.5) with NaOH solution. The reaction mixture was continuously extracted with chloroform for 36 hours. The CHCl 3 extract was dried over MgSO 4 and filtered. Distillation gave 108.2 g. product (60%), b.p. 132° - 138° C/0.6 Mm, m.p. 69° - 70° C.
EXAMPLE II
N-(Tetrahydro-2-Furoyl)Piperazine (2)
The furoyl piperazine of Example I was converted to the hydrobromide sale (m.p. 173° - 175° C.). 39.0 g. of this salt in 250 ml. methyl alcohol and 9.0 g. Raney nickel was hydrogenated at 3 atm. After uptake of H 2 ceased, the catalyst was filtered, the solvent concentrated, and the residue crystallized from isopropyl alcohol to give 35.2 g. tetrahydrofuroyl piperazine HBr, m.p. 152° - 156° C. This was suspended in 20 ml. H 2 O. Then 10.5 g. 50%, NaOH solution was added slowly followed by 2.0 g. solid Na 2 CO 3 . This was extracted with 4-100 ml. portions of warm CHCl 3 . The CHCl 3 extractions were distilled to give 22.5 g. tetrahydrofuroyl piperazine, b.p. 120° - 125° C/0.2 Mm.
EXAMPLE III
2[4-(Tetrahydro-2-Furoyl)Piperazinyl]-4-Amino-6,7-Dimethoxyquinazoline Hydrochloride (4) (Hydrochloride of the Compound of Formula II)
To 7.00 g. 2-chloro-4-amino-6,7-dimethoxyquinazoline (3) in 50 ml. methoxyethanol was added 10.8 g. tetrahydrofuroyl piperazine, and the mixture refluxed 3 hours. The clear solution was concentrated and an aqueous solution of potassium bicarbonate was added. The resultant solid that formed was filtered and washed with water. It was then added to methanol and the resulting suspension was acidified with a solution of hydrogen chloride in isopropyl alcohol. The resulting solution was concentrated and the residue crystallized from isopropyl alcohol giving 8.12 g. of product, m.p. 278° - 279° C.
EXAMPLE IV
Tetrahydropyran-2-Carboxylic Acid (6)
210 g. of the sodium salt of 3,4-dihydro-2H-pyran-2-carboxylic acid (5) was dissolved in 2 liters methanol and hydrogenated at 3 atm. pressure over 60 g. Raney nickel catalyst. After hydrogen uptake was complete, the catalyst was filtered and the solvents removed in vacuo. The residue was acidified with concentrated hydrochloric acid and extracted with chloroform. Distillation gave 143.8 g. product, b.p. 75° - 80° C./0.4 Mm, n 25 = 1.4623.
EXAMPLE V
N-(Tetrahydropyran-2-Carbonyl)(7)Piperazine (7)
To 20.5 g. tetrahydropyran-2-carboxylic acid (6) in 50 ml. benzene was added 50 g. oxalyl chloride. The solution was gently heated for 2 hours with vigorous gas evolution. Forty ml. of solvent was distilled through a column at atmospheric pressure. Then 60 ml. fresh benzene was added and 50 ml. solvent was again distilled at atmospheric pressure. The remainder was dissolved in 150 ml. benzene and added slowly to a solution of 27.4 g. N-benzyl piperazine and 17.5 g. triethylamine in 200 ml. benzene, while cooling in an ice bath. After addition, the mixture was stirred for 11/2 hours at room temperature. Then 17 g. sodium carbonate in 100 ml. water was added along with 350 ml. more benzene. The organic phase was separated after stirring, dried over MgSO 4 , and concentrated. The residue was dissolved in 200 ml. ethanol and hydrogenated at 3 atm. over 10.5 g. 5% palladium catalyst. After uptake of hydrogen ceased, the catalyst was filtered and the product isolated by distillation, b.p. 120° - 125° C/0.1 Mm. Solidified to white solid, m.p. 53° - 58° C.
EXAMPLE VI
2-[4(Tetrahydropyran-2-Carbonyl)Piperazinyl]-4-Amino-6,7-Dimethoxyquinazoline Hydrochloride (8) (Hydrochloride of the compound of formula III)
To 3.00 g. 2-chloro-4-amino-6,7-dimethoxyquinazoline (3) in 20 ml. methoxyethanol was added 5.75 g. 1(tetrahydropyran-2-carbonyl)piperazine (7), and the mixture was refluxed three hours. The mixture was cooled and the solid filtered and washed with isopropyl alcohol, giving 2.50 g. product as the HCl salt. The filtrate was concentrated in vacuo and the residue treated with potassium bicarbonate in water yielding a solid, m.p. 134° - 136° C. (Base of product). This was converted to the hydrochloride by suspending the methanol and treating with HCl in isopropyl alcohol. Total yield of hydrochloride was 4.30 g., m.p. 305° C. decomp.
The solubility of the compounds of formulas II and III were found to be considerably greater than the prior art compound, prazosin HCl (compound of formula I). The solubility of prazosin HCl was measured by stirring 368.5 mg. of the compound in 25 ml. of water, permitting it to remain overnight at room temperature and then filtering. The water in the filtrate was removed in vacuo and the residue weighed and found to be 16.7 mg. The solubility of prazosin HCl was consequently calculated as 0.67 mg./ml. of water.
The solubility of the hydrochloride salt of the compound of formula II was measured by weighing 91.4 mg. into a vial and adding water dropwise with stirring until a clear solution was formed and then weighing again. The weight of water required to dissolve 91.4 mg. of the compound was found to be 0.163 g. The solubility of the compound of formula II was calculated as 590 mg. per ml. of water. The ratio of solubility in comparison to the compound of formula I is 880.
Likewise, the solubility of the hydrochloride salt of the compound of formula III was found to be 56.5 mg. per ml. of water or about 100 times that of the compound of formula I.
The advantageous solubility of the compounds of formulas II and III facilitate their preparation into oral dosage and parenteral forms for human administration and more importantly, permit administration intravenously. As discussed in Dispensing of Medication, Eric W. Martin, Editor, 7th edition, 1975, injections provide the most direct route for achieving the effect of a drug within the human body. By planned formulation of the dosage form, combined with an appropriate choice of one of the injection routes, it is possible to vary the effect of a drug from an almost instantaneous onset with a few minutes duration to be delayed onset of several hours and a prolonged duration up to several weeks. This versatility of therapeutic effect makes the injection of therapeutic agents a very valuable route of administration. It is also noted that since the transport systems of the human body are aqueous in nature, medication to be injected should normally be in an aqueous system and when the product is immiscible with water, it must be limited to such routes of administration as intramuscular and subcutaneous. The article further notes that while suspensions and emulsions may be used, most parenteral products are preferably prepared as solutions.
It is therefore apparent that being highly soluble in water, the compounds described herein can readily be adopted for parenteral administration and moreover, can be used in hypertensive crises which generally require intravenous administration for rapid onset of action.
The antihypertensive effect of the hydrochloride salts of the compounds of formulas II and III were screened in spontaneously hypertensive (SH) rats and found to be potent antihypertensive agents. The screening is conducted as follows:
Male spontaneously hypertensive (SH) rats are trained to be restrained in a wire mesh cylinder in a warming box, at least two training cycles being conducted before testing. The rats are warmed for about 1/2 hour period to blood pressure measurement, the warming box being maintained at a constant temperature of 36° C.
An occluding cuff attached to the programed sphymomanometer is placed near the base of the tail of each rat and the pressure in the cuff is increased automatically from 0 to 250 milimeters of mercury (mm H g ) at a rate of 10 mm H g per second. The total time for each cycle of inflation and deflation of the cuff is 50 seconds and the interval between cycles is one minute.
A photocell is placed distal to the cuff to record the pulses due to forward motion of blood flow with each heart beat. As the pressure in the cuff increases, the pulse disappears completely at a point where cuff pressure equals or exceeds the arterial blood pressure and it reappears during deflation at approximately the same pressure. Five interference free signals for deflation are recorded for each rat. Rats with a blood pressure of 180 mm H g or more during the control period are used in the study. Blood pressure and heart rate readings are recorded on a model VII Grass polygraph at intervals of 1, 3, 5 and 24 hours after administration of the drug.
The data obtained is summarized in the following tables from which it is apparent that the compounds of formula II and III are potent antihypertensive agents which lower the blood pressure of spontaneously hypertensive rats without causing any significant changes in heart rate.
As an example, the hydrochloride of the compound of formula II produced a decrease in blood pressure of the magnitude of between 20 and 60% when administered intraperitoneally in the dose range from 0.3 - 30 mg./kg. The duration of the effect was greater than 24 hours at the dose of 30 mg./kg. while the lowest dose of 0.3 mg./kg. still caused an effect lasting for more than five hours. Likewise, when administered via the oral route, the compound caused a fall in blood pressure by up to approximately 40% when administered at doses of 3 and 10 mg./kg.
Table 1__________________________________________________________________________ANTIHYPERTENSIVE EFFECT OF THE COMPOUND OF FORMULA II,ORALLY ADMINISTERED IN SH RATS ControlOral Blood Heart Percent Change At:Dose Pressure Rate 1 Hour 3 Hours 5 Hours 24 Hours(mg/kg)N (mm Hg) (beats/min) BP HR BP HR BP HR BP HR__________________________________________________________________________30 4 Mean 224.5 365.0 -30.0 -9.8 -23.8 -8.8 -26.0 -15.5 -4.0 -8.0 S.E.M. ±1.9 ±26.3 ±2.1 ±5.9 ±1.7 ±5.1 ±1.8 ±5.9 ±1.1 ±8.710 4 Mean 227.5 355.0 -37.0 12.3 -42.0 16.5 -38.0 -10.3 -12.0 1.5 S.E.M. ±4.8 ±26.3 ±2.5 ±10.5 ±4.1 ±13.0 ±1.8 ±12.7 ±2.6 ±7.93 4 Mean 227.0 395.0 -29.0 -9.3 -33.3 -11.0 -31.5 -11.0 -12.3 -5.3 S.E.M. ±5.3 ±23.6 ±2.3 ±9.2 ±0.6 ±7.7 ±4.6 ±7.6 ±4.1 ±8.31 4 Mean 211.8 375.0 -15.8 -9.0 -17.3 -9.3 -22.5 -8.5 3.5 -4.5 S.E.M. ±8.4 ±29.9 ±3.5 ±1.8 ±3.7 ±11.1 ±5.3 ±11.5 ±3.6 ±4.50.3 4 Mean 203.5 325.0 -15.8 -1.0 -22.8 -2.8 -21.3 -2.8 2.0 10.5 S.E.M. ±9.5 ±28.7 ±5.6 ±7.2 ±3.1 ±18.0 ±1.8 ±1.6 ±4.2 ±10.00.1 4 Mean 204.3 350.0 3.8 3.0 1.8 4.8 -7.3 -6.8 -1.5 -0.3 S.E.M. ±4.9 ±20.8 ±2.4 ±8.9 ±4.3 ±3.1 ±2.2 ±3.9 ±1.5 ±6.70.03 4 Mean 230.3 350.0 -5.3 -4.3 -1.8 -8.5 -9.3 -14.5 -3.3 -8.8 S.E.M. ±6.2 ±5.8 ±3.6 ±4.4 ±2.6 ±5.1 ±2.7 ±4.9 ±3.9 ±5.6Intra-Peri- Controltoneal Blood Heart Percent Change At:Dose Pressure Rate 1 Hour 3 Hours 5 Hours 24 Hours(mg/kg)N (mm Hg) (beats/min) BP HR BP HR BP HR BP HR__________________________________________________________________________30 4 Mean 193.5 410.0 -59.5 -9.0 -42.3 1.8 -44.5 5.3 -22.3 5.8 S.E.M. ±3.5 ±19.1 ±4.1 ±7.8 ±9.5 ±6.7 ±6.9 ±8.2 ±11.8 ±6.510 4 Mean 207.3 355.0 -49.8 9.0 -41.5 24.5 -41.8 34.5 -7.5 14.0 S.E.M. ±7.4 ±15.0 ±6.4 ±3.0 ±7.2 ±6.7 ±3.8 ±6.9 ±3.4 ±9.73 4 Mean 201.8 405.0 -45.3 7.8 -39.0 -1.5 -40.0 3.0 -2.3 -0.5 S.E.M. ±4.3 ±33.0 ±2.0 ±12.4 ±1.8 ±5.8 ±4.1 ±7.5 ±3.2 ±9.11 4 Mean 198.5 370.0 -26.5 22.8 -27.5 2.8 -17.0 11.5 3.8 -9.5 S.E.M. ±3.6 ±10.0 ±7.7 ±4.3 ±0.6 ±3.7 ±4.9 ±8.5 ±2.1 ±1.20.3 4 Mean 205.8 320.0 -22.3 20.0 -26.5 10.3 -20.5 14.3 2.5 10.0 S.E.M. ±4.4 ±8.2 ±6.8 ±11.2 ±2.1 ±8.3 ±4.1 ±6.6 ±4.3 ±7.8__________________________________________________________________________
TABLE 2__________________________________________________________________________ANTIHYPERTENSIVE EFFECT OF THE COMPOUND OF FORMULA I,ORALLY ADMINISTERED IN SH RATS ControlOral Blood Heart Percent Change At:Dose Pressure Rate 1 Hour 3 Hours 5 Hours 24 Hours(mg/kg)N (mm Hg) (beats/min) BP HR BP HR BP HR BP HR__________________________________________________________________________30 4 Mean 232.5 335.0 -34.0 -3.8 -31.3 -11.5 -29.3 -14.8 -14.5 -1.5 S.E.M. ± 4.8 ±9.6 ±2.0 ±10.7 ±3.3 - 8.9 ±2.7 -6.8 ±3.6 ±1.510 4 Mean 212.5 300.0 -23.8 3.0 -22.3 12.3 -22.0 -0.8 -2.3 23.3 S.E.M. ±5.8 ±18.3 ±0.6 ±7.8 ±2.6 ±4.7 ±5.1 ±6.9 ±3.5 ±5.83 4 Mean 207.5 360.0 -19.3 0.5 -19.8 11.5 -20.5 1.5 5.3 6.0 S.E.M. ±2.4 ±23.1 ±3.2 ±12.0 ±2.3 ±17.9 ±2.4 ±17.7 ±3.4 ±5.71 4 Mean 226.8 325.0 -31.8 2.0 -17.8 6.8 -19.5 -1.0 -2.3 10.0 S.E.M. ±8.9 ±26.3 ±2.8 ±4.9 ±2.6 ±10.7 ±2.4 ±10.8 ±3.5 ±8.10.3 4 Mean 217.0 390.0 -32.8 -5.5 -33.8 -5.0 -30.0 -13.8 -12.3 3.0 S.E.M. ±5.8 ±40.4 ±1.3 ±8.8 ±1.0 ±8.6 ±2.3 ±4.8 ± 2.7 ±3.70.1 4 Mean 205.5 305.0 -9.8 13.5 -17.5 18.3 -22.8 1.5 -1.3 3.5 S.E.M. ±5.7 ±17.1 ±3.1 ±4.9 ±0.6 ±3.0 ±3.4 ±9.9 ±1.4 ±8.50.03 4 Mean 221.3 390.0 -4.5 4.8 -0.8 -9.3 -11.5 -9.8 1.3 -2.0 S.E.M. ±9.5 ±38.7 ±2.2 ±12.1 ±4.2 ±8.8 ±2.7 ±10.3 ±3.9 ±6.9Intra-Peri- Controltoneal Blood Heart Percent Change At:Dose Pressure Rate 1 Hour 3 Hours 5 Hours 24 Hours(mg/kg)N (mm Hg) (beats/min) BP HR BP HR BP HR BP HR30 4 Mean 211.3 375.0 -43.3 -1.8 -48.5 4.8 -55.5 3.5 -24.5 -6.5 S.E.M. ±6.1 ±12.6 ±2.8 ±5.8 ±5.0 ±7.7 ±2.2 ±8.8 ±6.1 ±4.210 4 Mean 201.8 360.0 -41.0 5.8 -34.0 14.8 -27.0 7.3 -13.0 -7.5 S.E.M. ±3.5 ±29.4 ±9.7 ±8.0 ±3.8 ±14.5 ±5.4 ±9.3 ±4.5 ±5.73 4 Mean 194.3 405.0 -45.0 0.3 -31.5 -6.5 -26.3 -17.0 -2.3 -4.0 S.E.M. ±6.5 ±23.6 ±4.4 ±3.3 ±3.5 ±8.6 ±2.7 ±6.8 ±3.8 ±8.81 4 Mean 201.3 365.0 -20.0 2.8 -15.3 1.8 -13.5 10.5 3.5 12.8 S.E.M. ±5.5 ±42.7 ±5.9 ±6.0 ±3.7 ±5.6 ±4.8 ±14.4 ±1.0 ±5.50.3 4 Mean 207.0 410.0 -20.8 -2.5 -18.3 -0.5 -13.8 -12.0 -4.3 -5.0 S.E.M. ±1.3 ±31.1 ±8.2 ±2.5 ±4.3 ±5.1 ±2.0 ±6.2 ±1.6 ±5.4__________________________________________________________________________
TABLE 3______________________________________ANTIHYPERTENSIVE EFFECT OF THE COMPOUNDOF FORMULA III IN SH RATS Percent Change (2 Rats) At: 1 Hour 3 Hours 5 Hours 24 Hours______________________________________Oral Dose1 mg./kg. -34,-30 -25,-26 -21,-18 -7,-3IntraperitonealAdministration,30 mg./kg. -58,-50 -71,-76 -47,-53 -28,-36______________________________________
The acute, intravenous toxicity in mice of the compound of Formula II in comparison to that of Formula I is summarized in Table 4.
TABLE 4______________________________________INTRAVENOUS TOXICITY IN MICE(MALE AND FEMALE) LD.sub.50 IN MG./KG. (95% Confidence Limits) Hydrochloride of Compound of Compound of FORMULA I FORMULA II______________________________________Injected Immediately 97.8 259.3**After Formulation (A) (93.7-102.6) (251.9-267.6)Injected 24 Hours 46.6* 252.9After Formulation (B) (44.5-49.3) (245.2-262.4)______________________________________ *Significant difference between A and B; p ≦ 0.05 **Significant difference between compounds; p ≦ 0.05?
From this data, it is apparent that the hydrochloride of the compound of Formula II exhibits significantly lower toxicity than the compound of Formula I when administered within twenty minutes following preparation of the solution or suspension, respectively. The difference in toxicities is even more significant when both compounds are injected twenty-four hours after preparation of the formulation.
The compounds of this invention can be formulated into various pharmaceutically acceptable dosage forms such as tablets, capsules, pills, and the like, for immediate or sustained release by combining the active compound with suitable pharmaceutically acceptable carriers or diluents according to methods well known in the art. Such dosage forms my include excipients, binders, fillers, flavoring and sweetening agents, and other therapeutically inert ingredients necessary in the formulation of the desired preparation. Preparations for parenteral administration generally include sterile aqueous or nonaqueous solutions, suspensions or emulsions.
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Described are antihypertensive agents selected from the class consisting of 2[4(tetrahydro-2-furoyl)-piperazino]-4-amino-6,7-dimethoxyquinazoline and 2-[4(tetrahydropyran-2-carbonyl)-piperazinyl]-4-amino-6,7-dimethoxyquinazoline, and pharmaceutically acceptable acid addition salts thereof. The compounds are highly water soluble and can be administered in time release form as well as parenterally, including intravenously.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention deals with the field of devices wherein ladders need to be stored on the external surface of a vehicle such as an emergency vehicle in such a manner as to be convenient when the vehicle is traveling while also providing a means for deploying the ladder to a lower position for immediate access thereto for emergency personnel in an environment where the access to the ladder is needed such as at the location of a fire. Such devices are commonly utilized on fire trucks and other similar emergency vehicles. Such devices need to provide an adaptability for usage with various different sizes of ladders and various different sizes and configurations of emergency vehicles while still utilizing the same basic mechanism for storing and/or deploying of the ladder.
2. Description of the Prior Art
A number of patents have been granted for positioning and re-positioning of ladder storage mechanism and ladders relative to vehicle such as shown in U.S. Pat. No. 1,890,940 was patented Dec. 13, 1932 to C. H. Fox and assigned to Ahrens-Fox Fire Engine Company on a “Fire Engine”; and U.S. Pat. No. 1,898,826 was patented Feb. 21, 1933 to C. H. Fox and assigned to Ahrens-Fox Fire Engine Company on a “Fire Engine”; and U.S. Pat. No. 1,991,900 was patented Feb. 19, 1935 to N. P. Larsen and assigned to The American Coach and Body Company on a “Ladder Support”; and U.S. Pat. No. 2,586,531 was patented Feb. 19, 1952 to D. L. Gordon on a “Wheeled Support Having Ladder Assembly”; and U.S. Pat. No. 2,946,397 was patented Jul. 26, 1960 to W. A. Berberich on a “Ladder Mount For Vehicles”; and U.S. Pat. No. 3,013,681 was patented Dec. 19, 1961 to E. V. Garnett on a “Device For Storage Of Elongated Articles On A Vehicle”; and U.S. Pat. No. 3,058,607 was patented Oct. 16, 1962 to J. T. Kiley and assigned to James A. Kiley Company on “Ladder Racks”; and U.S. Pat. No. 3,357,578 was patented Dec. 12, 1967 to J. O. Koenig on a “Boat Carrier For Pickup Mounted Camper Coaches”; and U.S. Pat. No. 3,608,759 was patented Sep. 28, 1971 to L. A. Spurgeon and assigned to said Spurgeon by said Sorenson on a “Car Top Carrier”; and U.S. Pat. No. 3,612,555 was patented Oct. 12, 1971 to C. L. Baker on a “Transportable Tank Trailer”; and U.S. Pat. No. 3,627,158 was patented Dec. 14, 1971 to F. Kobasic on a “Loader For Vehicle Trunk Compartment”; and U.S. Pat. No. 3,637,097 was patented Jan. 25, 1972 to R. R. Horowitz and assigned to S&H Industries, Inc. on a “Power-Operated Tailgate With Maximum Rearward Displacement Between Fully Elevated And Fully Lowered Positions”; and U.S. Pat. No. 3,672,549 was patented Jun. 27, 1972 to A. J. Chorey on a “Car Top Carrier And Access Ladder”; and U.S. Pat. No. 3,715,044 was patented Feb. 6, 1973 to G. A. Simons on a “Roof Mounted Carried For Automotive Vehicles”; and U.S. Pat. No. 3,715,044 was patented Feb. 6, 1973 to G. A. Simons on a “Roof Mounted Carried For Automotive Vehicles”; and U.S. Pat. No. 3,717,271 was patented Feb. 20, 1973 to D. L. Bargman, Jr. and assigned to Colorado Leisure Products, Inc. on a “Vehicle Tire Carrier”; and U.S. Pat. No. 3,720,334 was patented Mar. 13, 1973 to A. A>Permut et al on “Boat And Equipment Loading Systems”; and U.S. Pat. No. 3,823,839 was patented Jul. 16, 1974 to R. C. Petzing et al on a “Cartop Carrier Elevator”; and U.S. Pat. No. 3,877,624 was patented Apr. 15, 1975 to M. T. Carson on a “Vehicle Top Rack”; and U.S. Pat. No. 3,963,136 was patented Jun. 15, 1976 to T. J. Spanke on a “Retractable Ladder Rack”; and U.S. Pat. No. 4,008,838 was patented Feb. 22, 1977 to R. R. Correll on a “Ladder Rack”; and U.S. Pat. No. 4,062,464 was patented Dec. 13, 1977 to R. E. Grove on “Mounting Brackets For An Article Handling Apparatus”; and U.S. Pat. No. 4,161,997 was patented Jul. 24, 1979 to T. W. Norman on a “Self-Storing Step Structure For Vehicular Mounting”; and U.S. Pat. No. 4,170,331 was patented Oct. 9, 1979 to E. W. Faulstich on a “Vehicle Ladder Rack”; and U.S. Pat. No. 4,236,860 was patented Dec. 2, 1980 to D. Gottlieb et al on an “Apparatus For Lifting A Wheelchair Onto The Roof Of An Automobile”; and U.S. Pat. No. 4,239,438 was patented Dec. 16, 1980 to C. R. Everson on a “Device For Lifting And Carrying Loads On Top Of Pickup Trucks”; and U.S. Pat. No. 4,262,834 was patented Apr. 21, 1981 to W. H. Nutt and assigned to Teledyne Canada on a “Ladder Rack”; and U.S. Pat. No. 4,339,064 was patented Jul. 13, 1982 to T. Ziaylek, Jr. on a “Carrier Clamp For Fire Ladders”; and U.S. Pat. No. 4,339,223 was patented Jul. 13, 1982 to R. R. Golze on a “Roof Top Carrier”; and U.S. Pat. No. 4,376,611 was patented Mar. 15, 1983 to B. H. Koop on a “Car Top Carrier For Wheelchair”; and U.S. Pat. No. 4,390,117 was patented Jun. 28, 1983 to M. W. Fagan on a “Ladder Rack For Vehicle”; and U.S. Pat. No. 4,408,680 was patented Oct. 11, 1983 to D. O. Ross on a “Ladder Support Assembly”; and U.S. Pat. No. 4,431,082 was patented Feb. 14, 1984 to J. A. Bott on a “Vehicle Ladder”; and U.S. Pat. No. 4,439,086 was patented Mar. 27, 1984 to R. W Thede on a “Boat Loader”; and U.S. Pat. No. 4,618,083 was patented Oct. 21, 1986 to K. F. Weger, Jr. and assigned to Knaack Mfg. Co. on a “Ladder Clamping Device For Vehicle Rack”; and U.S. Pat. No. 4,751,981 was patented to J. C. Mitchell et al on Jun. 21, 1988 on a “Detachably Mounted Ladder Rack”; and U.S. Pat. No. 4,808,056 was patented Feb. 28, 1989 to S. Oshima on an “Elevator Device Transportable In A Motor Vehicle”; and U.S. Pat. No. 4,813,585 was patented Mar. 21, 1989 to W. H. Nutt and assigned to Teledyne Canada Limited on a “Ladder Rack”; and U.S. Pat. No. 4,826,387 was patented May 2, 1989 to M. Audet on a “Vehicle Roof Rack”; and U.S. Pat. No. 4,827,742 was patented May 9, 1989 to R. R. McDonald and assigned to Unistrut Australia Pty. Ltd. on a “Security Assembly For Vehicle Roofrack”; and U.S. Pat. No. 4,844,490 was patented Jul. 4, 1989 to R. E. Kohler on a “Fire Truck Ladder Support”; and U.S. Pat. No. 4,858,725 was patented Aug. 22, 1989 to L. H. Griffin on a “Ladder Brace”; and U.S. Pat. No. 4,877,108 was patented Oct. 31, 1989 to L. H. Griffin et al on a “Hydraulic Ladder Brace”; and U.S. Pat. No. 4,887,750 was patented Dec. 19, 1989 to R. K. Dainty and assigned to British Gasa plc on a “Rack Arrangement”; and U.S. Pat. No. 4,909,352 was patented Mar. 20, 1990 to K. McComb on a “Ladder Support System”; and U.S. Pat. No. 4,923,103 was patented to C. J. Sauber on May 8, 1990 on a “Ladder Rack”; and U.S. Pat. No. 4,953,757 was patented Sep. 4, 1990 to J. R. Stevens et al on a “Front Rack For A Truck”; and U.S. Pat. No. 5,009,350 was patented Apr. 23, 1991 to J. M. Schill et al on “Retainer Assemblies For Elongated Objects”; and U.S. Pat. No. 5,048,641 was patented Sep. 17, 1991 to J. N. Holcomb et al and assigned to Jack N. Holcomb on a “Van-Mounted Ladder Assembly With Concealed Radio Antennas”; and U.S. Pat. No. 5,058,791 was patented Oct. 22, 1991 to K. R. Henriquez et al and assigned to Slide-Out, Inc. on a “Vehicular Ladder Rack”; and U.S. Pat. No. 5,064,022 was patented Nov. 12, 1991 to G. W. Graham and assigned to Marrowbone Development Company on a “Ladder Apparatus And Method For Large Mobile Equipment”; and U.S. Pat. No. 5,104,280 was patented Apr. 14, 1992 to M. P. Ziaylek et al and assigned to Michael P. Ziaylek on an “Apparatus For Use With An Emergency Vehicle For Storage And Retrieval Of Remotely Located Emergency Devices”; and U.S. Pat. No. 5,154,563 was patented Oct. 13, 1992 to J. R. Phillips on a “Wheel Chair Carrier”; and U.S. Pat. No. 5,172,952 was patented Dec. 22, 1992 to R. Lasnetski on an “Overhead Storage Rack For Storing Ladders Or The Like”; and U.S. Pat. No. 5,174,411 was patented Dec. 29, 1992 to D. P. Oliver et al and assigned to Abru Aluminium Limited on “Ladder Improvements”; and U.S. Pat. No. 5,186,588 was patented Feb. 16, 1993 to C. W. Sutton et al on a “Ladder Rack Ladder Latch”; and U.S. Pat. No. 5,209,628 was patented May 11, 1993 to C. C. Hassell on a “Self-Loading Dolly Mount Apparatus”; and U.S. Pat. No. 5,242,094 was patented Sep. 7, 1993 to A. L. Finley on a “Ladder Rack”; and U.S. Pat. No. 5,255,757 was patented Oct. 26, 1993 to M. Horowitz et al and assigned to Martin Horowitz on a “Collapsible Ladder”; and U.S. Pat. No. 5,297,912 was patented to A. Y. Levi on Mar. 29, 1994 and assigned to JAJ Products, Inc. on a “Ladder Rack For Motor Vehicles”; and U.S. Pat. No. 5,346,357 was patented Sep. 13, 1994 to C. C. Hassell on a “Self-Locking Parallel-Motion Dolly Mount”; and U.S. Pat. No. 5,360,150 was patented Nov. 1, 1994 to J. L. Praz on “Roof Rack For Vehicles”; and U.S. Pat. No. 5,366,052 was patented to J. K. Lin on Nov. 22, 1994 on a “Reversible Folding Ladder”; and U.S. Pat. No. 5,398,778 was patented Mar. 21, 1995 to R. Sexton on a “Ladder Rack Securing And Release System”; and U.S. Pat. No. 5,405,234 was patented Apr. 11, 1995 to T. Ziaylek, Jr. et al on a “Pivotable Article Retaining Apparatus To Invert And Store A Collapsible Water Storage Tank On A Vehicle”; and U.S. Pat. No. 5,421,495 was patented Jun. 6, 1995 to L. Bubik et al and assigned to Innovative Bicycle Design Inc. on a “Vehicle Roof Rack”; and U.S. Pat. No. 5,438,925 was patented Aug. 8, 1995 to T. Ohmi et al and assigned to Tokyo Kikai Seisakusho, Ltd. on a “Ladder For Climbing Up To And Down From Working Floor Of Printing Press”; and U.S. Pat. No. 5,469,933 was patented Nov. 28, 1995 to J. Thomason on a “Vehicle Mounted Ladder”; and U.S. Pat. No. 5,518,357 was patented May 21, 1996 to T. Ziaylek, Jr. et al and assigned to Theodore Ziaylek, Jr. and Michael P. Ziaylek on a “Retaining And Retrieval Apparatus For Storage Of A Ladder Upon A Vehicle Shelf Area”; and U.S. Pat. No. 5,538,100 was patented Jul. 23, 1996 to R. I. Hedley on an “Access Device”; and U.S. Pat. No. 5,632,591 was patented May 27, 1997 to K. R. Henriquez on a “Ladder Storage And Transport Device”; and U.S. Pat. No. 5,709,521 was patented Jan. 220, 1998 to D. Glass et al on a “Lift Assist Bicycle Carrier For Car Rooftop”; and U.S. Pat. No. 5,791,857 was patented Aug. 11, 1998 to T. Ziaylek, Jr. et al and assigned to Theodore Ziaylek, Jr. and Michael Paul Ziaylek on an “Automatic Ladder Lowering And Storage Device For Use With An Emergency Vehicle”; and U.S. Pat. No. 5,850,891 was patented Dec. 22, 1998 to J. J. Olms et al and assigned to Trimble Navigation Limited on a “Motorized Rack System”; and U.S. Pat. No. 5,878,836 was patented Mar. 9, 1999 to I. F. Huang on a “Structure Of An Escaping Device”; and U.S. Pat. No. 6,003,633 was patented Dec. 21, 1999 to R. G. Rolson and assigned to Robert G. Rolson on a “Portable Truck Or Trailer Ladder Assembly”; and U.S. Pat. No. 6,012,545 was patented Jan. 11, 2000 to E. Faleide on a “Foldable Vehicle Ladder System”; and U.S. Pat. No. 6,086,312 was patented Jul. 11, 2000 to M. P. Ziaylek et al on a “Tank Handling Apparatus”; and U.S. Pat. No. 6,092,972 was patented Jul. 25, 2000 to A. Y. Levi on a “Truck Mounted Ladder Rack”; and U.S. Pat. No. 6,099,231 was patented Aug. 8, 2000 to A. Y. Levi on a “Drive Unit For Motor Vehicle Ladder Rack”; and U.S. Pat. No. 6,179,543 was patented Jan. 30, 2001 to D. Adame et al on a “Rack For Motor Vehicles”; and U.S. Pat. No. 6,257,534 was patented Jul. 10, 2001 to A. L. Finley and assigned to Fibre Body Industries Inc. on a “Ladder Rack Assembly”; and U.S. Pat. No. 6,273,668 was patented to F. Kameda on Aug. 14, 2001 and assigned to Nissin Jidosha Kogyo Co., Ltd. on a “Wheel Chair Storage Apparatus Of Car”; and U.S. Pat. No. 6,314,181 was patented Nov. 13, 2001 to J. A. Bradley et al and assigned to Adrian Steel Company on a “Ladder Rack Apparatus And Method”; and U.S. Pat. No. 6,321,873 was patented Nov. 27, 2001 to R. LaBrash and assigned to Tra-Lor-Mate, Inc. on a “Ladder Mounting System”; and U.S. Pat. No. 6,340,060 was patented Jan. 22, 2002 to L. G. Larson et al and assigned to Cold Cut Systems Svenska A. B. on a “Method And Equipment For Use In Rescue Service”; and U.S. Pat. No. 6,360,930 was patented Mar. 26, 2002 to M. Flickenger and assigned to L & P Property Management Company on a “Vehicle Rack Assembly With Hydraulic Assist”; and U.S. Pat. No. 6,427,889 was patented Aug. 6, 2002 to A. Y. Levi on a “Ladder Rack For Hi Bay Vans”; and U.S. Pat. No. 6,561,396 was patented May 13, 2003 to C. A. Ketterhagen and assigned to Johnson Outdoors Inc. on an “Automobile Cargo Carrier System”; and U.S. Pat. No. 6,578,666 was patented Jun. 17, 2003 to R. K. Miller on a “Portable Safety Ladder Assembly For A Truck Trailer”; and U.S. Pat. No. 6,764,268 was patented Jul. 20, 2004 to A. Y. Levi on a “Ladder Rack Assembly”; and U.S. Pat. No. 6,827,541 was patented Dec. 7, 2004 to M. P. Ziaylek et al on an “Apparatus For Holding Elongated Objects Horizontally Adjacent To A Vehicular Body Which is Movable Between An Upper Storage Position And A Lower Access Position”; and U.S. Pat. No. 6,854,627 was patented Feb. 15, 2005 to B. Foo et al and assigned to eRack LLC on a “Vehicular Utility Rack”; and U.S. Pat. No. 6,874,835 was patented Apr. 5, 2005 to L. A. Silverness on a “Collapsible Rack For Storing Ladders And The Like On A Land Vehicle”; and U.S. Pat. No. 6,929,162 was patented to L. R. Jordan on Aug. 16, 2005 on an “Automatic Locking Ladder Rack”; and U.S. Pat. No. 6,973,996 was patented Dec. 13, 2005 to F. J. Huff on a “Ladder Mounting Apparatus And Method Of Use”; and U.S. Pat. No. 7,097,409 was patented Aug. 29, 2006 to T. S. Richter and assigned to Adrian Steel Co. on a “Ladder Rack System”; and U.S. Pat. No. 7,114,690 was patented Oct. 3, 2006 to D. R. Bissen and assigned to Schwing America, Inc. on a “Universal Mast Support Frame And Method For Mounting Masts”; and U.S. Pat. No. 7,137,479 was patented Nov. 21, 2006 to M. P. Ziaylek et al and assigned to Michael P. Ziaylek, Theodore Ziaylek, Jr. and Theodore P. Ziaylek on a “Powered Ladder Storage Apparatus For An Emergency Vehicle”; and U.S. Pat. No. 7,165,650 was patented Jan. 23, 2007 to P. V. Korchagin et al on “High-Rise, Fire-Fighting, Rescue And Construction Equipment”; and U.S. Design Pat. No. D331,030 was patented Nov. 17, 1992 to M. P. Ziaylek et al and assigned to Michael P. Ziaylek on a “Unit For Use With An Emergency Vehicle For Storage And Retrieval Of Remotely Located Emergency Devices”; and U.S. Design Pat. No. D422,289 was patented Apr. 14, 2000 to M. Mariotta et al and assigned to AGIE SA on a “Machine Tool”; and U.S. Design Pat. No. D487,049 was patented Feb. 24, 2004 to T. Ziaylek, Jr. et al on an “Apparatus For Retaining Elongated Objects Relative To A Vehicular Body And Providing Access Thereto”; and French Registration No. 87 14525.
SUMMARY OF THE INVENTION
The ladder storage apparatus of the present invention is designed for use with an emergency vehicle and preferably includes an inner housing fixedly securable with respect to an emergency vehicle for the purposes of facilitating storage and retrieval of a ladder mounted thereupon. Also included in this construction is an outer housing movably attached with respect to the inner housing which is adapted to receive the ladder detachably secured thereto to facilitate storage and availability.
An arm assembly is also included movably secured to the inner housing and movably attached to the outer housing to facilitate movable attachment of the outer housing with respect to the inner housing. This arm assembly is movable in such a manner as to urge movement of the outer housing between a storage position with the outer housing positioned immediately adjacent the inner housing and a deployed position with the outer housing positioned spatially disposed from the inner housing.
The apparatus further includes an extensible means such as a drive cylinder which can be hydraulic or electro-hydraulic and can be attached with respect to the inner housing and also attached with respect to the outer housing. This drive is preferably longitudinally extendable to urge outward movement of the arm assembly in such a manner as to cause movement of the outer housing toward the deployed position. The longitudinally extensible drive means further is longitudinally retractable to alternatively urge inward movement of the arm assembly to cause movement of the outer housing toward the storage position.
An extension adjustment assembly is also included secured to the inner housing and movably attached to the extensible drive for providing adjustment and positioning thereof with respect to the inner housing. This extension adjustment mechanism can include a yoke fixedly secured to the inner housing and movably secured with respect to the extensible drive. The yoke is generally C-shaped and defines a receiving slot therewithin adapted to receive and retain a portion of the extensible drive extending thereinto and movably attached thereto. The yoke preferably defines a yoke aperture therein immediately adjacent the receiving slot. The extension adjustment construction further includes a threaded adjustment stud mounted in the inner housing and positioned extending outwardly therefrom toward the extensible drive. The yoke aperture is adapted to receive the threaded adjustment stud threadably engaged therewith to facilitate mounting of the yoke fixedly with respect to the inner housing as desired. A first jam nut is preferably included in the construction of the extension adjustment device in a position to be attached to the threaded adjustment stud outside of the yoke thereof and tightened against the yoke immediately adjacent the yoke aperture. A second jam nut is also preferably attached to the threaded adjustment stud within the receiving slot and is tightened against the yoke immediately adjacent the yoke aperture oppositely positioned from the first jam nut. In this manner the first jam nut and the second jam nut when tightened on the threaded adjustment stud toward one another and against the yoke will hold the yoke in place and provide adjustability in the positioning thereof which can be achieved by loosening of the first and second jam nuts as desired and repositioning of the threaded adjustment stud within the yoke aperture to a new chosen position of adjustment.
The apparatus of the present invention further includes a latching mechanism which can be secured to the inner housing which is movable between a locked position in engagement with the outer housing for receiving thereof in the storage position and an unlocked position allowing movement of the outer housing away from the storage position. The latching mechanism preferably includes a first engagement means fixedly mounted to the outer housing and a second engagement means movably mounted to the inner housing and engageable with respect to the first engagement means responsive to movement of the latching mechanism to the locked position thereof. The second engagement means is preferably movable between an engaged position in engagement with the first engagement means to retain the outer housing means for retaining thereof in the storage position detachably retained with respect to the inner housing means and a disengaged position with respect to the first engagement means to release the outer housing to be freely movable relative to the inner housing toward the deployed position. The latching mechanism can further include a latching spring operatively mounted with respect to the second engagement means for maintaining thereof in the engaged position which is defined to be the steady state position thereof A latching drive can also be included in the construction of the latching mechanism which can include a drive cylinder which is responsive to actuation thereof to urge movement of the second adjustment mechanism from the engaged position to the disengaged position for the purpose of facilitating release of the outer housing with respect to the inner housing. A manual lever can also be included within the construction of the latching mechanism which is pivotally mounted within the inner housing and extends outwardly therefrom and can be rotated to cause manual disengagement of the latching mechanism by movement thereof to the unlocked position. A linkage construction may also be attached to the manual lever and attached to the second engagement means in such a manner that manual movement of the manual lever urges movement of the linkage causing the second engagement means to move toward the disengaged position.
Furthermore the construction of the present invention is preferably made such that the extensible drive is pivotally attached with respect to the yoke to facilitate flexible movement thereof and movement of the arms to allow the outer housing to be easily movable away from the inner housing as desired. Furthermore the linkage of the latching mechanism will preferably include a drive cylinder which is longitudinally extensible. This drive cylinder is preferably responsive to powering thereof towards movement of the second engagement means toward the disengaged position and in this manner will simultaneously provide both a powered and manual means to urge movement of the second engagement means toward the disengaged position. Thus the user can operate the manual release or can operate a powered release to facilitate disengagement of the latching mechanism.
Also within the construction of the present invention the extension adjustment means is preferably defined to be entirely contained within the interior portion of the inner housing in such a manner that it remains stationary at all times including those times when the outer housing is moving between the deployed and storage position. Furthermore the first engagement means of the present invention preferably includes a first hook and a second engagement means preferably includes a second hook. These two hooks are preferably detachably engaged with respect to one another to facilitate engagement and disengagement therebetween.
It is an object of the ladder storing apparatus for use with an emergency vehicle of the present invention to movement of a ladder between a storage position on top of an emergency vehicle and a deployed position extending downwardly and rearwardly downwardly therefrom.
It is an object of the ladder storing apparatus for use with an emergency vehicle of the present invention to provide a construction wherein ladders and like can be maintained horizontally at any point over the external surface of the emergency vehicle for storage and also are capable of movement downwardly to a deployed position.
It is an object of the ladder storing apparatus for use with an emergency vehicle of the present invention to provide a construction wherein a ladder can be moved from an upper to a lower position conveniently and easily in an emergency situation such as by a fire truck at a fire.
It is an object of the ladder storing apparatus for use with an emergency vehicle of the present invention to provide a construction wherein adjustment in positioning of the deployed position relative to the storage position is significantly enhanced.
It is an object of the ladder storing apparatus for use with an emergency vehicle of the present invention to provide a construction wherein all aspects of the latching release mechanism are contained within the inner housing thereof
BRIEF DESCRIPTION OF THE DRAWINGS
While the invention is particularly pointed out and distinctly claimed in the concluding portions herein, a preferred embodiment is set forth in the following detailed description which may be best understood when read in connection with the accompanying drawings, in which:
FIG. 1 is a front three-quarter perspective of an embodiment of the ladder storing apparatus for use with an emergency vehicle of the present invention in the deployed position;
FIG. 2 is a front plan view of the embodiment shown in FIG. 1 ;
FIG. 3 is an exploded view of the extension adjustment mechanism of the present invention;
FIG. 4 is a side plan view of the embodiment shown in FIG. 1 ;
FIG. 5 is an exploded three-quarter perspective of the lower portion of the embodiment shown in FIG. 1 ;
FIG. 6 is an exploded three-quarter perspective of the upper portion of the embodiment shown in FIG. 1 ;
FIG. 7 is a side plan view of the embodiment shown in FIG. 1 in the storage position; and
FIG. 8 is a front plan view of the embodiment shown in FIG. 1 in the storage position.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
The present invention describes a ladder storage apparatus particularly usable with an emergency vehicle and being commonly usable with respect to fire trucks. The apparatus of the present invention includes an inner housing 12 which can be fixedly secured with respect to an emergency vehicle such as a fire truck and an outer housing 14 movable with respect thereto. An arm assembly 16 is preferably movably attached to the inner housing 12 and the outer housing 14 such as to control the independent movement of the outer housing 14 as the arm assembly is moved between the storage position 17 and the deployed position 18 thereof. A ladder 10 is detachably securable with respect to the outer housing 14 to be movable therewith between the storage position 17 and the deployed position 18 thereof to facilitate movement of the ladder between the generally higher storage or secured position and the generally lower deployed position for facilitating access.
Powering of movement of the outer housing 14 relative to the inner housing 12 is provided by a longitudinally extensible means 20 preferably comprising a drive cylinder which can be powered hydraulically or electrically or by any combination of powering means thereof The extensible means 20 is attached with respect to the inner housing 12 and the outer housing 14 and the positioning of the extensible housing 20 relative to these two housings is an important consideration.
As such, the present invention includes an extension adjustment means 22 designed particularly for the purpose of varying the relative position between the extensible drive means 20 and the inner housing 12 . This extension adjustment means 22 preferably includes a C-shaped yoke means 24 which defines a receiving slot 26 within the C-shaped configuration thereof A yoke aperture 27 extends through the yoke 24 immediately adjacent to the receiving slot 26 .
To facilitate adjustment the extension adjustment means 22 will preferably include a threaded adjustment stud 28 in threaded engagement with respect to the inner housing 12 as shown best in FIG. 3 . Preferably a mounting jam nut 34 will facilitate fixed mounting of the threaded adjustment stud 28 with respect to the boss defined in the inner housing 12 for receiving and engaging therewith. The threaded adjustment stud 28 will extend outwardly away from the inner housing 12 and will be adapted to engage the yoke 24 by threadably engaging with the yoke aperture 27 therein and partly extending into the receiving slot 26 as again shown best in FIG. 3 . Fixed securement between the threaded adjustment stud 28 and the yoke 24 is further enhanced by the positioning of a first jam nut on the portion of the threaded adjustment stud 28 between the yoke 24 and the mounting jam nut 34 . Another jam nut defined as the second jam nut 32 is preferably positioned in engagement with the threaded adjustment stud 28 at a position within the receiving slot 26 of the yoke 24 . In this manner the first jam nut 30 and the second jam nut 32 can be tightened toward one another and against the yoke 24 in the area thereof immediately adjacent to the yoke aperture 27 to firmly secure the yoke 24 with respect to the inner housing 12 through the interconnecting threaded adjustment stud 28 . The yoke can also define apertures through which a pivot pin 36 can extend which is held in place preferably by two pivot pin nuts 38 . The extensible drive means 20 can be movably or pivotally mounted upon the pivot pin 36 at a position within the receiving slot 26 of the yoke 24 in such a manner as to be movably retained thereby.
With this construction it can be seen that a firm securement is secured for the pivotal mounting of the extensible drive 20 by utilizing the construction of the yoke 24 and the surrounding parts to provide an extension adjustment means 22 which also additionally provides a means for adjustable positioning of the firmly held pivotally movable mounting apparatus for allowing firm yet movable mounting of the extensible drive 20 with respect to the inner housing 12 while allowing full adjustability of the specific chosen position for various applications and uses.
It is important that the ladder 10 be held firmly secured with the arm assembly 16 of the apparatus of the present invention when in the storage position 17 . For this purpose a latching mechanism 40 is preferably included which will retain the housings 12 and 14 immediately adjacent to one another with the arm assembly 16 in the storage position 17 until the latching mechanism is released. This added construction is included for the purpose of providing a means for firmly securing of the ladder relative to the emergency vehicle during transport when significant vibration and movement to the ladder and the ladder holding means is often encountered.
Latching mechanism 40 is movable between a locked position 42 which holds the inner and outer housings 12 and 14 in the storage position 17 and an unlocked position 44 which allows movement of the outer housing 14 away from the inner housing 12 such that the ladder 10 can be moved by the arm assembly 16 toward the deployed position.
Latching mechanism 40 preferably includes a first engagement means 46 preferably comprising a first hook means 47 preferably firmly mounted with respect to the outer housing 14 . A second engagement means 48 including a plurality of movable parts is preferably movably mounted with respect to the outer housing 14 . Second engagement means 48 preferably includes a second hook means 49 detachably engageable with respect to the first hook means 47 which can be attached thereto responsive to the latching mechanism 40 being in the locked position 42 . This is the engaged position 50 of the second engagement means 48 relative to the first engagement means 46 .
The first engagement means 46 and the second engagement means 48 can be separated by movement to the disengaged position 52 which allows the outer housing 14 to move away from the inner housing 12 such that the ladder 10 can travel to the deployed position for ready access by emergency personnel as needed.
The movable parts of the second engagement means 48 preferably include a latching spring 54 designed to maintain the second engagement means 48 of the latching mechanism 40 in the steady state engaged position. A latching drive 55 which can be either manually powered or electrically, pneumatically or hydraulically powered, is operative to disengage the latching mechanism 40 by movement thereof to the unlocked position 44 to in that manner allow the outer housing 14 to move away from the inner housing 12 for ladder deployment. The latching drive 55 either manual or powered is designed to overcome the steady state locking position urged upon the second hook 49 by the latching spring 54 .
The latching drive 55 can comprise a drive cylinder 56 such as a longitudinally extendable hydraulic or electrical cylinder or can include a manual lever 58 . Manual lever 58 is preferably connected through a plurality of linkage members 60 to the second engagement means 48 to facilitate disengagement of the second hook 49 with respect to the first hook 47 for the purpose of moving the latching mechanism to the unlocked position 44 . This linkage is best shown in FIGS. 5 and 6 . These figures also show the powered latching drive 55 .
Thus, the latching mechanism of the present invention can provide simultaneously both a powered disengaging means as well as a manual disengaging means either of which can be operated to cause movement of the latching mechanism 40 to be configured from the locked position 42 to the unlocked position 44 .
This is an important consideration in view of the fact that rapid deployment can be initiated by operating an automated unlocking means. However, also manual unlocking needs to be provided as a redundant backup system in case the powered system does not work or for some reason is inaccessible or inoperable. Thus, one of the novel aspects of the present invention is the combination of both a manual and an automated latch disengagement means for the latching mechanism 40 .
While particular embodiments of this invention have been shown in the drawings and described above, it will be apparent that many changes may be made in the form, arrangement and positioning of the various elements of the combination. In consideration thereof, it should be understood that preferred embodiments of this invention disclosed herein are intended to be illustrative only and not intended to limit the scope of the invention.
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A mechanism for facilitating the storage of ladders in the upper area on the outside of an emergency vehicle which includes the capability of moving of the ladder to a lower deployed position to facilitate immediate access thereto by emergency workers such as firemen and the like. The construction includes an inner housing attached to the vehicle and an outer housing movable by an arm assembly relative thereto to urge the ladder between the storage and deployed positions. An adjustment mechanism including a yoke is included for varying the position of the powering drive cylinder which operatively moves the outer housing relative to the inner housing.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] Not Applicable.
STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT
[0002] Not Applicable.
MICROFICHE APPENDIX
[0003] Not Applicable
BACKGROUND OF THE INVENTION
[0004] 1. Field of the Invention
[0005] This invention relates to the field of sports. More specifically, the invention comprises an oblong throwing ball containing a large central passage that is bounded by a rigid material, with the outer portions of the ball being made of compressible foam.
[0006] 2. Description of the Related Art
[0007] Spherical balls have been used in many sports and many amusement games. An example is the pressurized spherical ball used in the international game of football (known in America and some other regions as “soccer”). A spherical ball obviously rolls well and is easy to kick and otherwise manipulate with the feet. However, it is not easy to throw a large spherical ball.
[0008] The game of American football initially used a pressurized ball having an oblong shape. The original American football was similar in size and shape to the ball presently used in the sport of Rugby. However, as the forward pass evolved in American football during the first half of the 20 th century, the ball began to change as well. The ball evolved to include distinct point at each end and a more slender shape. This allowed the ball to be more easily gripped and thrown.
[0009] The modern American football has a distinct central axis, with points at each end lying along this central axis. A skilled passer can release the ball so that (1) the ball's central axis is parallel to its flight path, and (2) the ball's center of rotation coincides with its central axis. When these two conditions exist, the passer has achieved a “tight spiral.” When the two conditions do not exist, the ball appears to “flutter.” This is true primarily because the leading point of the ball does not lie on the axis of rotation. Instead, it rotates around the axis of rotation, This eccentricity of rotation tends to persist throughout the flight of the ball. It significantly increases drag and also reduces directional stability. A badly eccentric throw is often called a “wounded duck.” For the same amount of initial velocity, it will not travel nearly as far as a “tight spiral.”
[0010] Thus, significant skill is required to correctly throw a modern American football. The exterior surface of such a football is also relatively rigid and requires a strong grip to throw effectively. It would be advantageous to provide a football having a more compressible exterior surface that could be more easily gripped. It would also be advantageous to provide a football having eccentricity-correcting features so that the ball would tend to stabilize in flight even when thrown poorly. The present invention provides these features as well as additional features.
BRIEF SUMMARY OF THE PRESENT INVENTION
[0011] The present invention comprises a throwable ball having a large internal passage aligned with its central axis. A relatively rigid insert defines the bounds of the internal passage. This insert is surrounded by compressible foam that gives the ball an easy gripping surface. Interlock features are preferably provided between the insert and the compressible foam so that they do not slip relative to each other.
[0012] The diameter of the internal passage is large in comparison to the overall diameter of the ball. The diameter of the internal passage is preferably at least 50% of the overall diameter. Although the insert extends for most of the length of the ball, it does not extend to the two ends. The ends only contain the compressible foam. This prevents injury or damage when the ball strikes something.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0013] FIG. 1 is a perspective view, showing the inventive ball in an assembled state.
[0014] FIG. 2 is a perspective view, showing the insert alone.
[0015] FIG. 3 is an elevation view, looking down the central axis of the assembled ball.
[0016] FIG. 4 is a sectional elevation view.
[0017] FIG. 5 is an elevation view, showing the inventive ball from the side.
[0018] FIG. 6 is a transverse elevation view, illustrating the diameter of the central passage in comparison to the ball as a whole.
[0000]
REFERENCE NUMERALS IN THE DRAWINGS
10 orb ball
12 central passage
14 insert
16 rib
20 insert containment step
22 central axis
26 air flow
28 foam body
30 passage diameter
32 overall diameter
34 first end
36 second end
38 exterior profile
40 first insert end
42 second insert end
44 chamfer
46 fillet
48 compression region
50 insert recess
52 insert passage
54 foam body passage
DETAILED DESCRIPTION OF THE INVENTION
[0019] FIG. 1 shows a perspective view of the present invention, designated as orb ball 10 . The orb ball has an outward facing surface that is generally similar to the surface of an American football. it also includes central passage 12 a cavity running completely through the ball along its central axis. The orb ball includes two major components that are locked together. A relatively rigid insert forms the “core” of the ball. This insert is surrounded by pliable, high-density foam.
[0020] FIG. 2 shows a perspective view of insert 14 by itself. Insert 14 includes a cylindrical side wall defining a hollow internal passage. In the completed assembly it is surrounded by the high-density foam. The insert is preferably made from a relatively rigid material, such as an injection molded thermoplastic. The term “relatively rigid” refers to the relative rigidity of the insert with respect to the surrounding foam.
[0021] It is preferable to provide one or more interlocking features that will help lock the insert and the surrounding foam together. In the embodiment shown a pair of ribs 16 extend radially outward from the cylindrical wall. The foam is typically molded around the insert so the foam—while still in a non-set state—flows around the ribs. When the foam sets, the ribs create a mechanical interlock.
[0022] FIG. 3 provides an elevation view looking in a direction that is parallel to the orb ball's central axis. The reader will observe how central passage 12 extends through the orb ball. In addition, the reader will observe that the diameter of the central passage is quite large with respect to the overall diameter of the orb ball.
[0023] FIG. 4 is a sectional elevation view of the orb ball taken along the central axis. The reader will observe that all the features of the embodiment shown are radially symmetric about central axis 22 . As stated previously, insert 14 primarily consists of a cylindrical wall. The cylindrical wall has an inward facing surface and an outward facing surface. The inward facing surface of the cylindrical wall defines insert passage 52 .
[0024] Foam body 28 includes a cylindrical foam body passage 54 . Foam body passage 54 opens into a cylindrical insert recess 50 . The insert recess is a cylindrical recess that does not extend for the entire length of the foam body. Instead, it stops at two insert containment steps 20 . The first insert containment step abuts first insert end 40 and the second insert containment step abuts second insert end 42 . These abutting relationships—along with the ribs on the insert—create a good mechanical interlock between the insert and the foam body.
[0025] Surface adhesion between the insert and the foam body may also assist in the creation of the desired interlock. This surface adhesion may be created by a variety of processes, including molding the foam over the insert or the use of a separate spray-on or liquid adhesive.
[0026] FIG. 4 serves to illustrate several significant features of the invention. First, the reader will note that exterior profile 38 has a varying diameter. It is intended to resemble the exterior shape of the central portion of an American football. This portion of an American football has an elliptical profile, where the major axis of the defining ellipse is parallel to central axis 22 but also offset from the central axis.
[0027] Exterior profile 38 has a maximum diameter in the center of the orb ball. This diameter tapers toward either end of the ball. The diameter of the internal passage remains constant (or nearly so). Foam body 28 extends to first end 34 and second end 36 . However, in the embodiment shown, the elliptical exterior profile 38 does not extent all the way to the ends of the orb ball. Instead, a chamfer 44 is included proximate first end 34 and second end 36 . In addition, a fillet 46 is used to join the extreme end of each chamfer to foam body passage 54 .
[0028] As shown in FIG. 4 , insert 14 does not extend all the way to the two ends of the orb ball. Instead, it stops short. First end 34 of foam body 28 extends well beyond first insert end 40 and second end 36 extends well beyond second insert end 42 . This extension creates a compression region 48 on each end of the orb ball. The compression region helps reduce the risk of injury or damage when the orb ball strikes something. The rigidity of the insert maintains the overall shape of the orb ball. However, the portions of the orb ball that may actually strike an external object (the exterior profile and the two ends) remain pliable.
[0029] FIG. 5 shows an elevation view of the orb ball looking in a direction that is perpendicular to central axis 22 . When the ball is thrown, the central passage allows air flow 26 through the interior of the ball. Air flows over the exterior of the ball in a conventional fashion.
[0030] FIG. 6 shows a sectional elevation view through the “fattest” portion of the orb ball—taken in a direction that is transverse to the central axis. Passage diameter 30 is shown, as is overall diameter 32 . In the preferred embodiment, passage diameter 30 is greater than half the value of overall diameter 32 . In an even more preferred embodiment, the passage diameter is greater than 55% of the overall diameter.
[0031] Those skilled in the art will understand the principles of angular momentum. In viewing FIG. 6 , the reader will note that most of the orb ball's mass is concentrated near its perimeter rather than along its central axis. This fact provides greater spin-stability for a given overall mass.
[0032] Looking back at FIG. 4 , those skilled in the art will discern another significant operational feature of the orb ball. As mentioned in the background section, an American football that is launched with an eccentric rotation (the ball's central axis being misaligned with the direction of flight) will tend to become less stable in flight. The orb ball's configuration produces the opposite result.
[0033] When the orb ball is thrown, air flows through its central passage with considerable velocity. The central passage acts like a wind sock, in that it will always tend to align itself with the prevailing flow. The prevailing flow is of course determined by the direction of the orb ball's flight. Thus, the flow through the central passage acts like a yaw damper for an imperfect throw. The term “imperfect throw” may apply to several conditions including: (1) The ball's axis of rotation is angularly offset from central axis 22 , (2) The ball's central axis is misaligned with the direction of flight, and (3) combinations thereof.
[0034] For any of these conditions the flow of air through the orb ball's central passage will tend to damp the error. In other words, the flow through the central passage will tend to (1) Shift the ball's axis of rotation so that it lies on the central axis, and (2) Align the central axis with the direction of flight. These stabilizing forces tend to reduce drag and increase the range of a particular throw. A further drag reduction results from the fact that the central passage reduces the orb ball's projected frontal area.
[0035] Still looking at FIG. 4 , the reader may wish to know some of the manufacturing processes that can be used to create preferred embodiments of the invention. Injection molding may be used to create insert 14 . The insert may be molded as a solid body or may be “foam molded”—meaning that gas bubbles are injected into the liquid thermoplastic to create a rigid cellular structure. This technique creates a strong and light structure reminiscent of animal bone in that it has a solid exterior but a porous interior.
[0036] Foam body 28 may be created using an overmolding process. In overmolding, the completed insert is placed into a larger mold cavity. A liquid foam molding agent is then added to the cavity. The foam molding agent transitions to a solid while still in the mold. The unified assembly is then removed from the mold.
[0037] Insert 14 may be made of any desired thermoplastic. It could also be made using a thermoset material or a cross-linking material. For that matter, insert 14 could even be made of a metal such as aluminum.
[0038] Foam body 28 is preferably made from a high-density compressible foam. A suitable foam has a density in the range of 20 kilograms per cubic meter up to 60 kilograms per cubic meter. An even more preferable range lies between 30 kilograms per cubic meter and 50 kilograms per cubic meter. A foam's density is largely dependent upon the cell site in comparison to the cell wall thickness. A variety of techniques can be used to determine this value in order to bring the foam into the desired range of density. A wide variety of foams could be used. Examples include HDPE (high-density polyethylene) and polyurethane foams.
[0039] Overmolding tends to produce a good surface bond between the insert and the foam body. The assembly may be created in other ways, however. For example, the foam body could be separately molded and then connected to the insert. The foam body is quite pliable so the insert could be slipped into the interior and snapped into position. A separate adhesive could also be used to facilitate the surface bond.
[0040] Although the preceding description contains significant detail, it should not be construed as limiting the scope of the invention but rather as providing illustrations of the preferred embodiments of the invention. One skilled in the art may easily devise variations on the embodiments described. Thus, the scope of the invention should be fixed by the claims rather than the examples given.
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A throwable ball having a large internal passage aligned with its central axis. An insert defines the bounds of the internal passage. This insert is surrounded by compressible foam that gives the ball an easy gripping surface. Interlock features are preferably provided between the insert and the compressible foam so that they do not slip relative to each other.
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GOVERNMENT RIGHTS
This application was funded under United States Department of Agriculture Contract No. 90-34189-5014 Sub of 4501. The United States Government has certain rights under this application and any patent issuing thereon.
CROSS-REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of application Ser. No. 08/376,395, filed Jan. 23, 1995, now U.S. Pat. No. 5,527,959.
BACKGROUND OF THE INVENTION
(1) Summary of the Invention
The present invention relates to table salt (sodium chloride) substitute compositions and their method of use. In particular, the present invention relates to physical mixtures of lysine monohydrochloride and potassium chloride, and optionally succinic acid which produce a salty taste and which unexpectedly closely parallels the taste of table salt.
(2) Description of Related Art
Numerous compositions have been described by the prior art as table salt substitutes. Illustrative are U.S. Pat. Nos. 1,874,055 to Liebrecht; 2,824,008 to Perri et al; 2,829,056 to Kemmerer; 3,015,567 to Hause et al; 3,993,795 to Mauror et al; 5,145,707 to Lee; 5,173,323 to Omari; 5,176,934 to Lee and 5,229,161 to Turk. Some of the compositions use lysine mono- or dihydrochloride and potassium chloride mixed together (Omari and Kemmerer); however, there are additional ingredients, particularly glutamates which produce allergic reactions (asthma, headaches, etc. in certain people) and do not enhance taste or sodium chloride, which is to be avoided in salt-free diets.
OBJECTS
It is therefore an object of the present invention to provide novel potassium chloride lysine monohydrochloride mixtures, preferably with a small amount of succinic acid which closely parallels the taste of table salt. Further, it is an object of the present invention to provide a method for using the compositions. Further, it is an object of the present invention to provide the compositions which are easily prepared as an admixtures. These and other objects will become increasingly apparent by reference to the following description.
DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention relates to an edible composition having a salty taste which consists essentially of an admixture selected from the group consisting of (1) lysine monohydrochloride and potassium chloride, and (2) the lysine monohydrochloride, the potassium chloride and succinic acid each of which are food grade, wherein the weight ratio of the lysine monohydrochloride to potassium chloride is between about 1 to 9 and 3 to 2 and wherein the ratio of lysine monohydrochloride to succinic acid is between about 3 to 1 and 13 to 1 and the composition has a pH between about 5.5 and 6.3.
The present invention also relates to a method for imparting a salty taste to a food which comprises providing an edible composition in the food which consists essentially of an admixture selected from the group consisting of (1) lysine monohydrochloride and potassium chloride, and (2) the lysine monohydrochloride, the potassium chloride and succinic acid which are food grade, wherein the ratio of the lysine monohydrochloride to potassium chloride is between about 1 to 9 and 3 to 2 and wherein the ratio of lysine monohydrochloride to succinic acid is between about 3 to 1 and 13 to 1 and the composition has a pH between about 5.5 and 6.3.
The composition is easily prepared by simple mixing of the ingredients. In order to mask the bitter aftertaste of the potassium chloride there must be between 10% to 60% of the lysine monohydrochloride. When crystals of lysine monohydrochloride are physically mixed with crystals of potassium chloride, the resulting mixture has the appearance of, and taste intensity of, table salt, without the characteristic taste of the potassium ion. Lysine monohydrochloride can also be co-crystallized with potassium chloride from a solution in which they are soluble (such as water) to produce a salty crystalline mixture. The succinic acid produces a more salty taste in amounts between about 0.1 and 10 percent by weight in the composition. In the most preferred compositions the weight ratio of lysine monohydrochloride to potassium chloride is between 2 and 3 to 7. When succinic acid is present, the weight ratio of lysine monohydrochloride to potassium chloride is 2 and 2.99 to 7 and the succinic acid is included in an amount between 0.1 and 10 percent by weight of the composition.
Lysine is an essential amino acid and thus is a dietary supplement. Potassium chloride is commonly used as a salt substitute to avoid sodium intake. Succinic acid is a common food acid. Thus, the composition fulfills dietary as well as taste needs.
The following are illustrative Examples of the compositions of the present invention.
EXAMPLE 1
Table 1 shows the results of taste tests by a taste panel of 3 people of various compositions incorporating lysine monohydrochloride (LysMhc) lysine monohydrate (Lysmh) potassium chloride (KCl) and an acid (HCl) or base (KOH).
TABLE 1______________________________________Salt Molar Ratio ofname Lys/Cl/K Solution comp. Sol. pH Taste______________________________________1 2:4:2 Lysmhc + KCl 5.55 Salty+++2 2:3:1 Lysmhc + KCl 5.66 Salty-acid3 2:2:1 Lysmhc + Lysmh + KCl 9.34 Salty4 4:3:1 Lysmhc + Lysmh + KCl 9.48 Salty-sweet5 2:2:1 Lysmhc + KOH 9.50 Salty- metallic6 2:6:2 Lysmhc + KCl + HCl 1.00 Acidic______________________________________ *The salt+ tastes saltier than salty and salty- tastes less saltier than salty. ** The water used was double distilled water.
A crystallized dry salt product composed of Lysmhc and KCl (1) with a molar ratio of 2:4 was found to possess the desired salty taste.
EXAMPLE 2
Table 2 shows the results of taste tests by a taste panel of 3 people for various mixtures of lysine monohydrochloride (Lysmhc) and KCl mixtures as dry salts and in solution.
TABLE 2______________________________________weight % Sol./2 gLysmhc/KCl Dry Mixture water pH______________________________________0/100 (25%) Irritates Irritates 7.6210/90 Salty++++* Salty++++ 6.2320/80 Salty+++ Salty++++ 6.2130/70 Salty++ Salty+++ 6.1240/60 Salty++ Salty+++ 6.0150/50 Salty+ Salty+ 5.9960/40 Salty Salty 5.9770/30 Salty- Salty+ 5.8780/20 Salty-- Salty+ 5.8390/10 Salty--- Salty-- 5.71100/0 (33%) Salty-sweet Salty-sweet 5.75100% dd** Water -- -- 5.70______________________________________ *The salt+ tastes saltier than salty and salty- tastes less saltier than salty. **double distilled water.
As can be seen from Table 2 mixtures including 10 to 60% of the lysine monohydrochloride with potassium hydrochloride had the desired taste both in dry form and in solution. These mixtures also had an acid pH between about 5.5 and 6.3 depending upon the amount of lysine monohydrochloride.
EXAMPLE 3
Table 3 shows different concentrations of a thirty weight percent (30%) lysine monohydrochloride to potassium chloride mixture (dry) mixed which is then dissolved in water used in taste tests by a taste panel of 3 people.
As can be seen, the mixture can be used in an amount up to about 30% by weight in water to produce the desired salty taste.
TABLE 3______________________________________30 wt % Lys/KClCont. in water pH Taste Comment______________________________________10 6.04 salty Clear sol.20 6.02 salty+ Clear sol.30 6.02 Salty++ Clear sol.40 5.90 Irritates Saturated25% (100% KCl) 7.62 Irritates Clear sol.25% (100% 7.11 Standard BlurredNaCl) sol.______________________________________
No other amino acid tested (including glutamic acid, glutamic acid monohydrochloride, glycine, glycine monohydrochloride, and lysine monohydrate) provided the masking of the potassium taste. The optimal concentration of lysine monohydrochloride in the mixture was about thirty percent (30%) by weight in Example 3 based upon taste tests.
EXAMPLE 4
A preference test was conducted in which 38 panelists participated and tasted four dry samples in random order. The samples were:
1. 70/30 wt % potassium chloride/crystalline lysine monohydrochloride, which is the subject of the current application.
2. Commercially available MORTON SALT SUBSTITUTE (containing potassium chloride, fumaric acid, tri- and mono-calcium phosphate).
3. Example 1 of U.S. Pat. No. 2,829,056 (containing lysine dihydrochloride, mono-potassium glutamate, potassium chloride and tricalcium phosphate).
4. Regular table salt.
The results of this test indicated the composition No. 1 of the invention was preferred to No. 2 and No. 3. The ranking of Samples No. 1, No. 2 and No. 3 were 61, 75, and 86, respectively, with the lowest number being preferred. The ranking was determined as follows: There was statistically difference at the 95% level between No. 1 and No. 3 (U.S. Pat. No. 2,829,056), but the difference between No. 1 and No. 2 was not statistically significant.
EXAMPLE 5
Taste trials were performed to assess the intensity of the composition No. 1 of the invention in aqueous solution. In these trials a fifth sample was added to those of Example 4.
5. Same as No. 1 with 10% succinic acid added.
A 4% solution was prepared of each sample and the rank scores were 16, 49, 50, 55, and 55 for samples No. 4, No. 5, No. 2, No. 3 and No. 1, respectively. This test indicates that the samples No. 1 and No. 5 were about 50% the intensity of regular table salt.
EXAMPLE 6
Succinic acid (SA) was added to physical mixtures of potassium chloride (KCl) and lysine monohydrochloride (LysMhc). The results are shown in the following Table 4.
TABLE 4______________________________________Wt % KCl/LysMhc/SA Dry Mixture Taste 4% Solution Taste______________________________________70/30/00 salty very mild salty70/15/15 very acidic, irritates very acidic, irritates70/20/10 very acidic acidic70/25/05 salty acidic salty acidic70/27.5/2.5 very good salty mild salty45/45/10 salty acidic very little saltiness______________________________________
These data indicate that there is a taste improvement by addition of a small amount of succinic acid. The ratio of lysine monohydrochloride to succinic acid that gives this advantage is 10:1 as in application Ser. No. 08/376,395, filed Jan. 23, 1995. Preferably between about 2.5 and 2.9 percent of the composition is succinic acid and the remainder is potassium chloride.
It is intended that the foregoing description be only illustrative of the present invention and that the present invention be limited only by the hereinafter appended claims.
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A physical mixture which consists essentially of compositions of lysine monohydrochloride and potassium chloride alone or admixed with small amounts of succinic acid, in particular weight ratios, and which has a salty taste comparable to table salt (sodium chloride). The mixture masks the bitter aftertaste of the potassium chloride and can provide dietary lysine which is an essential amino acid.
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RELATED APPLICATIONS
Applicants claim priority of Japanese Application No. 2005-123595, filed on Apr. 21, 2005, and Japanese Application No. 2005-152777, filed on May 25, 2005.
FIELD OF THE INVENTION
The present invention relates to a fuel system and more particularly to a fuel control device for a combustion engine.
BACKGROUND OF THE INVENTION
Internal combustion engines can operate on multiple types of gaseous fuels such as petroleum-based propane gas and butane gas. Unfortunately, propane gas and butane gas have different calorific values and therefore must be provided to the engine at specific pre-determined pressures dependent upon the type of gas. Because specific gasses must flow at specific pressures the ability of an engine to run utilizing a variety of different fuels is somewhat moot because an easy and economical means of varying fuel supply pressures to correspond to different gas types is not available.
SUMMARY OF THE INVENTION
A fuel control device for a combustion engine, that is capable of running on any one of a plurality of fuels, has a fuel selection module with a plurality of fuel type settings for selecting a specific fuel type. The fuel control device controls the outlet pressure of a chosen fuel to a fuel pressure that generally corresponds to the calorific properties of the chosen fuel, preferably in a gaseous state. The fuel selection module preferably operates a plurality of fuel flow circuits for each fuel-type setting each having a biased closed inlet valve supported by an inlet valve bank and a biased closed outlet valve supported by an outlet valve bank. Preferably, the fuel selection module includes a single rotating camshaft having a plurality of cams with each cam associated with a specific one of the plurality of fuel flow circuits. Each flow circuit includes a pair of pushrods or followers that are selectively activated by the respective cam to simultaneously open respective inlet and outlet valves. Located preferably between each inlet and outlet valve is a pressure regulator unit or jet designated for the specific fuel type and controlling the outlet fuel flow pressure.
Located preferably between the pressure regulating units and the inlet valves is a fuel metering apparatus having a shutoff valve for preventing fuel flow after the fuel-type is chosen by an operator but before the engine is started and a flow valve adapted to operate relative to a fuel metering chamber for controlling the amount of fuel flowing through the outlet valve bank. Actuators of the flow and shutoff valves of the fuel metering apparatus are preferably of a diaphragm-type and generally open the valves upon specific pressure signals produced by the starting and/or running engine allowing for a relatively compact fuel metering apparatus design. Preferably, the biased closed flow valve opens upon a sufficient vacuum or decrease in pressure sensed from a venturi region of a mixing passage of a carburetor upstream from a throttle valve. The shutoff valve is preferably biased closed and opens upon a vacuum or decrease in pressure sensed from the mixing passage downstream of the throttle valve.
In one implementation, the shutoff valve of the fuel metering apparatus and the associated valve actuator preferably operate along a common centerline. Unlike known pressure regulators or fuel metering apparatuses, the fuel flowing through the open shutoff valve of the fuel metering apparatus is not exposed directly to the actuator vacuum and thus is not restricted to a pressure needed to open the valve. The shutoff valve is preferably of a poppet-type having a valve stem that moves along the centerline when an elongated member of the actuator moves along the same centerline and pushes upon the valve stem to move a head of the valve away from a valve seat. The elongated member of the actuator connects to a large diaphragm located between a reference chamber and a vacuum chamber communicating with the mixing passage and a smaller diaphragm near the shutoff valve. The smaller diaphragm generally divides a displacement chamber that communicates with the vacuum pressure of the vacuum chamber and a valve cavity through which the selected fuel type flows downstream of the valve seat. The elongated member of the actuator is displaced linearly toward the valve stem by a force equated from the difference between the vacuum exposed surfaces of the large and smaller diaphragms.
Because in this implementation the shutoff valve and pressure of the fuel flowing therethrough is independent of the needed operational pressures of the valve actuator and because the elongated member of the actuator moves linearly in the direction of the diaphragm movement, the only relative forces are linear adding to stability of the valve actuation and durability of the diaphragm.
Moreover, since the vacuum diaphragm is provided externally of the fuel metering chamber associated with the actuator of the flow valve, freedom in layout design can be improved and the size of the vacuum diaphragm can be selected at wi11 without regard to the size of the fuel metering chamber. Therefore, even when the vacuum pressure is small, a relatively large force can be produced, and this expands the range of the control of the shutoff valve. For instance, the shutoff valve can be opened even while the vacuum pressure is relatively small. Whereas, if the vacuum diaphragm of the shutoff valve actuator is provided in the metering chamber of the flow valve actuator, an increase in the size of the vacuum diaphragm necessarily increases the overall size of the fuel metering apparatus.
Other advantages of the present invention include a fuel control device that facilitates selection of fuel-types, can be mounted to an engine capable of running on any one of a plurality of fuels, and a fuel metering apparatus that is easily adapted to different specifications so as to meet the needs of different engines while utilizing an identical structure. Other advantages include a robust shutoff valve actuator that is generally free of air leakage concerns about the elongated member, and a device that automatically shuts off fuel flow when the engine is stopped thereby conserving fuel, a device that is simple in design and inexpensive enough to warrant use on small engine applications, and in service has a long and useful life. Of course, other advantages may be realized and devices incorporating the present invention may achieve some, all, or none of these advantages.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other objects, features and advantages of the invention will become apparent from the following detailed description of preferred embodiments and best mode, appended claims, and accompanying drawings in which:
FIG. 1 is a cross section of a fuel control device embodying the present invention having a fuel metering apparatus shown closed and a fuel selection module shown in an all-closed position;
FIG. 2 is a cross section of a first or upper fuel circuit of the selection module shown closed and taken along line 2 - 2 of FIG. 1 ;
FIG. 3 is a cross section of a second or lower fuel circuit of the selection module shown closed and taken along line 3 - 3 of FIG. 2 ;
FIG. 4 is a partial cross section of the fuel control device similar in perspective to FIG. 1 and illustrating the first fuel circuit closed and the second fuel circuit open when the selection module is in a first selected gas position;
FIG. 5 is a cross section of the first fuel circuit being closed and taken along line 5 - 5 of FIG. 4 ;
FIG. 6 is a cross section of the second fuel circuit being open and taken along line 6 - 6 of FIG. 4 ;
FIG. 7 is a partial cross section of the fuel control device similar in perspective to FIG. 1 and illustrating the first fuel circuit of the fuel switching device open and the second fuel circuit closed when the selection module is in a second selected gas position;
FIG. 8 is a cross section of the first fuel circuit being open and taken along line 8 - 8 of FIG. 7 ;
FIG. 9 is a cross section of the second fuel circuit being closed and taken along line 9 - 9 of FIG. 7 ;
FIG. 10 is an enlarged cross section of the fuel metering apparatus shown open and similar in perspective to FIG. 1 ; and
FIG. 11 is an enlarged cross section of a shutoff valve of the fuel metering apparatus shown open and taken from circle 11 of FIG. 10 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
As best illustrated in FIG. 1 , a fuel control device 20 supplies any selected one of a plurality of preferably petroleum-based fuels to a multi-fuel compatible combustion engine. As illustrated, the number of different fuels are preferably two (although more than two may be used) which are preferably butane and propane, which may be stored in a pressurized liquid state and expand into a gaseous state generally when flowing into the device 20 from a propane storage cylinder or source 22 and a butane storage cylinder or source 24 . Although the multiple gaseous fuels are illustrated as propane and butane gas, the present invention is not limited to this example and may be adapted to handle any number or variety of gaseous fuels including but not limited to natural gas.
The fuel control device 20 is generally modularized, having a centralized fuel selection module 26 located between an inlet valve bank 28 and an interacting outlet valve bank 30 . A fuel metering apparatus 32 is in gaseous communication with and is preferably attached sealably to a side of the fuel selection module 26 spanning between the valve banks 28 , 30 . Preferably, a control knob 34 projects through a fourth side of the fuel selection module 26 located opposite to the side supporting the metering apparatus 32 .
A support body 36 of the inlet valve bank 28 carries a propane inlet port 38 that generally communicates with and preferably threads to the propane storage cylinder 22 via suitable tubular or pipe fittings. A propane inlet passage 40 in the support body 36 communicates between the inlet port 38 and an intake manifold 42 generally defined between the support body 36 of the inlet valve bank 28 and a centralized main body 44 of the fuel selection module 26 . Similarly, a butane inlet passage 46 extends through the support body 36 and intermittently communicates between the intake manifold 42 and preferably a butane conditioning module 48 that receives butane fuel from the butane storage cylinder 24 at an inlet port 50 of the module 26 , is heated as the butane flows through a heating element 52 and pressure controlled at a butane gas pressure regulator 54 of the module 26 typically known in the art. Preferably, the inlet port 50 is threaded for receipt of external butane cylinder fittings and is carried by a heater cover 56 that when removed from the conditioning module 48 exposes the heating element 52 for repair and/or replacement. One skilled in the art would now know that the butane conditioning module 48 can be remotely located away from the fuel switching and pressure regulating device 20 or may not be required at all if butane fuel is not one of the plurality of fuels controlled by device 20 .
As best illustrated in FIGS. 1-4 , a blind bore 58 in the main body 44 of the fuel selection module 26 receives a camshaft 60 that rotates about axis 62 and projects outward to a distal end terminating at the control knob 34 . Preferably, the camshaft 60 is held axially in the blind bore 58 by a retaining pin 64 fixed to the main body 44 and projecting into a circumferential, continuous groove 66 in the camshaft 60 . As illustrated, the camshaft 60 carries two preferably recessed cams described as a butane cam 68 ( FIG. 2 ) and a propane cam 70 ( FIG. 3 ) for opening and closing respective flow circuits 72 , 74 each having a biased closed inlet valve 76 and a generally redundant and biased closed outlet valve 78 . The axial cross section of the butane cam 68 is preferably generally S-shaped (see FIG. 2 ) and the axial cross section of the propane cam 70 is generally a mirror image or Z-shaped (see FIG. 3 ). Both shapes are substantially symmetric about the axis 62 . Alternatively, one skilled in the art would now know that the cams 68 , 70 could be more than two, thus controlling more than two flow circuits. Furthermore, one skilled in the art would now know that the cams need not be radially recessed but can, for example, be lobes that project radially outward from the shaft 60 , and the cross sections could both be S-shaped or otherwise contoured or shaped, for instance restricting rotation of knob 34 in the counter-clockwise direction or vise-versa.
As best illustrated in FIGS. 2-4 , each flow circuit 72 , 74 has an inlet push rod 80 associated with the inlet valve 76 and an outlet push rod 82 associated with the outlet valve 78 . The push rods 80 , 82 are preferably opposed diametrically to one another with respect to axis 62 and are supported axially slidably in respective inlet and outlet through-bores 84 , 86 in the main body 44 of the fuel selection module 26 . The inlet though-bores 84 extend and communicate between the blind bore 58 and the intake manifold 42 defined preferably by the main body 44 and a body 36 of the inlet valve bank 28 . Similarly, the outlet through-bore 86 associated with the butane flow circuit 72 extends and communicates between the blind bore 58 and a butane cavity 88 defined between the main body 44 of the fuel selection module 26 and a support body 90 of the outlet valve bank 30 . The outlet through-bore 86 associated with the propane flow circuit 74 extends and communicates between the blind bore 57 and a propane cavity 92 defined between the main body 44 of the fuel selection module 26 and the support body 90 of the outlet valve bank 30 .
The inlet and outlet push rods 80 , 82 preferably reciprocate along a common centerline 94 concentric to the through-bores 84 , 86 and substantially perpendicular to axis 62 . Each rod 80 , 82 of each flow circuit 72 , 74 when open (see FIGS. 4 and 6 - 8 ) is biased against the butane and propane cams 68 , 70 at rounded radial inward ends 99 , 101 by respective compression springs 96 , 98 coiled about the opposite radially outward ends 100 , 102 of the respective push rods 80 , 82 . Preferably, the spring 96 associated with the inlet push rod 80 is compressed axially between a circumferentially extending and radially projecting collar 104 of push rod 80 and the body 36 of the inlet valve bank 28 . The outward end 100 , the spring 96 and the collar 104 are generally located in the intake manifold 42 . Similarly, the spring 98 associated with the outlet push rod 82 is compressed axially with respect to centerline 94 between a circumferentially extending and radially projecting collar 106 of push rod 82 and the body 90 of the outlet valve bank 30 . The outward ends 102 , the springs 98 and the collars 106 are generally located in the respective cavities 88 , 92 .
Pressure regulating units or jets 95 , 97 permit a desired fuel supply pressure to be achieved and provided into respective cavities 88 , 92 from a common distribution chamber 93 in the main body 44 . The pressure regulating units 95 , 97 are preferable fuel jets press fitted or fixed into bores defined by the main body 44 . The butane and propane jets 95 , 97 preferably are manufactured with equal outer diameters but have varying inner diameters dependent upon the type of gaseous fuel they will flow. As best shown in FIGS. 1 and 10 , the distribution chamber 93 receives the flow of gaseous fuel from the metering apparatus 32 , which meters fuel flow and in-part controls fuel pressure regardless of fuel type. The metering apparatus 32 communicates with and receives fuel flow from the upstream intake manifold 42 . Because the gaseous fuel pressure at the inlet side of the butane and propane jets 95 , 97 is known and held substantially constant by the metering apparatus 32 , the inner diameters of the respective jets 95 , 97 are sized to obtain the desired fuel pressures at a given flow rate for the respective gases at an outlet passage 120 of the fuel control device 20 in the outlet valve bank 30 . Although fuel jets are an efficient and economical way to control fuel pressure, one skilled in the art would now know that other types of pressure regulating units can be exchanged with the fuel jets including, for example, more complex units typically incorporating biasing springs and/or resilient diaphragms.
The biased closed inlet valves 76 of the butane and propane flow circuits 72 , 74 are preferably poppet valves and have peripheral housings or sleeves 108 (see FIGS. 4 and 7 ) that press fit or thread into outlets of the respective butane and propane inlet passages 46 , 40 . A valve stem 110 of each valve carries an enlarged head 112 at a leading end and an enlarged abutment or heel 114 at the opposite trailing end along the centerline 94 . A semi-conical compression spring 116 is located concentrically about the associated centerline 94 and compressed axially between an annular surface carried by the sleeve 108 and the enlarged abutment 114 for biasing the valve head 112 sealably against an annular valve seat 130 carried by the sleeve 108 and substantially facing upstream into the passages 46 , 40 . The spring 116 and abutment 114 of valve stem 110 are generally exposed in the intake manifold 42 .
Similarly, the biased closed outlet valves 78 of the butane and propane flow circuits 72 , 74 are preferably poppet valves and have peripheral housings or sleeves 118 that press fit or thread into inlet ports of the common outlet passage 120 of the outlet valve bank 30 in the support body 90 . As best shown in FIGS. 2-3 and 5 - 6 , a valve stem 122 of each outlet valve 78 carries an enlarged head 124 at one end and an enlarged abutment or heel 126 at the opposite end. A semi-conical compression spring 128 is located concentrically about the associated centerline 94 and compressed axially between an annular surface carried by the sleeve 118 and the enlarged abutment 126 for biasing the valve head 124 sealably against an annular valve seat 130 carried by the sleeve 118 and substantially facing downstream into the outlet passage 120 (see FIG. 7 ). The spring 128 and abutment 126 of valve stem 122 or respective butane and propane flow circuits 72 , 74 are generally exposed in respective butane and propane cavities 88 , 92 . The enlarged abutments 114 , 126 of the respective inlet and outlet valves 76 , 78 co-axially confront the radially outward ends 100 , 102 of the inlet and outlet push rods 80 , 82 .
As best illustrated in FIG. 1 , the intake manifold 42 communicates with an inlet channel 140 in a support body 138 of the metering apparatus 32 . The distribution chamber 93 receives gaseous fuel at a prescribed pressure and generally regardless of fuel type from an outlet channel 144 in the support body 138 .
As best illustrated in FIGS. 1 and 10 , the support body 138 includes a base portion 146 that also includes a cover 148 , a middle plate 150 , and a cap 152 . The middle plate 150 is sealably carried between the cover 148 and the base portion 146 , and the base portion 146 is disposed between the middle plate 150 and the cap 152 . The base portion 146 supports an upstream, diaphragm-operated, shutoff valve 154 of the metering apparatus 32 orientated operatively between the inlet channel 140 and a mid channel 156 in the base portion 146 and supports a downstream, diaphragm-operated, flow valve 158 biased closed and orientated operatively between the mid channel 156 and the outlet channel 144 .
As best illustrated in FIGS. 10 and 11 , the shutoff valve 154 is preferably a poppet valve actuated by a vacuum pressure from an operating combustion engine, and similar in design to the inlet and outlet valves 76 , 78 . The shutoff valve 154 is preferably an insert 160 fitted into an outlet end or counter bore of the inlet channel 140 through a first side 162 of the base portion 146 . Preferably, the insert 160 includes a cylindrical spring retainer 164 and a valve seat 174 press-fit to the retainer 164 . The valve seat 174 and retainer 164 surround or encircle a valve stem 166 . The valve stem 166 extends axially and carries an enlarged head 168 at a leading end and an enlarged abutment or heel 170 at a trailing opposite end. A semi-conical or frustum-shaped compression spring 172 is located concentrically about the valve stem 166 and compressed axially with respect to the centerline between an annular ledge preferably carried by the spring retainer 164 and a spring clip 165 engaged to the heel 170 for biasing the valve head 168 sealably against the valve seat 174 . One skilled in the art would now know that other alternatives exist to hold an insert 160 carrying a valve seat 174 firmly to the base portion 146 of the support body. For instance, the insert 160 could be engaged threadably to the base portion 146 or if orientation and machining techniques permit, the annular seat 174 could be machined directly to the base portion 146 .
The heel 170 of the shutoff valve 154 communicates with a chamber 176 that communicates directly downstream with the mid channel 156 and is generally defined between a gas side of a resiliently flexible diaphragm 178 sealed along a periphery to the middle plate 150 of the support body 138 , and the first side 162 of the base portion 146 of the body 138 . A displacement chamber 180 is defined between an opposite vacuum side of the diaphragm 178 and the middle plate 150 .
An actuator 182 of the shutoff valve 154 opens the shutoff valve 154 preferably upon receiving a sufficient vacuum pressure from a starting or running combustion engine. The actuator 182 preferably has reciprocating rod or member 184 located and supported slidably in a bore 186 in the supplemental portion 150 . A first end of the member 184 is generally located in the middle plate 180 and is attached to a central portion of the diaphragm 178 . The rod 84 is connected at its other end to a resilient diaphragm 190 that defines a vacuum or pressure chamber 188 on one side and a reference chamber 192 on the other side. The reference chamber may communicate with the atmosphere through a vent 193 . Because the actuator 182 must produce a sufficient axial force to open the shutoff valve 154 against the resilient compressive force of spring 172 , the diameter or size of diaphragm 190 preferably is substantially larger than that of the diaphragm 178 .
A peripheral edge 194 of the diaphragm 190 is sealed continuously between the middle plate 150 and the cover 148 . A compression return spring 196 is disposed in the pressure chamber 194 for compression between the middle plate 150 and a reinforcement plate 198 generally carried by the diaphragm 190 . The cover 148 further has an inward projecting stop that opposes or confronts the diaphragm 190 in the reference chamber 192 to define the maximum displacement of the diaphragm 190 under the biasing force of the return spring 196 .
Preferably, the middle plate 150 supports a barbed nipple 200 that generally communicates with a fuel-and-air mixing passage 202 of a carburetor downstream of a throttle valve 204 (see FIG. 1 ) and a vacuum channel 206 in the supplemental portion 150 that tees-off to communicate with both the displacement chamber 180 and the pressure chamber 188 (see FIG. 10 ). One skilled in the art would now know that alternatively to the carburetor, the nozzle 200 and thus vacuum chamber 184 could communicate with an intake manifold of the engine, or a crankcase of a two-stroke engine.
For two-stroke engine applications which produce positive pressure pulses or blow-back from the engine, a check valve 208 ( FIG. 10 ) preferably is located at the inlet of the vacuum channel 206 and preferably is supported by the middle plate 150 adjacent to the nozzle 200 . The check valve 208 opens when the pressure in the displacement chamber 180 and pressure chamber 188 are greater than in the nipple 200 , and closes when this condition does not exist or a positive pressure impulse is received from the two-stroke engine. For four-stroke engine applications, the check valve 208 can be omitted since such engines provide a stable negative pressure signal.
As best illustrated in FIGS. 1 and 10 , the flow valve 158 of the metering apparatus 32 located downstream of and communicating with the shutoff valve 154 via the mid channel 156 is preferably actuated or opened by a diaphragm-type actuator 210 and biased closed by a compression spring 212 . An elongated lever or arm 214 of the flow valve 158 connects pivotally to a pin 216 fixed to the base portion 146 of the support body 138 . When the valve 158 is biased closed, a valve head 218 fixed to one end of the lever 214 releasably seats against an annular valve seat 220 carried by a cylindrical, flanged, ring 222 press fitted into a counter bore of the mid channel 156 (see FIG. 10 ). An opposite end 224 of the lever 214 is located substantially diametrically opposite the valve head 218 with respect to the center pin 216 and is biased away from an external side 226 of the base portion 146 by the biasing force of the spring 212 compressed axially between the end 224 and the external side 226 . Preferably, the external side 226 of the body portion 146 generally faces in an opposite direction with respect to the face or side 162 of the body portion 146 .
The spring 212 , the lever 214 , the pin 216 and the valve head 218 are located in a control or fuel metering chamber 228 of the actuator 210 communicating between the mid channel 156 and the outlet channel 144 of the metering apparatus 32 . The metering chamber 228 is generally defined between the external side 226 of the base portion 146 and a gaseous side of a resiliently flexible diaphragm 230 . A reference or atmospheric chamber 232 of the actuator 210 is defined generally between an opposite or dry side of the metering diaphragm 230 and the cap 152 . A breathing hole 236 in the cap 152 communicates the reference chamber 232 with the outside environment and a peripheral edge 238 of the metering diaphragm 230 is compressed sealably between the base portion 146 and the cap 152 .
The metering diaphragm 230 of the flow valve actuator 210 carries a centrally positioned projection 240 located in the metering chamber 228 that confronts and is preferably spaced from the end 224 of the lever 214 when the flow valve 158 is closed and the actuator 210 is in a rest position (see FIG. 1 ). When the control chamber 228 is communicated with a vacuum pressure preferably from a venturi region 242 of the carburetor, operation of the actuator 210 is initiated and the diaphragm 230 flexes toward the lever 214 against the biasing force of a return spring 244 located in the reference chamber 232 and engaged under tension between the lid structure 234 and the dry side of the diaphragm 230 . Continued flexing of the diaphragm 230 upon sufficient vacuum pressure in the control chamber 228 causes the projection 240 to push upon the end 224 of lever 214 against the compressive force of the spring 212 to open the flow valve 158 (see FIG. 10 ).
As a fuel flow adjustment feature, the cap 152 of the fuel metering device 32 preferably carries a threaded cylindrical member or screw 246 . An external end of the screw 246 has a diametrically extending slot or recess 248 for receipt of a screwdriver or tool. An opposite end of the screw 246 is located in the reference chamber and has a surface 250 that engages the return spring 244 . During adjustment, rotation of the screw 246 toward the diaphragm 230 relieves a portion of the tensile force produced by the return spring 244 , thus less vacuum is required in the metering chamber 228 to open the flow valve 158 . Movement of the screw 246 away from the diaphragm 230 increases the spring force on the diaphragm 230 so a greater magnitude pressure signal is required to open the valve 158 .
As best illustrated in FIGS. 1-3 , when the combustion engine is shutdown, the operator rotates knob 34 to place the fuel selection module 26 in an all-closed position 252 so that gaseous fuel does not leak through the carburetor and engine. When in the all-closed position 252 , the inlet and outlet push rods 80 , 82 of the butane flow circuit 72 fully project into the blind bore 58 by the biasing force of the respective springs 96 , 98 , and are preferably radially spaced with respect to axis 62 from the cam 68 and spaced axially with respect to centerline 94 or from the respective heels 114 , 126 of the inlet and outlet valves 76 , 78 of the butane flow circuit 72 . Axial spacing of the rods 80 , 82 from the heels 114 , 126 permits the biasing force of the valve springs 116 , 128 to seat the respective valve heads 112 , 124 sealably against the valve seats 130 . Similar to the butane flow circuit 72 , the inlet and outlet pushrods 80 , 82 of the propane flow circuit 74 are axially spaced from the respective heels 114 , 126 of the inlet and outlet valves 76 , 78 . Unlike the butane flow circuit 72 , the inlet and outlet pushrods 80 , 82 of the propane flow circuit 74 are not radially spaced from the propane cam 70 of the camshaft 60 . Instead, the pushrods 80 , 82 are slightly biased against the propane cam 70 in respective and diametrically opposed intermediate recesses 254 , 256 carried by the propane cam 70 . Placement of the propane pushrods 80 , 82 into the respective recesses 254 , 256 provides a positive indication to the operator that the fuel selection module 26 is in the all-closed position 252 .
Also with the engine not running, the vacuum pressure required to open the shutoff valve 154 and the flow valve 158 of the fuel metering apparatus 32 is not present, hence, the valves 154 , 158 are biased closed by respective springs 172 , 212 . Primarily, closure of shutoff valve 154 , and to a lesser degree closure of flow valve 158 , act as a backup to further assure gaseous fuel does not leak into the engine during engine shutdown conditions.
As best illustrated in FIGS. 4-6 , when operating the engine with propane gas, the operator first rotates the knob 34 of the camshaft 60 by about ninety rotational degrees in a clockwise direction. This places the fuel selection module 26 in a propane flow position 258 prior to starting the engine. When rotating toward the propane flow position 258 , the general Z-shape of the propane cam 70 causes the inlet and outlet pushrods 80 , 82 of the propane flow circuit 74 to ride radially against the propane cam 70 and out of the respective intermediate recesses 254 , 256 . Continued rotation in the clockwise direction moves the pushrods 80 , 82 linearly and radially outward against the biasing force of the respective springs 96 , 98 , and when the pushrods 80 , 82 abut the valve heels 114 , 116 , then also against the biasing force of the respective inlet and outlet valve springs 116 , 128 . The camshaft 60 rotates until the pushrods 80 , 82 slip into diametrically opposed recesses 260 , 262 opened radially outward in the propane cam 70 . Placement of the propane pushrods 80 , 82 into the respective recesses 260 , 262 provides a positive indication to the operator that the fuel selection module 26 is in the propane flow position 258 .
When rotated into the propane flow position 258 , the butane cam 68 of the camshaft 60 has simultaneously rotated with the propane cam 70 , however, the S-shape of the butane cam 68 maintains a radial and circumferential space between the corresponding inlet and outlet pushrods 80 , 82 thus the respective inlet and outlet valves 76 , 78 of the butane flow circuit 72 remain spring-biased closed as previously described. Moreover, because the engine is not yet started, the fuel metering apparatus 32 , located between the intake manifold 42 and the outlet passage 120 , remains closed and propane does not yet flow through the fuel control device 20 (see FIG. 1 ).
When the combustion engine is started, the vacuum chamber 188 and the displacement chamber 180 of the shutoff valve actuator 182 receive a vacuum signal via the vacuum channel 206 and preferably from the mixing passage 202 of the carburetor downstream from the throttle valve 204 . A force generally equal to the vacuum pressure times the difference between the exposed areas of the diaphragm 190 and the diaphragm 178 overcomes the biasing force of the actuator spring 196 and moves the diaphragm 190 toward the middle plate 150 (see FIG. 10 ). Because the member 184 is connected between the diaphragms 178 and 190 , the diaphragm 190 also displaces the member 184 and the diaphragm 178 until the member 184 or diaphragm 178 engages the heel 170 and opens the shutoff valve 154 against the combined biasing force of the valve spring 172 and the actuator spring 196 .
With the shutoff valve 154 open, propane gas flows through the propane inlet passage 40 from the propane cylinder 22 , past the open propane inlet valve 74 , through the intake manifold 42 , the inlet channel 140 of the fuel metering apparatus 32 , past the open shutoff valve 154 and generally to the mid channel 156 . As the shutoff valve actuator 182 receives the vacuum pressure from downstream of the throttle valve 204 , the flow valve actuator 210 of the fuel metering apparatus 32 receives a substantially smaller vacuum pressure from the venturi region 242 of the mixing passage 202 upstream of the substantially or nearly closed throttle valve 204 and during engine starting. This smaller vacuum pressure during engine start is transmitted through the outlet passage 120 of the outlet valve bank 30 , then through the open propane outlet valve 78 , through the propane cavity 92 , the propane jet 97 , the distribution chamber 93 , and then through the outlet channel 144 of the fuel metering apparatus 32 that communicates directly with the metering chamber 228 of the flow valve actuator 210 . The vacuum pressure from the carburetor venturi region 242 creates a force acting on the diaphragm 230 and tending to flex the diaphragm toward the lever 214 .
With sufficient vacuum, the diaphragm 230 moves until the projection 240 of the diaphragm pushes against the end 224 of the lever 214 and against the added compressive force of valve spring 212 and generally minus any force produced by the propane pressure against the confronting valve head 218 . Movement of the end 224 of the lever 214 moves the head 218 away from the valve seat 220 opening the flow valve 158 until a sufficient increase in pressure in the metering chamber 228 causes the valve to close. When open as in FIG. 10 , the propane gas flows through the metering chamber 228 , the outlet channel 144 and the distribution chamber 93 . From chamber 93 and as illustrated in FIG. 4 , the propane gas flows through the propane jet 97 sized to cause a prescribed pressure drop placing the propane gas at a desired pressure for running the engine specifically on propane. The propane gas at the prescribed pressure flows past the open propane outlet valve 78 , through the outlet passage 120 and into the venturi region 242 of the carburetor.
After the engine has started, and the throttle valve 204 moves toward a wide open throttle position, the vacuum at the venturi region 242 increases causing preferably a greater deflection of the diaphragm 230 and preferably at a greater frequency. This causes the head 218 of the flow valve 158 to move further from the valve seat 220 and generally more often thus increasing propane gas flow to coincide with the increase in quantity of air flow resulting in a substantially consistent fuel-to-air mixture ratio supplied to the running engine.
As best illustrated in FIGS. 7-9 , when operating the engine with butane gas, the operator first rotates the knob 34 of the camshaft 60 by about ninety rotational degrees in a counter-clockwise direction. This places the fuel selection module 26 in a butane flow position 264 prior to starting the engine. When rotating toward the butane flow position 264 , the general S-shape of the butane cam 68 causes the inlet and outlet pushrods 80 , 82 of the butane flow circuit 72 to ride radially against the rotating butane cam 68 and the pushrods 80 , 82 of the propane flow circuit 74 to ride out of the respective intermediate recesses 254 , 256 . Continued rotation in the counter-clockwise direction moves the pushrods 80 , 82 of the butane flow circuit 72 linearly and radially outward against the biasing force of the respective rod springs 96 , 98 and when the pushrods 80 , 82 abut the valve heels 114 , 116 , then also against the biasing force of the respective inlet and outlet valve springs 116 , 128 of the butane flow circuit 72 (see FIG. 8 ). The camshaft 60 rotates until the pushrods 80 , 82 slip into diametrically opposed butane recesses 266 , 268 opened radially outward in the butane cam 68 . Placement of the butane pushrods 80 , 82 into the respective recesses 266 , 268 provides a positive indication to the operator that the fuel selection module 26 is in the butane flow position 264 .
When rotated into the butane flow position 264 , the propane cam 70 of the camshaft 60 has simultaneously rotated with the butane cam 68 , however, the Z-shape of the propane cam 70 creates a radial space between the inlet and outlet pushrods 80 , 82 thus the respective inlet and outlet valves 76 , 78 of the propane flow circuit 74 remain spring-biased closed as previously described (see FIG. 9 ). Moreover, because the engine is not yet started, the fuel metering apparatus 32 , located between the intake manifold 42 and the outlet passage 120 , remains closed and butane does not yet flow through the fuel control device 20 (see FIG. 1 ).
Starting of the engine with butane gas is similar to starting the engine with propane gas, and operation of the fuel metering device 32 is generally the same. However, the inlet passage 46 is preferably fitted with the butane pressure regulator 54 so that when the butane fuel is gradually consumed from the butane cylinder 24 the decrease in butane pressure in the commonly marketed and relatively small cylinder is not transmitted through the fuel metering apparatus 32 . Instead, the pressure regulator 32 supplies fuel at a relatively consistent pressure regardless of any considerable pressure decrease in the cylinder 24 . The butane gas preferably is further pressure regulated by the butane jet 95 before it is supplied to the carburetor mixing passage 202 .
When the operator shuts down the engine and the intake vacuum pressure decreases with the sudden decrease in engine speed or power, the resilient biasing force of springs 172 and 196 acting upon the large-diameter diaphragm 190 of the shutoff valve actuator 182 overcomes the force produced by vacuum pressure in the pressure chamber 188 and the shutoff valve 154 closes. With shutoff valve 154 closed, the supply of gaseous fuel flowing to the engine is stopped.
While the forms of the invention herein disclosed constitute presently preferred embodiments, many others are possible. For instance, the fuel selection module 26 and fuel flow circuits 72 , 74 can be replaced with solenoid valves requiring an electric power and an electric/electronic control unit. Furthermore, if the fuel is stored in gaseous form air can be premixed with the fuel thus alleviating the need for a conventional carburetor. It is not intended herein to mention all the possible equivalent forms, modifications or ramifications of the invention. It is understood that terms used herein are merely descriptive, rather than limiting, and that various changes may be made without departing from the spirit or scope of the invention as defined by the following claims.
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A fuel control device for a combustion engine capable of running on any one of a plurality of fuels has a fuel selection module with a plurality of fuel type settings for selecting a specific fuel type whereupon the fuel control device controls the outlet pressure of the chosen fuel to a desired fuel pressure corresponding to the calorific properties of the chosen fuel. The fuel selection module preferably operates a plurality of fuel flow circuits each designated for a specific fuel type, and each having a biased closed inlet valve and a biased closed outlet valve. Located preferably between each inlet and outlet valve is a pressure regulator designated for the specific fuel type and controlling the outlet fuel pressure. The device preferably includes a fuel metering apparatus and a shutoff valve that communicate with, and control in part, fuel flow through the fuel flow circuits.
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation application of and claims the benefit and priority of, U.S. patent application Ser. No. 14/305,357, filed on Jun. 16, 2014, which is a continuation-in-part of U.S. patent application Ser. No. 13/325,953, filed on Dec. 14, 2011, now U.S. Pat. No. 8,752,535, which claims priority to: (i) U.S. Provisional Patent Application No. 61/494,500, filed on Jun. 8, 2011; (ii) U.S. Provisional Patent Application No. 61/440,563, filed on Feb. 8, 2011; and (iii) U.S. Provisional Patent Application No. 61/422,770, filed on Dec. 14, 2010. The entire contents of the foregoing applications are hereby incorporated by reference.
FIELD
[0002] The present disclosure relates to devices for decocking a cocked crossbow. More particularly, the disclosure relates to a crossbow having an integrally incorporated device for facilitating decocking of the crossbow without dry firing or firing a projectile.
BACKGROUND
[0003] The disclosure relates to a crossbow that integrates a device uncocking of the crossbow, also called decocking of a crossbow. More directly, the disclosure relates to uncocking or decocking a ready-to-fire crossbow without dry firing or firing a projectile known in the art as an arrow or sometimes referred to as a bolt, a medieval term for a short arrow.
[0004] Crossbows are generally cocked by a manually drawing the bowstring by hand to a loaded position or by using a drawstring or a winch-type cranking mechanism that draws the bowstring that is attached to the bowlimbs of the crossbow into a loaded position where the string is locked by a trigger mechanism. This load also known as potential elastic energy is measured in the art today by draw pounds. Most modern crossbows bear draw weights from 100-200 pounds. Once the release mechanism is actuated by the trigger, the bowstring is released and the potential elastic energy transitions to potential kinetic energy.
[0005] Drawing a crossbow string to a cocked position is accomplished in several ways. Most commonly today, crossbows are outfitted with a steel or aluminum stirrup mounted on the front of the crossbow. The stirrup is used to hold the front of the bow down with one foot, while the bowstring is drawn using a drawstring typically comprised of braided nylon or polypropylene rope attached to hooks on each end with a “T” or “D” handle that traverses on the drawstring. By attaching the hooks to the bowstring, then stepping in the stirrup and pulling on the handles in an upward motion, the bowstring of the crossbow is drawn into a loaded cocked position.
[0006] Another method of cocking the crossbow is a cranktype mechanism. This mechanism uses a gear reduction manual cranking means as the method to draw the bowstring into the loaded position. Efficient as a cocking device, it is generally not recommended to attempt to uncock or decock the crossbow using this device as it can and may cause serious injury to the operator and potentially damage to the crossbow.
[0007] Once the bow is cocked, this stored load of elastic energy can be released transitioning to potential kinetic energy by the actuation of a trigger mechanism releasing the bowstring, which then propels a projectile known as an arrow although sometimes referred to as a bolt, with tremendous thrust and speed, away from the crossbow. This is also the typical manner of uncocking, decocking or unloading a cocked or loaded crossbow, which can result in losing, damaging or destroying the deployed arrow. In some jurisdictions it is illegal to exit a hunting area with a loaded weapon, such as a crossbow, requiring one to discharge the crossbow, propelling the arrow prior to exiting the field, a potentially dangerous and inefficient manner of unloading.
[0008] Accordingly, there is a need for a decocking structure that can be incorporated into a crossbow structure and operable to decock the crossbow without dry firing or tiring a projectile.
SUMMARY
[0009] The disclosure provides a crossbow having an integrated decocking system.
[0010] In one aspect, a crossbow according to the disclosure includes a stock having a static portion and a movable portion, a bow having a bowstring, a bowstring catch, a resistance system, and a bowstring coupling system coupled to the resistance system.
[0011] The resistance system includes a fluid containing cylinder having a movable piston and located within the static portion of the stock, and a shaft extending from the piston and having a terminal end. The piston is movable between a first position and a second position, and the cylinder includes an orifice having a size and extending through the piston to enable fluid to travel from one side of the piston to the other and to control the movement of the piston to a desired rate.
[0012] The bowstring coupling system includes a cable having a first portion releasably securable to the bowstring and a second portion of the cable interfacing with a location on the shaft of the resistance system.
[0013] The crossbow is decocked from a cocked state by releasably securing the cable to the bowstring, applying pressure to the piston by pulling on the shaft to extend the shaft, then actuating the catch to release the bowstring, wherein the released bowstring applies pressure to retract the shaft, which pressure is resisted by the resistance system, with the size of the orifice controlling the retraction of the shaft and thereby controlling travel of the bowstring and decocking of the crossbow.
[0014] In another aspect, a crossbow according to the disclosure includes a bow having a bowstring, a bowstring catch, a resistance system operatively associated with the crossbow, and a bowstring coupling system coupled to the resistance system.
[0015] The resistance system includes a fluid containing cylinder having a movable piston, the piston being movable between a first position and a second position at a desired rate.
[0016] The bowstring coupling system includes a cable having a first portion releasably securable to the bowstring and a second portion of the cable interfacing with the resistance system.
[0017] The crossbow is decocked from a cocked state by releasably securing the cable to the bowstring, applying pressure to the piston, then actuating the catch to release the bowstring, wherein the released bowstring applies pressure, which pressure is resisted by the resistance system to control travel of the bowstring and decocking of the crossbow.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] Further advantages of the disclosure are apparent by reference to the detailed description when considered in conjunction with the figures, which are not to scale so as to more clearly show the details, wherein like reference numbers indicate like elements throughout the several views, and wherein:
[0019] FIGS. 1-3 show a crossbow according to the disclosure having an integrated decocking system.
[0020] FIGS. 4-7 depict activation of the decocking system so that the crossbow may be decocked.
[0021] FIGS. 8-12 operation of the decocking system to decock the crossbow.
DETAILED DESCRIPTION
[0022] With reference to the drawings, there is shown a crossbow 10 having a decocking system 12 integrated into the crossbow 10 . The decocking system 12 is operable to enable decocking of the crossbow 10 without The crossbow 10 is shown in a relaxed state in FIGS. 1-3 . FIGS. 4-7 show the crossbow 10 in a tensioned state in which the crossbow is typically loaded with a bolt or arrow, with FIGS. 4-7 showing activation of the decocking system 12 so that the crossbow 10 may be decocked without dry firing thereof and without firing of a bolt or arrow. FIGS. 8-12 shows operation of the decocking system 12 to decock the crossbow 10 .
[0023] The crossbow 10 includes a bow 14 , bowstring 16 , trigger 18 , a stock including a forestock 20 and a butt stock 22 having a static portion 22 a and a movable portion 22 b, a catch 24 , and arrow groove 26 . An arrow or bolt is oriented in the groove 26 so that a nock of the bolt is maintained in contact with a central portion of the bowstring 16 retained by the catch 24 . To fire the crossbow 10 , a user activates the trigger 18 , which manipulates the catch to release the bowstring and thereby fire the bolt, and decock the crossbow.
[0024] The decocking system 12 includes a resistance system 30 and a bowstring coupling system 32 . The resistance system 30 supplies a resistance force to enable controlled return of the crossbow from the drawn state to the relaxed state. In this regard, the bowstring coupling system 32 couples the bowstring 16 to the resistance system 30 so as to enable the resistance system 30 to interact with the bowstring 16 .
[0025] The resistance system 30 may include a double-acting fluid cylinder 40 . In this regard, the term “fluid” will be understood to encompass both liquid and gas cylinders. A preferred fluid cylinder is a pneumatic cylinder having an internal piston from which extends in one direction a shaft 42 . A through-bored orifice extends through the piston to permit gas/air for other fluid) to travel from one side of the piston to the other side, it being understood that the size of the orifice controls passage of fluid and, hence, travel of the piston and, hence the shaft 42 , connected to the piston. A desired dimension of the orifice is 1/16 inches. The cylinder 40 includes an endcap 40 a at each end of the cylinder 40 , with the shaft 42 extending outwardly through one of the endcaps 40 a. The cylinder also includes a pair of ports located at opposite ends of the cylinder 40 for introduction of fluid (air for a pneumatic cylinder) into the cylinder 40 . Double acting pneumatic cylinders utilize air pressure to control movement in both the extending and retracting strokes, i.e., extension of the shaft out of the cylinder and retraction into the cylinder. In this regard, as will be explained more filly below, manual pressure is provided by pulling on the movable portion 22 b of the butt stock 22 coupled to the end of the shaft 42 to extend the shaft 42 and, when the bowstring 16 is released, the bowstring 16 applies pressure to retract the shaft 42 , with the size of the orifice controlling the retraction of the shaft 42 and thereby controlling de-tensioning of the crossbow 10 . The cylinder 40 may be otherwise integrated into the crossbow 10 and need not necessarily be located within the butt stock 20 .
[0026] The coupling system 32 couples the resistance system 30 to the bowstring 16 and includes a pair of pulleys 50 rotatably located on the shaft 42 interior of the movable portion 22 b of the butt stock 22 , a pair of cable cords or decocking cables 52 , one trained around each of the pulleys 50 . One free end of each of the cables 52 is secured to a spring-loaded cable reel 54 , and the other free end of each of the cables 52 is attached to a bow string hook 56 or other connecting structure for releasably connecting the end of the cables 52 to the bowstring 16 . Thus, each of the cables 52 is connectable to the bowstring 16 . While a single cable could be utilized, it is preferred to utilize at least two for redundancy. Each of the bow string hooks 56 is attached to one side of a cradle 58 that is releasably positionable on the crossbow 10 adjacent the arrow groove 26 . The cradle 58 is nominally positioned and maintained out of the way of the arrow groove 26 . However, when desired to activate the decocking system 12 , the cradle 58 is positioned within the arrow groove 26 so that the hooks 56 engage the bowstring 16 . In addition, the cradle 58 is configured to include a rearward surface that simulates the shape of a bolt so as to cooperate with safety features of the bow 10 that serve to disengage the trigger 18 when a bolt is not loaded and prohibit dry firing of the bow 10 . The cable reel 24 serves to retract the other ends of the cables 52 to maintain them taught relative to the static portion 22 a of the butt stock 22 . An additional pulley 60 is desirably located within the interior of the static portion 22 a of the butt stock 22 for separating the cables 52 to avoid tangling, one of the cables 52 being routed over the pulley 60 and the other over the pulley 60 . Additional pulleys and the like may be used to reduce friction and the like for routing the cables 52 in and out and within the butt stock 22 .
[0027] To utilize the decocking system 12 with a cocked crossbow, the bolt or arrow is removed and the system 12 is arranged to fill the cylinder 40 with fluid and the cradle 58 is located in the arrow groove 26 to position the hooks 56 to engage with the bowstring 16 . This is depicted in the sequence of FIGS. 4-7 . For example, as shown in FIGS. 4 and 5 , the cradle 58 is moved from its inactive position out of the way of the groove 26 and positioned on the groove 26 with the hooks 56 located adjacent the bowstring 16 . Next, as shown in FIGS. 6 and 7 , the movable portion 22 b of the butt stock 22 is pulled rearward which serves to extend the shaft 42 and thereby draw fluid (air) into the piston 40 . This also serves to tension the cables 52 and pull the hooks 56 into engagement with the bowstring 16 .
[0028] To decock the bow 10 , as depicted in FIGS. 8-12 , the trigger 16 is actuated to release the bowstring from the catch 24 . The force supplied by the bow 14 via the bowstring 16 acts via the cables 52 to urge the piston and the shaft 42 to the retracted position in the cylinder 40 . This movement of the piston forces fluid through the orifice thereof, moving the fluid from the front of the piston to behind the piston within the cylinder 40 . The small orifice size regulates the fluid volume at a specific flow rate, permitting the piston to move through the cylinder 40 at a slow regulated pace, thus allowing the crossbow to decock under a controlled state. By doing so, the bowstring 16 which is attached to the bow, moves slowly from a tensioned position to a neutral uncocked position.
[0029] Accordingly, it will be appreciated that crossbows according to the disclosure include an integrated decocking system that enables a bowstring of the crossbow to be positioned from a cocked, ready-to-fire position, to an uncocked and at-rest position without firing a projectile or without dry firing the crossbow.
[0030] The foregoing description of preferred embodiments for this disclosure has been presented for purposes of illustration and description, it is not intended to be exhaustive or to limit the disclosure to the precise form disclosed. Obvious modifications or variations are possible in light of the above teachings. The embodiments are chosen and described in an effort to provide the best illustrations of the principles of the disclosure and its practical application, and to thereby enable one of ordinary skill in the art to utilize the disclosure in various embodiments and with various modifications as are suited to the particular use contemplated.
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A crossbow de-tensioning apparatus includes, in an embodiment, a de-tensioning device configured to be coupled to a crossbow. The de-tensioning apparatus also includes at least one hook operatively coupled to the de-tensioning device. The at least one hook is configured to be hooked onto a bowstring of the crossbow.
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FIELD OF THE INVENTION
[0001] The present invention relates to a novel process for the preparation of indolinone derivatives, in particular 3-pyrrole substituted 2-indolinones having amide moieties on the pyrrole ring. Such compounds are useful in the treatment of abnormal cell growth, such as cancer, in mammals. The invention further relates to novel intermediates useful in said process and to compositions comprising indolinone derivatives as prepared by said process.
BACKGROUND OF THE INVENTION
[0002] Pyrrole substituted indolinone compounds, in particular those having an amide group on the pyrrole ring have been of interest. These compounds modulate protein kinase activity and are thus useful in treating diseases relating to abnormal protein kinase activity, for example various types of cancer.
[0003] A process for preparing the amide derivatives is disclosed in WO 01/60814. An appropriate pyrrole is formylated and subsequently condensed with a 2-indolinone to give a respective 5-(2-oxo-1,2-dihydroindole-3-ylidenemethyl)-1H-pyrrole. If a particular amide derivative of the pyrrole is desired, a formylated pyrrole having a carboxylic acid group is selected. The carboxylic acid group is reacted with the desired amine in the presence of DMF, 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide and 1-hydroxybenzotriazole. A scale-up procedure is also disclosed in which the amidation is conducted in the presence of DMF, benzotriazol-1-yloxytris(dimethylamino)phosphonium hexafluorophosphate (BOP) and TEA.
[0004] US 2003/0229229 relates to methods of synthesizing pyrrole substituted indolinone compounds having amide moieties on the pyrrole ring. The reaction proceeds via a pyrrole compound having aldehyde and acid moieties at the 5- and 3-positions respectively, which is then coupled with an amine and an oxindole to form the desired pyrrole substituted indolinone compound.
[0005] US 2006/0009510 relates to a method of synthesizing indolinone compounds, particularly pyrrole substituted indolinone compounds having amide moieties on the pyrrole ring. The method involves combining 2-oxindole with an amide substituted pyrrole compound in the presence of a formylating agent. This application refers to the process disclosed in US 2003/0229229, stating that the use of an acid-aldehyde substituted pyrrole compound results in consumption of excess amine due to formation of an imine-amide intermediate. This is overcome in the claimed process by utilizing a pyrrole intermediate with the desired amide substitution already in place.
[0006] Other examples of such compounds and their synthesis can be found, for example in WO 01/45689, WO 99/48868, U.S. Pat. No. 6,316,429, U.S. Pat. No. 6,316,635, U.S. Pat. No. 6,133,305, U.S. Pat. No. 6,248,771 and GB 1,384,097.
[0007] An example of a commercially available pyrrole substituted indolinone is sunitinib malate, marketed as Sutent®. Sunitinib is a multi-targeted receptor tyrosine kinase (RTK) inhibitor that was approved by the FDA for the treatment of renal cell carcinoma (RCC) and imatinib-resistant gastrointestinal stromal tumor (GIST).
[0008] In view of the importance of pyrrole substituted indolinones for the treatment of cancer, there is a great need for developing an alternative, relatively simple, economical and commercially feasible process for the synthesis of pyrrole substituted indolinones with a commercially acceptable yield and high purity.
SUMMARY OF THE INVENTION
[0009] It is therefore an object of the present invention to provide a novel improved but simple, economical and commercially feasible process for the synthesis of pyrrole substituted indolinones with a commercially acceptable yield and high purity.
[0010] The present inventors have surprisingly found that pyrrole substituted indolinones can be prepared with very high purity employing a simple and efficient process comprising novel intermediates. The prior art processes all employ 2-oxindole as an intermediate which is then coupled with an aldehyde substituted pyrrole compound. The present inventors have surprisingly found that utilizing a novel aldehyde substituted 2-oxindole results in pyrrole substituted indolinones of high purity.
[0011] Accordingly, in a first aspect there is provided a process for the preparation of a 3-pyrrole substituted 2-indolinone of formula (I)
[0000]
[0012] wherein:
[0013] R 1 is selected from the group consisting of hydrogen, halo, alkyl, cycloalkyl, aryl, heteroaryl, heteroalicyclic, hydroxy, alkoxy, —C(O)R 15 , —NR 13 R 14 , —(CH 2 ) r R 16 and —C(O)NR 8 R 9 ;
[0014] R 2 is selected from the group consisting of hydrogen, halo, alkyl, trihalomethyl, hydroxy, alkoxy, cyano, —NR 13 R 14 , —NR 13 C(O)R 14 , —C(O)R 15 , aryl, heteroaryl, —S(O) 2 NR 13 R 14 and —SO 2 R 20 ;
[0015] R 3 is selected from the group consisting of hydrogen, halo, alkyl, trihalomethyl, hydroxy, alkoxy, —C(O)R 15 , —NR 13 R 14 , —NR 13 C(O)R 14 , —NR 13 C(O)OR 14 and —SO 2 R 20 ;
[0016] R 4 is selected from the group consisting of hydrogen, halo, alkyl, hydroxy, alkoxy and —NR 13 R 14 ;
[0017] R 5 is selected from the group consisting of hydrogen, alkyl and —C(O)R 10 ;
[0018] R 6 is selected from the group consisting of hydrogen, alkyl and —C(O)R 10 ;
[0019] R 7 is selected from the group consisting of hydrogen, alkyl, aryl, heteroaryl, —C(O)R 10 and —C(O)R 17 ; or
[0020] R 6 and R 7 may combine to form a group selected from the group consisting of —(CH 2 ) 4 —, —(CH 2 ) 5 — and —(CH 2 ) 6 —;
[0021] with the proviso that at least one of R 5 , R 6 or R 7 must be —C(O)R 10 ;
[0022] R 8 and R 9 are independently selected from the group consisting of hydrogen, alkyl and aryl;
[0023] R 10 is selected from the group consisting of hydroxy, alkoxy, aryloxy, —N(R 11 )(CH 2 ) n R 12 and —NR 13 R 14 ;
[0024] R 11 is selected from the group consisting of hydrogen and alkyl;
[0025] R 12 is selected from the group consisting of —NR 13 R 14 , hydroxy, —C(O)R 15 , aryl, heteroaryl, —N + (O − )R 13 R 14 , —N(OH)R 13 and —NHC(O)R a (wherein R a is unsubstituted alkyl, haloalkyl or aralkyl);
[0026] R 13 and R 14 are independently selected from the group consisting of hydrogen, alkyl, cyanoalkyl, cycloalkyl, aryl and heteroaryl; or
[0027] R 13 and R 14 may combine to form a heterocycle group;
[0028] R 15 is selected from the group consisting of hydrogen, alkoxy, hydroxy and aryloxy;
[0029] R 16 is selected from the group consisting of hydroxy, —C(O)R 15 , —NR 13 R 14 and —C(O)NR 13 R 14 ;
[0030] R 17 is selected from the group consisting of alkyl, cycloalkyl, aryl and heteroaryl;
[0031] R 20 is alkyl, aryl, aralkyl, heteroaryl or heteroaralkyl; and
[0032] n and r are independently 1, 2, 3 or 4;
[0033] or a salt such as a pharmaceutically acceptable salt thereof;
[0034] comprising the step of reacting a compound of formula (III)
[0000]
[0000] or a salt thereof, wherein R 1 to R 4 are as hereinbefore described, with a compound of formula (II)
[0000]
[0000] or a salt thereof, wherein R 5 to R 7 are as hereinbefore described.
[0035] In a preferred embodiment of the first aspect of the present invention, R 1 , R 2 , R 3 and R 4 are each independently selected from hydrogen or a fluoro, chloro or bromo group. More preferably R 1 , R 3 and R 4 are each hydrogen and R 2 is selected from a fluoro, chloro or bromo group. Most preferably R 1 , R 3 and R 4 are each hydrogen and R 2 is a fluoro group.
[0036] In another embodiment of the first aspect of the present invention, R 20 is alkyl, aryl, aralkyl or heteroaryl.
[0037] In one embodiment of the process, at least one of R 5 , R 6 and R 7 is —COOH. Preferably one of R 5 , R 6 and R 7 is —COOH and two of R 5 , R 6 and R 7 are independently selected from hydrogen or an alkyl group such as a C 1-4 alkyl group. Preferably any alkyl groups of R 5 , R 6 and R 7 are unsubstituted. Preferably R 6 is —COOH. Preferably compound (II) is a carboxylic acid having structure (IIa)
[0000]
[0000] or a salt thereof, preferably wherein R 5 and R 7 are independently selected from hydrogen or an alkyl group such as a C 1-4 alkyl group, more preferably wherein R 5 and R 7 are independently selected from a C 1-4 alkyl group, and most preferably wherein R 5 and R 7 are methyl.
[0038] In an alternative process according to the invention, at least one of R 5 , R 6 and R 7 is —COR wherein R is selected from the group consisting of —N(R 11 )(CH 2 ) n R 12 and —NR 13 R 14 ; and R 11 to R 14 and n are as hereinbefore described. Preferably one of R 5 , R 6 and R 7 is —COR and two of R 5 , R 6 and R 7 are independently selected from hydrogen or an alkyl group such as a C 1-4 alkyl group. More preferably one of R 5 , R 6 and R 7 is —COR and two of R 5 , R 6 and R 7 are independently selected from a C 1-4 alkyl group. Preferably any alkyl groups of R 5 , R 6 and R 7 are unsubstituted. Preferably R 6 is —COR. Preferably compound (II) is an amide having structure (IIb)
[0000]
[0000] or a salt thereof, wherein:
[0039] R 5 and R 7 are as hereinbefore described;
[0040] R is selected from the group consisting of —N(R 11 )(CH 2 ) n R 12 and —NR 13 R 14 ; and
[0041] R 11 to R 14 and n are as hereinbefore described.
[0042] Most preferably R 5 and R 7 are methyl and/or R is —NH(CH 2 ) 2 NEt 2 .
[0043] In a preferred embodiment of a process according to the first aspect of the invention, the reaction occurs in an acidified polar solvent system. The polar solvent may be selected from polar aprotic solvents including ethers such as THF (tetrahydrofuran), diethyl ether and methyl t-butyl ether, N,N-dimethylformamide, dimethylsulfoxide, acetonitrile, esters such as ethyl acetate, and ketones such as acetone. Preferably the solvent is a polar protic solvent such as an alcohol or a carboxylic acid. More preferably the solvent is a hydroxylic organic solvent, preferably an alcohol. Preferably the alcohol is R α OH, wherein R α is selected from an optionally substituted alkyl or aralkyl group. Preferably the alcohol is monohydric. Preferably R α is an optionally substituted C 1-8 alkyl group, more preferably R α is an optionally substituted C 1-4 alkyl group. Preferably the alcohol is methanol, ethanol, 1-propanol, isopropanol, 1-butanol, 2-methyl-1-propanol, t-butanol, 1-pentanol, cyclopentanol, 1-hexanol, cyclohexanol, 1-heptanol or 1-octanol. Most preferably the solvent is ethanol.
[0044] In an alternate embodiment of a process according to the first aspect of the invention, the reaction occurs in an acidified non-polar solvent system, such as acidified toluene.
[0045] In another embodiment the acid is selected from the group comprising hydrohalogenic acids (for example, hydrofluoric, hydrochloric, hydrobromic or hydroiodic acid) or other mineral acids (for example, nitric, perchloric, sulfuric or phosphoric acid); or organic acids such as organic carboxylic acids (for example, propionic, butyric, glycolic, lactic, mandelic, citric, acetic, benzoic, salicylic, succinic, malic or hydroxysuccinic, tartaric, fumaric, maleic, hydroxymaleic, mucic or galactaric, gluconic, pantothenic or pamoic acid), organic sulfonic acids (for example, methanesulfonic, trifluoromethanesulfonic, ethanesulfonic, 2-hydroxyethanesulfonic, benzenesulfonic, toluene-p-sulfonic, naphthalene-2-sulfonic or camphorsulfonic acid) or amino acids (for example, ornithinic, glutamic or aspartic acid). Preferably the acid is selected from hydrohalogenic and other mineral acids, for example, hydrochloric acid, concentrated hydrochloric acid, sulfuric acid, concentrated sulfuric acid, and organic acids such as glacial acetic acid, p-toluene sulfonic acid. More preferably the acid is a hydrohalogenic acid. Most preferably the acid is hydrochloric acid, in particular when the solvent is ethanol.
[0046] In one embodiment of the first aspect of the present invention, the reaction occurs at a temperature of from 20 to 200° C., more preferably at a temperature of from 50 to 150° C., more preferably still at a temperature of from 70 to 100° C., most preferably at a temperature of about 80° C. In one embodiment, the reaction occurs at the reflux temperature of the solvent.
[0047] Preferably the reaction of the first aspect of the present invention occurs over a period of 30 minutes to 48 hours. More preferably the reaction occurs over a period of 2 to 24 hours, more preferably still over a period of 4 to 18 hours. Most preferably the reaction occurs over a period of 6 to 12 hours.
[0048] The inventors have found that utilizing the novel intermediate having structure (III) and in particular intermediate (IIIa) in the preparation of sunitinib results in a process that provides the claimed advantages. This intermediate is not taught or even alluded to in the prior art documents where it is only the 2-oxindole intermediate without the aldehyde substitution at the 3-position of the indole ring that is taught.
[0049] One embodiment of the first aspect according to the invention provides a process for preparing sunitinib having structure:
[0000]
[0000] or a pharmaceutically acceptable salt thereof, the process comprising the step of reacting a compound of formula (IIc)
[0000]
[0000] or a salt thereof, with a compound of formula (IIa)
[0000]
[0000] or a salt thereof.
[0050] In an alternative embodiment according to the first aspect according to the invention, a process for preparing sunitinib having structure
[0000]
[0000] or a pharmaceutically acceptable salt thereof, is provided, comprising the steps of reacting a compound of formula (IIIa)
[0000]
[0000] or a salt thereof, with a compound of formula (IIa) or (IIb)
[0000]
[0000] or a salt thereof, wherein R 5 and R 7 are both methyl groups and R is as hereinbefore described, and optionally converting the resulting intermediate to sunitinib.
[0051] Preferably according to either of the above two embodiments of the first aspect of the invention, a process is provided wherein the reaction occurs in an acidified polar solvent system, such as one discussed above. Preferably the solvent is a hydroxylic organic solvent, most preferably the solvent system is ethanolic hydrogen chloride.
[0052] Preferably also according to either of the above two embodiments, the acid is selected from those discussed above in relation to the first aspect of the present invention, more preferably the acid is selected from the group comprising mineral acids, for example, hydrochloric acid, concentrated hydrochloric acid, sulfuric acid, concentrated sulfuric acid, and organic acids such as glacial acetic acid, p-toluene sulfonic acid. Preferably the acid is hydrochloric acid, in particular when the solvent is ethanol.
[0053] A second aspect of the present invention provides a process for preparing an acid of formula (IIa), (IIa′) or (IIa″)
[0000]
[0000] or a salt thereof, wherein said acid (IIa), (IIa′) or (IIa″) is formed from the corresponding pyrrole ester (IId), (IId′) or (IId″)
[0000]
[0000] or a salt thereof, wherein;
[0054] R 5 to R 7 are as hereinbefore described; and
[0055] R e is an alkyl, aryl, heteroaryl, aralkyl, cycloalkyl or heterocycle group.
[0056] The acid (IIa), (IIa′) or (IIa″) may be formed from the corresponding pyrrole ester (IId), (IId′) or (IId″) by any method known in the art, such as those exemplified in “Protective Groups in Organic Synthesis” by T. W. Greene and P. G. M. Wuts (Wiley-Interscience, 4 th edition, 2006). For instance where R e is an aralkyl group such as a benzyl group, the acid may be formed from the corresponding pyrrole ester by hydrogenation.
[0057] Preferably the acid (IIa), (IIa′) or (IIa″), or a salt thereof, is formed from the corresponding pyrrole ester (IId), (IId′) or (IId″), or a salt thereof, by hydrolysis.
[0058] In those aspects and embodiments that employ the pyrrole intermediate (IIa), there is provided a preferred embodiment of the second aspect according to the invention comprising a process wherein the acid (IIa) or a salt thereof is formed by hydrolysis of pyrrole ester (IId)
[0000]
[0000] or a salt thereof, wherein:
[0059] R 5 and R 7 are as hereinbefore described; and
[0060] R e is an alkyl, aryl, heteroaryl, aralkyl, cycloalkyl or heterocycle group.
[0061] The hydrolysis of the second aspect of the invention may be acid or base catalysed. Preferably the hydrolysis is base catalysed. In certain embodiments according to the invention, the hydrolysis is performed in a solvent system comprising one or more polar solvent(s) and a base. The polar solvent(s) may be selected from polar aprotic solvents including N,N-dimethylformamide, dimethylsulfoxide, acetonitrile and ketones such as acetone, or from polar protic solvents including water, alcohols, carboxylic acids and amines, or from mixtures thereof. Preferably the solvent system comprises water, optionally with a second polar protic solvent such as an alcohol.
[0062] Preferably the solvent system comprises 1 to 50% water by volume, more preferably 5 to 25% water by volume, most preferably 10 to 15% water by volume.
[0063] Where an alcohol is used, preferably the alcohol is R β OH, wherein R β is selected from an optionally substituted alkyl or aralkyl group. Preferably the alcohol is monohydric. Preferably R β is an optionally substituted C 1-8 alkyl group, more preferably R β is an optionally substituted C 1-4 alkyl group. Preferably the alcohol is methanol, ethanol, 1-propanol, isopropanol, 1-butanol, 2-methyl-1-propanol, t-butanol, 1-pentanol, cyclopentanol, 1-hexanol, cyclohexanol, 1-heptanol or 1-octanol. Most preferably the alcohol is methanol.
[0064] Preferably the base is an alkoxide base such as a methoxide, ethoxide, t-butoxide, or an aryloxide base such as a phenoxide, or a hydroxide base. More preferably the base is a hydroxide base, preferably an alkali metal hydroxide such as sodium or potassium hydroxide.
[0065] In one embodiment of the second aspect of the present invention, the solvent system is a combination of methanol and potassium hydroxide. Alternatively, the solvent comprises one or more of the group comprising water, one or more alcohols and a base. In a preferred embodiment the solvent comprises a combination of water and methanol, which in a particularly preferred embodiment are in a ratio of about 0.4:3. In another embodiment of the process according to the second aspect, the base is an inorganic base. In a particularly preferred embodiment, the inorganic base is potassium hydroxide. The inventors have found a solvent system comprising methanol, water and potassium hydroxide to be particularly advantageous, in particular in the preparation of sunitinib.
[0066] Preferably the hydrolysis of the second aspect of the present invention occurs at a temperature of from 20 to 200° C., more preferably at a temperature of from 50 to 150° C., more preferably still at a temperature of from 60 to 110° C., most preferably at a temperature of about 65° C. In one embodiment, the reaction occurs at the reflux temperature of the solvent system.
[0067] Preferably the hydrolysis of the second aspect of the present invention occurs over a period of 30 minutes to 48 hours. More preferably the hydrolysis occurs over a period of 1 to 24 hours, more preferably still over a period of 3 to 12 hours. Most preferably the hydrolysis occurs over a period of 5 to 6 hours.
[0068] In another embodiment of the second aspect of the present invention, R e is an alkyl or cycloalkyl group. Preferably R e comprises from 1 to 6 carbon atoms, more preferably from 1 to 4 carbon atoms. More preferably R e is selected from a methyl, ethyl, iso-propyl or n-propyl group. Most preferably R e is an ethyl group.
[0069] A particularly preferred embodiment of the second aspect provides a process wherein the pyrrole ester (IId) is a compound having structure (IIe)
[0000]
[0000] or a salt thereof.
[0070] A third aspect of the present invention provides a process for preparing an amide of formula (IIb), (IIb′) or (IIb″)
[0000]
[0000] or a salt thereof, wherein said amide (IIb), (IIb′) or (IIb″) is formed from the corresponding acid (IIa), (IIa′) or (IIa″)
[0000]
[0000] or a salt thereof, wherein R and R 5 to R 7 are as hereinbefore described.
[0071] Preferably said process is for preparing an amide of formula (IIb) or a salt thereof, from the corresponding acid (IIa) or a salt thereof. More preferably said process is for preparing the amide (IIc)
[0000]
[0000] or a salt thereof, from the corresponding acid (IIf)
[0000]
[0000] or a salt thereof.
[0072] A fourth aspect of the present invention relates to a process for preparing an amide of formula (Ib), (Ib′) or (Ib″)
[0000]
[0000] or a salt such as a pharmaceutically acceptable salt thereof, wherein said amide (Ib), (Ib′) or (Ib″) is formed from the corresponding acid (Ia), (Ia′) or (Ia″)
[0000]
[0000] or a salt thereof, wherein R and R 1 to R 7 are as hereinbefore described.
[0073] Preferably said process is for preparing an amide of formula (Ib) or a salt thereof, from the corresponding acid (Ia) or a salt thereof. More preferably said process is for preparing sunitinib having structure:
[0000]
[0000] or a salt such as a pharmaceutically acceptable salt thereof, from the corresponding acid 5-[(5-fluoro-2-oxo-1,2-dihydro-3H-indol-3-ylidene)methyl]-2,4-dimethyl-1H-pyrrole-3-carboxylic acid:
[0000]
[0000] or a salt thereof.
[0074] In one embodiment of either the third or fourth aspects of the present invention, the acid is converted to the corresponding amide via chemical activation of the —COOH group and subsequent reaction with RH, or a salt thereof, wherein R is as hereinbefore described.
[0075] As used herein, “chemical activation” of the —COOH group refers to the use of chemical reagents to convert the —COOH group into a species that is more reactive towards nucleophilic attack, for example, by primary or secondary amines. Methods of performing such chemical activation are well known in the art and include for instance the conversion of the —COOH group into an acyl halide such as —COCl, into an anhydride such as —C(O)OC(O)OMe, or into an active ester such as a pentafluorophenyl ester (—COOPfp), or the use of coupling reagents such as DCC(N,N′-dicyclohexylcarbodiimide) and HOBT (1-hydroxybenzotriazole), TBTU (O-(benzotriazol-1-yl)-N,N,N′,N′-tetramethyluronium tetrafluoroborate or the guanidinium N-oxide isomer thereof) or HAM (O-(7-azabenzotriazol-1-yl)-N,N,N′,N′-tetramethyluronium hexafluorophosphate or the guanidinium N-oxide isomer thereof).
[0076] Preferably the chemical activation is achieved via the use of a carbodiimide coupling reagent, optionally in conjunction with 1-hydroxybenzotriazole (HOBT) and/or a suitable base (i.e. one that will not form a side product by reaction with the activated —COOH group) such as a tertiary amine.
[0077] Suitable carbodiimide coupling reagents include for instance DCC (N,N′-dicyclohexylcarbodiimide), DIC (N,N′-diisopropylcarbodiimide), EDC (1-ethyl-3-(3-dimethylaminopropyl)carbodiimide) and salts thereof.
[0078] Most preferably the chemical activation is achieved via the use of 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride, HOBT and triethylamine (TEA).
[0079] Preferably RH is N,N-diethylethylenediamine or a salt thereof.
[0080] Preferably from 1 to 10 molar equivalents of RH are used, more preferably from 2 to 5 molar equivalents of RH are used, most preferably about 3 molar equivalents of RH are used.
[0081] In one embodiment, the chemical activation and subsequent reaction with RH is performed in an aprotic solvent, preferably a polar aprotic solvent. Suitable polar aprotic solvents include ethers such as THF (tetrahydrofuran), diethyl ether and methyl t-butyl ether, DMF (N,N-dimethylformamide), DMSO (dimethylsulfoxide), acetonitrile, esters such as ethyl acetate, and ketones such as acetone. Most preferably the polar aprotic solvent is THF.
[0082] In one embodiment, the chemical activation and subsequent reaction with RH is performed at a temperature of from 0 to 100° C., more preferably at a temperature of from 10 to 50° C., most preferably at a temperature of from 20 to 30° C.
[0083] Preferably the reaction with RH occurs over a period of 1 to 48 hours. More preferably the reaction occurs over a period of 3 to 24 hours, more preferably still over a period of 6 to 12 hours. Most preferably the reaction occurs over a period of 8 to 10 hours.
[0084] A fifth aspect of the present invention provides a process for preparing a compound of formula (III)
[0000]
[0000] or a salt thereof, comprising adding a formyl group at the 3-position of a 2-oxindole having structure (IIIc)
[0000]
[0000] or a salt thereof, wherein R 1 to R 4 are as hereinbefore described.
[0085] In one embodiment of the fifth aspect of the present invention, the process is for preparing a compound of formula (Ma) or a salt thereof according to the invention, comprising adding a formyl group at the 3-position of 5-fluoro-2-oxindole (IIIe)
[0000]
[0000] or a salt thereof.
[0086] The formyl group may be added using for instance formate esters such as methyl, ethyl, n-propyl or iso-propyl formate; mixed anhydrides of formic acid such as acetic formic anhydride or formic benzenesulfonic anhydride; disubstituted formamides such as N-phenyl-N-methyl-formamide in conjunction with phosphorus oxychloride or phosgene (the Vilsmeier-Haack reaction); chloroform in conjunction with a hydroxide source (the Reimer-Tiemann reaction); dichloromethyl methyl ether in conjunction with AlCl 3 ; or formyl fluoride and BF 3 .
[0087] Preferably a formate ester is used. Most preferably the process of the fifth aspect of the present invention comprises reacting 2-oxindole (IIIc) such as 5-fluoro-2-oxindole (IIIe) or a salt thereof with ethyl formate.
[0088] In one embodiment of the fifth aspect of the present invention, the formylation is base catalysed. Preferably the base is an alkoxide base such as a methoxide, ethoxide or t-butoxide, or an aryloxide base such as a phenoxide, or an alkali metal such as sodium. More preferably the base is an alkoxide base, preferably a C 1-4 alkoxide base such as sodium methoxide or sodium ethoxide.
[0089] In another embodiment of the fifth aspect of the present invention, the formylation is performed in a polar solvent. The polar solvent may be selected from polar aprotic solvents including N,N-dimethylformamide, dimethylsulfoxide, acetonitrile, esters such as ethyl acetate, and ketones such as acetone; or from polar protic solvents including alcohols, carboxylic acids and amines; or from mixtures thereof. Preferably the solvent is a polar protic solvent, more preferably a hydroxylic solvent and most preferably the solvent is an alcohol.
[0090] Where an alcohol is used, preferably the alcohol is R γ OH, wherein R γ is selected from an optionally substituted alkyl or aralkyl group. Preferably the alcohol is monohydric. Preferably R γ is an optionally substituted C 1-8 alkyl group, more preferably R γ is an optionally substituted C 1-4 alkyl group. Preferably the alcohol is methanol, ethanol, 1-propanol, isopropanol, 1-butanol, 2-methyl-1-propanol, t-butanol, 1-pentanol, cyclopentanol, 1-hexanol, cyclohexanol, 1-heptanol or 1-octanol. Most preferably the alcohol is methanol.
[0091] In certain embodiments of the process, the reaction takes place in the presence of a hydroxylic solvent and one of sodium methoxide, sodium ethoxide or sodium metal.
[0092] Preferably the formylation of the fifth aspect of the present invention occurs at a temperature of from 20 to 200° C., more preferably at a temperature of from 50 to 150° C., more preferably still at a temperature of from 60 to 110° C., most preferably at a temperature of about 65° C. In one embodiment, the reaction occurs at the reflux temperature of the solvent.
[0093] Preferably the formylation of the fifth aspect of the present invention occurs over a period of 10 minutes to 6 hours. More preferably the formylation occurs over a period of 15 minutes to 3 hours, more preferably still over a period of 30 minutes to 2 hours. Most preferably the formylation occurs over a period of about 1 hour.
[0094] In a sixth aspect of the present invention a process for preparing a 2-oxindole compound (IIIc)
[0000]
[0000] or a salt thereof, is provided, the process comprising reacting hydrazine hydrate with an isatin having structure (IIId)
[0000]
[0000] or a salt thereof, wherein R 1 to R 4 are as hereinbefore described.
[0095] Preferably the reaction takes place in the presence of a hydroxylic solvent and one of sodium methoxide, sodium ethoxide or sodium metal.
[0096] One embodiment of the sixth aspect according to the invention provides a process for preparing a compound (IIIe) or a salt thereof for use in the synthesis of sunitinib and salts, solvates and crystalline forms thereof, comprising reacting hydrazine hydrate with 5-fluoro-isatin having structure (IIIf)
[0000]
[0000] or a salt thereof.
[0097] Preferably the reaction takes place in the presence of a hydroxylic solvent and one of sodium methoxide, sodium ethoxide or sodium metal, most preferably in the presence of sodium methoxide. In a particularly preferred embodiment the 5-fluoro-isatin (IIIf) is added stepwise to the hydrazine hydrate.
[0098] A seventh aspect of the present invention relates to a method comprising two or more processes selected from:
(a) the process according to the sixth aspect of the present invention; (b) the process according to the fifth aspect of the present invention; (c) the process according to the second aspect of the present invention; and (d) the process according to the first aspect of the present invention.
[0103] Optionally the method of the seventh aspect of the present invention comprises three or preferably all four of processes (a) to (d). Preferably the method comprises process (d). In one embodiment, the method of the seventh aspect of the present invention comprises processes (b) and (d). In another embodiment, the method comprises processes (c) and (d), or (b), (c) and (d). In yet another embodiment, the method comprises processes (a), (b) and (d).
[0104] Optionally, the two or more processes may further be selected from, or the method of the seventh aspect may include, (e) the process according to the fourth aspect of the present invention. In such a case it is preferred that the method comprises process (d) wherein in the first aspect of the present invention at least one of R 5 , R 6 and R 7 is —COOH.
[0105] Alternatively, the two or more processes may further be selected from, or the method of the seventh aspect may include, (f) the process according to the third aspect of the present invention. In such a case it is preferred that the method comprises process (d) wherein in the first aspect of the present invention at least one of R 5 , R 6 and R 7 is —COR.
[0106] An eighth aspect provides a method or process according to any aspect or embodiment according to the invention for the preparation of sunitinib and/or any salt, solvate or polymorph thereof. In a preferred embodiment, the method or process further comprises preparing the malic acid salt of sunitinib. In a particularly preferred embodiment, the malic acid salt is the L-malic acid salt.
[0107] A ninth aspect according to the invention provides a compound having structure (III)
[0000]
[0000] or a salt thereof, wherein R 1 to R 4 are as hereinbefore described.
[0108] As mentioned previously this intermediate is useful in the preparation of pyrrole substituted indolinone compounds. Further, the intermediate is not known from the prior art where reactions between the pyrrole and indolinone intermediates were facilitated by the aldehyde group being present on the pyrrole intermediate.
[0109] In a particularly preferred embodiment, there is provided a compound having structure (IIIa)
[0000]
[0000] or a salt thereof.
[0110] Compound (IIIa) is particularly useful in the preparation of sunitinib.
[0111] A tenth aspect according to the invention provides a compound having structure (IIa), (IIa′) or (IIa″)
[0000]
[0000] or a salt thereof, wherein. R 5 to R 7 are as hereinbefore described.
[0112] In one embodiment of the tenth aspect of the present invention, the compound has structure (IIa) or is a salt thereof.
[0113] In another embodiment of the tenth aspect of the present invention, R 5 to R 7 are each independently selected from hydrogen or alkyl. Preferably R 5 to R 7 are each independently selected from hydrogen or C 1-4 alkyl. More preferably R 5 to R 7 are each independently selected from C 1-4 alkyl. Preferably any alkyl groups of R 5 , R 6 and R 7 are unsubstituted. Most preferably R 5 to R 7 are methyl.
[0114] In a preferred embodiment according to the tenth aspect of the present invention, there is provided a compound having structure (IIf)
[0000]
[0000] or a salt thereof.
[0115] An eleventh aspect according to the invention provides a compound having structure (Ia)
[0000]
[0000] or a salt thereof, wherein:
[0116] R 1 to R 4 are as hereinbefore described; and
[0117] R 5 and R 7 are each independently selected from hydrogen or alkyl.
[0118] In one embodiment of the eleventh aspect of the present invention, R 5 and R 7 are each independently selected from hydrogen or C 1-4 alkyl. Preferably R 5 and R 7 are each independently selected from C 1-4 alkyl. Preferably any alkyl groups of R 5 and R 7 are unsubstituted. Most preferably R 5 and R 7 are methyl.
[0119] In a preferred embodiment according to the eleventh aspect of the present invention, there is provided a compound having structure:
[0000]
[0000] or a salt thereof.
[0120] A twelfth aspect according to the present invention relates to a compound of formula (I) or a salt such as a pharmaceutically acceptable salt thereof as prepared according to any of the first eight aspects of the present invention or a compound of formula (I) or a salt such as a pharmaceutically acceptable salt thereof prepared utilising a compound according to any of the ninth, tenth or eleventh aspects of the present invention. Preferably the compound of formula (I) is sunitinib or a pharmaceutically acceptable salt thereof. More preferably the compound of formula (I) is sunitinib malate.
[0121] A thirteenth aspect of the present invention provides a pharmaceutical composition comprising a compound of formula (I) or a pharmaceutically acceptable salt thereof according to the twelfth aspect of the present invention and one or more pharmaceutically acceptable excipient(s).
[0122] In a particularly preferred embodiment of said composition, the compound is sunitinib malate.
[0123] Preferably the composition is a solid oral composition, most preferably a tablet or a capsule, most preferably a tablet.
[0124] A fourteenth aspect provides the use of a compound of formula (I) or a pharmaceutically acceptable salt thereof according to the twelfth aspect of the present invention, or of a pharmaceutical composition according to the thirteenth aspect of the present invention, in the treatment of a protein kinase mediated disorder. Preferably the disorder is a cell proliferative disorder, most preferably cancer, particularly preferred is wherein the disorder is a solid tumour, most preferably the disorder is one of advanced renal cell carcinoma (RCC) or gastrointestinal stromal tumor (GIST).
[0125] A fifteenth aspect of the present invention provides the use of a compound of formula (I) or a pharmaceutically acceptable salt thereof according to the twelfth aspect of the present invention, or of a pharmaceutical composition according to the thirteenth aspect of the present invention, in the manufacture of a medicament for the treatment of a protein kinase mediated disorder. Preferably the disorder is a cell proliferative disorder, most preferably cancer, particularly preferred is wherein the disorder is a solid tumour, most preferably the disorder is one of advanced renal cell carcinoma (RCC) or gastrointestinal stromal tumor (GIST).
[0126] A sixteenth aspect of the present invention provides a method of treating a protein kinase mediated disorder, comprising administering to a patient in need thereof a therapeutically effective amount of a compound of formula (I) or a pharmaceutically acceptable salt thereof according to the twelfth aspect of the present invention, or of a pharmaceutical composition according to the thirteenth aspect of the present invention. Preferably the disorder is a cell proliferative disorder, most preferably cancer, particularly preferred is wherein the disorder is a solid tumour, most preferably the disorder is one of advanced renal cell carcinoma (RCC) or gastrointestinal stromal tumor (GIST). Preferably the patient is a mammal, preferably a human.
[0127] For the avoidance of doubt, insofar as is practicable any embodiment of a given aspect of the present invention may occur in combination with any other embodiment of the same aspect of the present invention. In addition, insofar as is practicable it is to be understood that any preferred or optional embodiment of any aspect of the present invention should also be considered as a preferred or optional embodiment of any other aspect of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0128] The term “pyrrole substituted indolinones” as used herein throughout the description and claims includes any salt, solvate or polymorph thereof.
[0129] For the purposes of the present invention, an “alkyl” group is defined as a saturated aliphatic hydrocarbon radical including straight chain and branched chain groups of 1-20 carbon atoms. Wherever a numerical range, e.g. 1-20, is stated herein, it means that the group, in this case the alkyl group, may contain 1 carbon atom, 2 carbon atoms, 3 carbon atoms, etc. up to and including 20 carbon atoms. Alkyl groups containing 1-4 carbon atoms are referred to as lower alkyl groups. When said lower alkyl groups lack substituents, they are referred to as unsubstituted lower alkyl groups. More preferably, an alkyl group is a medium size alkyl group having 1-10 carbon atoms, e.g. methyl, ethyl, propyl, 2-propyl, n-butyl, iso-butyl, tert-butyl, pentyl and the like. More preferably it is a lower alkyl group having 1-4 carbon atoms, e.g. methyl, ethyl, propyl, 2-propyl, n-butyl, iso-butyl, tert-butyl and the like. The alkyl group may be substituted or unsubstituted.
[0130] When substituted, the substituent group(s) is/are preferably one or more, more preferably one to three groups which are independently of each other hydroxy; halo; unsubstituted lower alkyl; unsubstituted lower alkoxy; aryloxy optionally substituted with one or more groups, preferably one, two or three groups, which are independently of each other hydroxy, halo, unsubstituted lower alkyl or unsubstituted lower alkoxy groups; 6-membered heteroaryl having from 1 to 3 nitrogen atoms in the ring, the carbon atoms in the ring being optionally substituted with one or more groups, preferably one, two or three groups, which are independently of each other hydroxy, halo, unsubstituted lower alkyl or unsubstituted lower alkoxy groups; 5-membered heteroaryl having from 1 to 3 heteroatoms in the ring, selected from the group consisting of nitrogen, oxygen and sulfur, the carbon and the nitrogen (if present) atoms in the ring being optionally substituted with one or more groups, preferably one, two or three groups, which are independently of each other hydroxy, halo, unsubstituted lower alkyl or unsubstituted lower alkoxy groups; mercapto; (unsubstituted lower alkyl)thio; arylthio optionally substituted with one or more groups, preferably one, two or three groups, which are independently of each other hydroxy, halo, unsubstituted lower alkyl or unsubstituted lower alkoxy groups; cyano; acyl; thioacyl; O-carbamyl; N-carbamyl; O-thiocarbamyl; N-thiocarbamyl; C-amido; N-amido; nitro; N-sulfonamido; S-sulfonamido; —S(O)R 18 ; —S(O) 2 R 18 ; —C(O)OR 18 ; —OC(O)R 18 ; and —NR 18 R 19 ; wherein R 18 and R 19 are independently selected from the group consisting of hydrogen, unsubstituted lower alkyl, trihalomethyl, unsubstituted (C 3 -C 6 )cycloalkyl, unsubstituted lower alkenyl, unsubstituted lower alkynyl and aryl optionally substituted with one or more groups, preferably one, two or three groups, which are independently of each other hydroxy, halo, unsubstituted lower alkyl or unsubstituted lower alkoxy groups.
[0131] Preferably, the alkyl group is substituted with one or two substituents independently selected from the group consisting of hydroxy; a 5- or 6-membered heteroalicyclic group having from 1 to 3 heteroatoms in the ring, selected from the group consisting of nitrogen, oxygen and sulfur, the carbon and the nitrogen (if present) atoms in the ring being optionally substituted with one or more groups, preferably one, two or three groups, which are independently of each other hydroxy, halo, unsubstituted lower alkyl or unsubstituted lower alkoxy groups; 5-membered heteroaryl having from 1 to 3 heteroatoms in the ring, selected from the group consisting of nitrogen, oxygen and sulfur, the carbon and the nitrogen (if present) atoms in the ring being optionally substituted with one or more groups, preferably one, two or three groups, which are independently of each other hydroxy, halo, unsubstituted lower alkyl or unsubstituted lower alkoxy groups; 6-membered heteroaryl having from 1 to 3 nitrogen atoms in the ring, the carbon atoms in the ring being optionally substituted with one or more groups, preferably one, two or three groups, which are independently of each other hydroxy, halo, unsubstituted lower alkyl or unsubstituted lower alkoxy groups; or —NR 18 R 19 wherein R 18 and R 19 are independently selected from the group consisting of hydrogen and unsubstituted lower alkyl.
[0132] Even more preferably, the alkyl group is substituted with one or more substituents which are independently of each other hydroxy, dimethylamino, ethylamino, diethylamino, dipropylamino, pyrrolidino, piperidino, morpholino, piperazino, 4-lower alkyl-piperazino, phenyl, imidazolyl, pyridinyl, pyridazinyl, pyrimidinyl, oxazolyl, triazinyl and the like.
[0133] “Cycloalkyl” refers to an all-carbon 3- to 8-membered monocyclic ring, such as an all-carbon 5- or 6-membered monocyclic ring, or an all-carbon 6- to 12-membered fused bicyclic ring, or an all-carbon fused polycyclic ring (a “fused” ring system means that each ring in the system shares at least two atoms such as an adjacent pair of atoms with another ring in the system) wherein one or more of the rings may contain one or more double bonds but none of the rings has a completely conjugated pi-electron system. Examples, without limitation, of cycloalkyl groups are cyclopropane, cyclobutane, cyclopentane, cyclopentene, cyclohexane, cyclohexadiene, adamantane, cycloheptane, cycloheptatriene and the like. A cycloalkyl group may be substituted or unsubstituted.
[0134] When substituted, the substituent group(s) is/are preferably one or two groups independently selected from the group consisting of hydroxy; halo; lower alkyl; unsubstituted lower alkoxy; aryl optionally substituted with one or more groups, preferably one or two groups, which are independently of each other hydroxy, halo, unsubstituted lower alkyl or unsubstituted lower alkoxy groups; 6-membered heteroaryl having from 1 to 3 nitrogen atoms in the ring, the carbon atoms in the ring being optionally substituted with one or more groups, preferably one or two groups, which are independently of each other hydroxy, halo, unsubstituted lower alkyl or unsubstituted lower alkoxy groups; 5-membered heteroaryl having from 1 to 3 heteroatoms in the ring, selected from the groups consisting of nitrogen, oxygen and sulfur, the carbon and the nitrogen (if present) atoms in the ring being optionally substituted with one or more groups, preferably one or two groups, which are independently of each other hydroxy, halo, unsubstituted lower alkyl or unsubstituted lower alkoxy groups; a 5- or 6-membered heteroalicyclic group having from 1 to 3 heteroatoms in the ring, selected from the group consisting of nitrogen, oxygen and sulfur, the carbon and the nitrogen (if present) atoms in the ring being optionally substituted with one or two groups, preferably one or two groups, which are independently of each other hydroxy, halo, unsubstituted lower alkyl or unsubstituted lower alkoxy groups; mercapto; (unsubstituted lower alkyl)thio; arylthio optionally substituted with one or more groups, preferably one or two groups, which are independently of each other hydroxy, halo, unsubstituted lower alkyl or unsubstituted lower alkoxy groups; cyano; acyl; thioacyl; O-carbamyl; N-carbamyl; O-thiocarbamyl; N-thiocarbamyl; C-amido; N-amido; nitro; N-sulfonamido; S-sulfonamido; —S(O)R 18 ; —S(O) 2 R 18 ; —C(O)OR 18 ; —OC(O)R 18 and —NR 18 R 19 ; wherein R 18 and R 19 are as defined above.
[0135] “Alkenyl” refers to a lower alkyl group, as defined herein, consisting of at least two carbon atoms and at least one carbon-carbon double bond. Representative examples include, but are not limited to, ethenyl, 1-propenyl, 2-propenyl, 1-, 2- or 3-butenyl, and the like.
[0136] “Alkynyl” refers to a lower alkyl group, as defined herein, consisting of at least two carbon atoms and at least one carbon-carbon triple bond. Representative examples include, but are not limited to, ethynyl, 1-propynyl, 2-propynyl, 1-, 2- or 3-butynyl, and the like.
[0137] “Aryl” refers to an all-carbon monocyclic or fused polycyclic ring (a “fused” ring system means that each ring in the system shares an adjacent pair of atoms with another ring in the system) of 5-12 carbon atoms having a completely conjugated pi-electron system. Examples, without limitation, of aryl groups are phenyl, naphthalenyl and anthracenyl. The aryl groups may be substituted or unsubstituted. When substituted, the substituent group(s) is/are preferably one or more groups, more preferably one, two or three groups, even more preferably one or two groups, independently of each other selected from trihalomethyl; hydroxy; halo; unsubstituted lower alkyl; unsubstituted lower alkoxy; mercapto; (unsubstituted lower alkyl)thio; arylthio optionally substituted with one or more groups, preferably one or two groups, which are independently of each other selected from hydroxy, halo, unsubstituted lower alkyl or unsubstituted lower alkoxy groups; cyano; acyl; thioacyl; O-carbamyl; N-carbamyl; O-thiocarbamyl; N-thiocarbamyl; C-amido; N-amido; nitro; N-sulfonamido; S-sulfonamido; —S(O)R 18 ; —S(O) 2 R 18 ; —C(O)OR 18 ; —OC(O)R 18 and —NR 18 R 19 ; wherein R 18 and R 19 are as defined above. Preferably the aryl group is optionally substituted with one or two substituents independently selected from hydroxy, halo, unsubstituted lower alkyl, unsubstituted lower alkoxy, cyano, mercapto, N-amido, mono- or dialkylamino, carboxyl or N-sulfonamido.
[0138] “Heteroaryl” refers to a monocyclic or fused polycyclic ring (a “fused” ring system means that each ring in the system shares an adjacent pair of atoms with another ring in the system) of 5-12 ring atoms containing one, two or three ring heteroatoms selected from N, O or S, the remaining ring atoms being C, and in addition having a completely conjugated pi-electron system. Examples, without limitation, of unsubstituted heteroaryl groups are pyrrole, furan, thiophene, imidazole, oxazole, thiazole, pyrazole, pyridine, pyrimidine, quinoline, iso-quinoline, purine and carbazole. The heteroaryl group may be substituted or unsubstituted. When substituted, the substituent group(s) is/are preferably one or more groups, more preferably one, two or three groups, even more preferably one or two groups, independently of each other selected from trihalomethyl, hydroxy, halo, unsubstituted lower alkyl, unsubstituted lower alkoxy, mercapto, (unsubstituted lower alkyl)thio, cyano, acyl, thioacyl, O-carbamyl, N-carbamyl, O-thiocarbamyl, N-thiocarbamyl, C-amido, N-amido, nitro, N-sulfonamido, S-sulfonamido, —S(O)R 18 , —S(O) 2 R 18 , —C(O)OR 18 , —OC(O)R 18 and —NR 18 R 19 , wherein R 18 and R 19 are as defined above. Preferably the heteroaryl group is optionally substituted with one or two substituents independently selected from hydroxy, halo, unsubstituted lower alkyl, trihalomethyl, cyano, mercapto, N-amido, mono- or dialkylamino, carboxyl or N-sulfonamido.
[0139] “Heteroalicyclic” refers to a monocyclic or fused polycyclic ring group having 5-9 ring atoms of which one or two are ring heteroatoms selected from N, O, or S(O) n , where n is an integer from 0 to 2, the remaining ring atoms being C. The ring(s) may also have one or more double bonds. However the ring(s) does/do not have a completely conjugated pi-electron system. Examples, without limitations, of unsubstituted heteroalicyclic groups are pyrrolidino, piperidino, piperazino, morpholino, thiomorpholino, homopiperazino, and the like. The heteroalicyclic ring may be substituted or unsubstituted. When substituted, the substituent group(s) is/are preferably one or more groups, more preferably one, two or three groups, even more preferably one or two groups, independently of each other selected from trihalomethyl, hydroxy, halo, unsubstituted lower alkyl, unsubstituted lower alkoxy, mercapto, (unsubstituted lower alkyl)thio, cyano, acyl, thioacyl, O-carbamyl, N-carbamyl, O-thiocarbamyl, N-thiocarbamyl, C-amido, N-amido, nitro, N-sulfonamido, S-sulfonamido, —S(O)R 18 , —S(O) 2 R 18 , —C(O)OR 18 , —OC(O)R 18 and NR 18 R 19 , wherein R 18 and R 19 are as defined above. Preferably, the heteroalicyclic group is optionally substituted with one or two substituents independently selected from hydroxy, halo, unsubstituted lower alkyl, trihalomethyl, cyano, mercapto, N-amido, mono- or dialkylamino, carboxyl or N-sulfonamido.
[0140] “Heterocycle” means a saturated cyclic radical of 3-8 ring atoms of which one or two are ring heteroatoms selected from N, O or S(O) n , where n is an integer from 0 to 2, the remaining ring atoms being C, where 1 or 2 C atoms may optionally be replaced by a carbonyl group. The heterocycle ring may optionally be substituted with one, two or three substituents independently selected from optionally substituted lower alkyl (optionally substituted with one or two substituents independently selected from carboxyl or ester), haloalkyl, cyanoalkyl, halo, nitro, cyano, hydroxy, alkoxy, amino, monoalkylamino, dialkylamino, aralkyl, heteroalkyl, heteroaralkyl, —COR (where R is a alkyl) or —COOR (where R is hydrogen or alkyl). More specifically the term heterocycle includes, but is not limited to, tetrahydropyranyl, 2,2-dimethyl-1,3-dioxolanyl, piperidino, N-methyl-piperidin-3-yl, piperazino, pyrrolidino, morpholino, thiomorpholino, thiomorpholino-1-oxide, thiomorpholino-1,1-dioxide, 4-ethyloxycarbonyl-piperazino, 3-oxo-piperazino, 2-imidazolinonyl, 2-pyrrolidinonyl, 2-oxo-homopiperazino, tetrahydropyrimin-2-onyl, and derivatives thereof. Preferably, the heterocycle group is optionally substituted with one or two substituents independently selected from halo, unsubstituted lower alkyl and lower alkyl substituted with carboxyl, ester, hydroxy, mono- or dialkylamino.
[0141] “Carboxyl” means a —COOH group.
[0142] “Hydroxy” means —OH group.
[0143] “Alkoxy” preferably refers to both an —O-(unsubstituted alkyl) and an —O-(unsubstituted cycloalkyl) group, but may also refer to both an O-(substituted alkyl) and an —O-(substituted cycloalkyl) group. Representative examples include, but are not limited to, methoxy, ethoxy, propoxy, butoxy, cyclopropyloxy, cyclobutyloxy, cyclopentyloxy, cyclohexyloxy, and the like. An “alkoxide” is similarly defined as an alkoxy group with a negative charge on the oxygen.
[0144] “Aryloxy” refers to both an —O-aryl and —O-heteroaryl group, as defined herein. Representative examples include, but are not limited to, phenoxy, pyridinyloxy, furanyloxy, thienyloxy, pyrimidinyloxy, pyrazinyloxy, and the like, and derivatives thereof. An “aryloxide” is similarly defined as an aryloxy group with a negative charge on the oxygen.
[0145] “Mercapto” means —SH group.
[0146] “Alkylthio” preferably refers to both an —S-(unsubstituted alkyl) and an —S-(unsubstituted cycloalkyl) group, but may also refer to an —S-(substituted alkyl) and an —S-(substituted cycloalkyl) group. Representative examples include, but are not limited to, methylthio, ethylthio, propylthio, butylthio, cyclopropylthio, cyclobutylthio, cyclopentylthio, cyclohexylthio, and the like.
[0147] “Arylthio” preferably refers to both an —S-(unsubstituted aryl) and an —S-(unsubstituted aralkyl) group, but may also refer to both an —S-(substituted aryl) and an —S-(substituted aralkyl) group. Representative examples include, but are not limited to, phenylthio, pyridinylthio, furanylthio, thienylthio, pyrimidinylthio, and the like.
[0148] “Acyl” refers to a —C(O)R″ group, where R″ is selected from the group consisting of hydrogen; unsubstituted lower alkyl; trihalomethyl; unsubstituted cycloalkyl; aryl optionally substituted with one or more groups, more preferably one, two or three groups, selected from the group consisting of unsubstituted lower alkyl, trihalomethyl, unsubstituted alkoxy, halo and —NR 18 R 19 groups; and heteroalicyclic (bonded through a ring carbon) optionally substituted with one or more groups, more preferably one, two or three groups, selected from the group consisting of unsubstituted lower alkyl, trihalomethyl, unsubstituted alkoxy, halo and —NR 18 R 19 groups; wherein R 18 and R 19 are as defined above. Representative acyl groups include, but are not limited to, acetyl, trifluoroacetyl, benzoyl, and the like.
[0149] “Aldehyde” means an acyl group, wherein R″ is hydrogen.
[0150] “Thioacyl” refers to a —C(S)R″ group, wherein R″ is as defined above.
[0151] “Ester” means a —C(O)OR″ group, wherein R″ is as defined above except that R″ cannot be hydrogen.
[0152] “Acetyl” refers to a —C(O)CH 3 group.
[0153] “Halo” refers to fluorine, chlorine, bromine or iodine, preferably fluorine or chlorine.
[0154] “Trihalomethyl” refers to a —CX 3 group, wherein X is a halo group as defined above.
[0155] “Trihalomethylsulfonyl” refers to a —S(O) 2 CX 3 groups, wherein X is a halo group as defined above.
[0156] “Cyano” refers to a —C≡N group.
[0157] “Methylenedioxy” refers to a —OCH 2 O— group, where the two oxygen atoms are bonded to adjacent carbon atoms.
[0158] “Ethylenedioxy” refers to a —OCH 2 CH 2 O— group, where the two oxygen atoms are bonded to adjacent carbon atoms.
[0159] “S-sulfonamido” refers to a —S(O) 2 NR 18 R 19 group, wherein R 18 and R 19 are as defined above.
[0160] “N-sulfonamido” refers to a —NR 18 S(O) 2 R 19 group, wherein R 18 and R 19 are as defined above.
[0161] “O-carbamyl” refers to a —OC(O)NR 18 R 19 group, wherein R 18 and R 19 are as defined above.
[0162] “N-carbamyl” refers to a —NR 18 C(O)OR 19 group, wherein R 18 and R 19 are as defined above.
[0163] “O-thiocarbamyl” refers to a —OC(S)NR 18 R 19 group, wherein R 18 and R 19 are as defined above.
[0164] “N-thiocarbamyl” refers to a —NR 18 C(S)OR 19 group, wherein R 18 and R 19 are as defined above.
[0165] “Amino” refers to a —NR 18 R 19 group, wherein R 18 and R 19 are as defined above.
[0166] “C-amido” refers to a —C(O)NR 18 R 19 group, wherein R 18 and R 19 are as defined above.
[0167] “N-amido” refers to a —NR 18 C(O)R 19 group, wherein R 18 and R 19 are as defined above.
[0168] “Nitro” refers to a —NO 2 group,
[0169] “Haloalkyl” means an otherwise unsubstituted alkyl, preferably an otherwise unsubstituted lower alkyl, which is substituted with one or more same or different halo atoms, e.g. —CH 2 Cl, —CF 3 , —CH 2 CF 3 , —CH 2 CCl 3 , and the like.
[0170] “Aralkyl” means an otherwise unsubstituted alkyl, preferably an otherwise unsubstituted lower alkyl, which is substituted with an aryl group, wherein said aryl group may be unsubstituted or further substituted, e.g. —(CH 2 )-phenyl, —(CH 2 ) 2 -phenyl, —(CH 2 ) 3 -phenyl, —CH 2 CH(CH 3 )CH 2 -phenyl, and the like.
[0171] “Heteroaralkyl” means an otherwise unsubstituted alkyl, preferably an otherwise unsubstituted lower alkyl, which is substituted with a heteroaryl group, wherein said heteroaryl group may be unsubstituted or further substituted, e.g. —(CH 2 )-pyridinyl, —(CH 2 ) 2 -pyrimidinyl, —(CH 2 ) 3 -imidazolyl, and the like.
[0172] “Monoalkylamino” means a radical —NHR 30 where R 30 is an unsubstituted alkyl or unsubstituted cycloalkyl group as defined above, e.g. methylamino, (1-methylethyl)amino, cyclohexylamino, and the like.
[0173] “Dialkylamino” means a radical —N(R 30 ) 2 where each R 30 is independently an unsubstituted alkyl or unsubstituted cycloalkyl group as defined above, e.g. dimethylamino, diethylamino, (1-methylethyl)ethylamino, cyclohexylmethylamino, cyclopentylmethylamino, and the like.
[0174] “Cyanoalkyl” means an otherwise unsubstituted alkyl, preferably an otherwise unsubstituted lower alkyl, which is substituted with 1 or 2 cyano groups.
[0175] “Optional” or “optionally” means that the subsequently described event or circumstance may but need not occur and that the description includes instances in which it does not For example, “heterocycle optionally substituted with an alkyl group” means that the alkyl group may but need not be present and that the description includes situations where the heterocycle group is not substituted with the alkyl group.
[0176] The terms “2-indolinone”, “indolin-2-one” and “2-oxindole” are used interchangeably herein to refer to a compound having the chemical structure:
[0000]
[0177] The term “pyrrole” refers to a compound having the chemical structure:
[0000]
[0178] The terms “pyrrole substituted 2-indolinone” and “3-pyrrolidenyl-2-indolinone” are used interchangeably herein to refer to a compound having the chemical structure shown in formula (I):
[0000]
[0179] Compounds that have the same molecular formula but differ in the nature or sequence of bonding of their atoms or the arrangement of their atoms in space are termed “isomers”. Isomers that differ in the arrangement of their atoms in space are termed “stereoisomers”. Stereoisomers that are not mirror images of one another are termed “diastereomers” and those that are non-superimposable mirror images of each other are termed “enantiomers”. When a compound has an asymmetric center, for example, an atom bonded to four different groups, the compound may have a pair of enantiomers. An enantiomer can be characterized by the absolute configuration of its asymmetric center, and is described by the R- and S-sequencing rules of Cahn and Prelog, or by the manner in which the compound rotates plane-polarized light and designated as dextrorotatory or levorotatory (i.e. as (+) or (−)-isomers respectively). A chiral compound can exist as either individual enantiomer or as a mixture, for example, a mixture containing equal proportions of the enantiomers called a “racemic mixture”.
[0180] The compounds of this invention may possess one or more asymmetric centers; such compounds can therefore be produced as individual (R)- or (S)-stereoisomers or as mixtures thereof. For example, if the R 6 substituent in a compound of formula (I) is 1-hydroxyethyl, then the carbon to which the hydroxy group is attached is an asymmetric center and therefore the compound of formula (I) can exist as an (R)- or (S)-stereoisomer.
[0181] Unless indicated otherwise, the description or naming of a particular compound in the specification and claims is intended to include both individual enantiomers and mixtures thereof, racemic or otherwise.
[0182] The compounds of formula (I), including (Ia), (Ib), etc. may exhibit the phenomenon of tautomerism and structural isomerism. For example, the structures described herein may adopt an E or a Z configuration about the double bond connecting the 2-indolinone moiety to the pyrrole moiety or they may be a mixture of E and Z. This invention encompasses any tautomeric or structural isomeric form and mixtures thereof which possess the ability to modulate RTK, CTK and/or STK activity and is not limited to any one tautomeric or structural isomeric form.
[0183] A “pharmaceutical composition” refers to a mixture of one or more of the compounds described herein, or physiologically or pharmaceutically acceptable salts or prodrugs or metabolites thereof, with other chemical components such as physiologically or pharmaceutically acceptable carriers and excipients. The purpose of a pharmaceutical composition is to facilitate administration of a compound to an organism.
[0184] The compounds of formula (I) may also act as a prodrug. A “prodrug” refers to an agent, which is converted into the parent drug in vivo. Prodrugs are often useful because in some situations, they may be easier to administer than the parent drug. They may for instance be bioavailable by oral administration whereas the parent drug is not. A prodrug may also have improved solubility in pharmaceutical compositions compared to the parent drug.
[0185] Additionally, it is contemplated that a compound of formula (I) would be metabolized by enzymes in the body of an organism such as a human being to generate a metabolite that can modulate the activity of the protein kinases. Such metabolites are within the scope of the present invention.
[0186] A physiologically or pharmaceutically acceptable carrier refers to a carrier or diluent that does not cause significant irritation to an organism and does not abrogate the biological activity and properties of the administered compound.
[0187] A pharmaceutically acceptable excipient refers to a preferably inert substance that is added to a pharmaceutical composition to further facilitate administration of a compound. Examples without limitation of excipients include calcium carbonate, calcium phosphate, various sugars and types of starch, cellulose derivatives, gelatin, vegetable oils and polyethylene glycols.
[0188] As used herein, the term “pharmaceutically acceptable sale” refers to those salts, which retain the biological effectiveness and properties of the parent compound. Such salts are preferably non-toxic.
[0189] Salts according to the invention include:
[0190] (i) acid addition salts which are obtained by the reaction of the free base of the parent compound with inorganic acids such as hydrochloric acid, hydrobromic acid, nitric acid, phosphoric acid, sulfuric acid, perchloric acid and the alike, or with organic acids such as acetic acid, oxalic acid, (D)- or (L)-malic acid, maleic acid, methanesulfonic acid, salicylic acid, tartaric acid, citric acid, succinic acid, malonic acid and alike, preferably hydrochloric acid or (L)-malic acid, more preferably (L)-malic acid (such as to provide the L-malate salt of 5-(5-fluoro-2-oxo-1,2-dihydroindol-3-ylidenemethyl)-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (2-diethylamioethyl)amide); or
[0191] (ii) salts formed when an acidic proton present in the parent compound either is replaced by a metal ion (e.g. an alkaline metal ion, an alkaline earth metal ion or an aluminium ion) or coordinates with an organic base (such as ethanolamine, diethanolamine, triethanolamine, tromethamine, N-methylglucamine, and the like).
[0192] Scheme I illustrates a general reaction scheme for carrying out a preferred method of the invention.
[0000]
[0193] The acid (IIa) may be reacted with the aldehyde (III) in the presence of an acidified polar solvent system to form the pyrrole substituted 2-indolinone (Ia). In preferred embodiments, the polar solvent system comprises one or more hydroxylic solvent(s). Preferably the solvent is a hydroxylic organic solvent, most preferably ethanol. In another embodiment, the acid is selected from the group comprising mineral acids, for example, hydrochloric acid, concentrated hydrochloric acid, sulfuric acid, concentrated sulfuric acid, and organic acids such as glacial acetic acid, p-toluene sulfonic acid. Preferably the acid is hydrochloric acid, in particular when the solvent is ethanol, Non-limiting examples of acidified polar solvent systems according to the invention include:
[0194] 1. ethanol containing a catalytic amount of glacial acetic acid;
[0195] 2. ethanol containing a catalytic amount of concentrated hydrochloric acid;
[0196] 3. ethanol containing a catalytic amount of concentrated sulfuric acid;
[0197] 4. ethanol containing a catalytic amount or molar equivalent of p-toluene sulfonic acid;
[0198] 5. tetrahydrofuran containing a catalytic amount of concentrated hydrochloric acid;
[0199] 6. acidic tetrahydrofuran (i.e. HCl purged in THF);
[0200] 7. tetrahydrofuran containing a catalytic amount of glacial acetic acid;
[0201] 8. tetrahydrofuran containing a catalytic amount of concentrated sulfuric acid;
[0202] 9. toluene containing a catalytic amount or molar equivalent of p-toluene sulfonic acid;
[0203] 10. iso-propyl alcohol (IPA) containing a catalytic amount of glacial acetic acid;
[0204] 11. IPA containing a catalytic amount of concentrated hydrochloric acid;
[0205] 12. IPA containing a catalytic amount of concentrated sulfuric acid;
[0206] 13. IPA containing a catalytic amount or molar equivalent of p-toluene sulfonic acid;
[0207] 14. acidic IPA (i.e. HCl purged in IPA);
[0208] 15. methanolic hydrogen chloride;
[0000] and similar solvent systems that are within the scope of the invention and are within the skill set of the notional skilled person without inventive capacity to determine. Most preferably the acidified solvent system is ethanolic hydrogen chloride.
[0209] In preferred embodiments, the reaction mass obtained from the coupling of intermediates (IIa) and (III) can be diluted, preferably with an aqueous base. Any type of base may be used, non-limiting examples include aqueous solutions of potassium bicarbonate, sodium carbonate, potassium carbonate, sodium hydroxide and potassium hydroxide. In certain embodiments, the resulting product (Ia) may be isolated, preferably by filtration and drying under reduced pressure.
[0210] The acid (Ia) may then be reacted with the desired amine to form the corresponding product with the desired amide substitution. For example, in a particularly preferred embodiment, when scheme I is employed to prepare sunitinib, the amine added is N,N-diethylethylenediamine. This reaction preferably takes place in a solvent which preferably is a polar aprotic solvent such as THF, DMF or an ether. A number of further reagents may be added during this reaction. In preferred embodiments, a coupling agent may be added to the reaction mixture, for example, N,N′-dicyclohexylcarbodiimide (DCC), 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (EDC.HCl) or N,N′-carbonyldiimidazole (CDI), preferably together with a suitable organic base such as a tertiary or aromatic amine. Suitable organic bases include 4-dimethylaminopyridine (DMAP), N-methyl-morpholine, trimethylamine, pyridine, 1,8-diazabicyclo[5.4.1]undec-7-ene, pyrolidone, N-methyl-piperidone, diisopropylethylamine and triethylamine (TEA). Preferably a catalyst such as 1-hydroxybenzotriazole (HOBT) is also used. In certain preferred embodiments, the reaction mass comprising the acid (Ia) and the coupling agent and optionally the base and catalyst may be refluxed for preferably between about 1-10 hours, most preferably between about 3-5 hours.
[0211] The desired product is then isolated by any suitable means. For example, the reaction mass may be extracted by any suitable solvent. The inventors have found that when sunitinib is prepared, extraction with ethyl acetate is particularly suitable. The extracted layer is then separated and dried. For example, in the continued example of sunitinib extracted in ethyl acetate the product may be dried over anhydrous sodium and/or magnesium sulfate, wherein subsequent filtration and evaporation of the ethyl acetate yields the desired product. Of course, the skilled person will understand that there are a number of techniques that may be employed to isolate the desired compound.
[0212] Scheme II illustrates an alternative method of the general reaction for carrying out the methods of the invention.
[0000]
[0213] The acid (IIa) is reacted with the desired amine, for example, when the compound sunitinib is prepared, the desired amine is N,N-diethylethylenediamine, to form the amide (IIb). A similar reaction, albeit with a formyl-substituted pyrrole, is described in more detail and exemplified, for example, in WO 01/60814 which is incorporated herein by reference in its entirety.
[0214] The reaction in preferred embodiments may be carried out in a polar aprotic solvent which in further preferred embodiments may be selected from the group comprising THF, diethyl ether, methyl t-butyl ether, acetonitrile (ACN) and DMF. Further polar aprotic solvents may be employed within the scope of the invention. Preferably, the reaction is carried out at ambient temperatures, for example, between about 20-30° C., although the person skilled in the art will appreciate that the reaction may be conducted at different temperatures.
[0215] The amide (IIb) is then reacted with the aldehyde (III) to form the free base product (Ib). Preferably the reaction occurs in an acidified polar solvent system. Preferably the solvent is a hydroxylic organic solvent, most preferably ethanol. In another embodiment, the acid is selected from the group comprising mineral acids, for example, hydrochloric acid, concentrated hydrochloric acid, sulfuric acid, concentrated sulfuric acid, and organic acids such as glacial acetic acid, p-toluene sulfonic acid. Preferably the acid is hydrochloric acid, in particular when the solvent is ethanol. Non-limiting examples of acidified polar solvent systems according to the invention include:
[0216] 1. ethanol containing a catalytic amount of glacial acetic acid;
[0217] 2. ethanol containing a catalytic amount of concentrated hydrochloric acid;
[0218] 3. ethanol containing a catalytic amount of concentrated sulfuric acid;
[0219] 4. ethanol containing a catalytic amount or molar equivalent of p-toluene sulfonic acid;
[0220] 5. tetrahydrofuran containing a catalytic amount of concentrated hydrochloric acid;
[0221] 6. acidic tetrahydrofuran (i.e. HCl purged in THF);
[0222] 7. tetrahydrofuran containing a catalytic amount of glacial acetic acid;
[0223] 8. tetrahydrofuran containing a catalytic amount of concentrated sulfuric acid;
[0224] 9. toluene containing a catalytic amount or molar equivalent of p-toluene sulfonic acid;
[0225] 10. iso-propyl alcohol (IPA) containing a catalytic amount of glacial acetic acid;
[0226] 11. IPA containing a catalytic amount of concentrated hydrochloric acid;
[0227] 12. IPA containing a catalytic amount of concentrated sulfuric acid;
[0228] 13. IPA containing a catalytic amount or molar equivalent of p-toluene sulfonic acid;
[0229] 14. acidic IPA (i.e. HCl purged in IPA);
[0230] 15. methanolic hydrogen chloride;
[0000] and similar solvent systems that are within the scope of the invention and are within the skill set of the notional skilled person without inventive capacity to determine. Most preferably the acidified solvent system is ethanolic hydrogen chloride.
[0231] In preferred embodiments, the reaction mass obtained can be diluted, preferably with a base. Any type of base may be used, non-limiting examples include potassium bicarbonate, sodium carbonate, potassium carbonate, sodium hydroxide and potassium hydroxide.
[0232] If desired, the free base product (Ib), however prepared, can in preferred embodiments be further reacted with a suitable acid to form a salt, preferably a pharmaceutically acceptable salt. In a preferred embodiment, the salt prepared is the malic acid salt, by reaction with malic acid. Particularly preferred is preparation of the L-malic acid salt. Although in certain other embodiments non-pharmaceutically acceptable salts maybe be prepared as intermediates in the preparation of pharmaceutically acceptable compounds.
[0233] The solid obtained from the above described procedures may be isolated by any suitable means. The inventors have found that filtering under conditions of reduced pressure, preferably under vacuum is particularly advantageous. The filtered solid may then be washed and dried.
[0234] For the purposes of the present invention, a compound is “substantially pure”, if it comprises less than 1% impurity by HPLC, preferably less than 0.5%, preferably less than 0.3%, preferably less than 0.2%, preferably less than 0.1%. In preferred embodiments the compounds of the invention are substantially pure.
[0235] The present inventors have surprisingly found that the invention includes the advantages of large reductions in reaction time as compared to the prior art processes and results in a compound of very high purity (>99% by HPLC).
[0236] In the present invention, the novel synthetic intermediate products are not purified. However, as part of the present invention, the synthetic intermediates may be purified if so desired. Any suitable purification technique may be employed, for example, recrystallisation from suitable solvents.
[0237] The pharmaceutical composition of the present invention can be a solution or suspension, but is preferably a solid dosage form such as a solid oral dosage form. Preferred oral dosage forms in accordance with the invention include tablets, capsules and the like which, optionally, may be coated if desired. Tablets can be prepared by conventional techniques, including direct compression, wet granulation and dry granulation. Capsules are generally formed from a gelatin material and can include a conventionally prepared granulate of excipients in accordance with the invention.
[0238] The pharmaceutical composition according to the present invention typically comprises one or more conventional pharmaceutically acceptable excipient(s) selected from the group comprising a filler, a binder, a disintegrant, a lubricant, and optionally further comprises at least one excipient selected from colouring agents, adsorbents, surfactants, film-formers and plasticizers.
[0239] If the solid pharmaceutical formulation is in the form of coated tablets, the coating may be prepared from at least one film-former such as hydroxypropyl methyl cellulose, hydroxypropyl cellulose or methacrylate polymers which optionally may contain at least one plasticizer such as polyethylene glycols, dibutyl sebacate, triethyl citrate, and other pharmaceutical auxiliary substances conventional for film coatings, such as pigments, fillers and others.
[0240] It is also envisaged that in certain embodiments the compositions according to the invention may comprise a second or further active ingredient(s).
[0241] The details of the invention, its objects and advantages are illustrated below in greater detail by the following non-limiting examples.
EXAMPLES
Example 1
Preparation of Pyrrole Intermediate
Example 1a
2,4-dimethyl-1H-pyrrole-3-carboxylic acid
[0242] To a solution of ethyl 2,4-dimethyl-1H-pyrrole-3-carboxylate (1 eq) in methanol (3 vol) was added a solution of KOH (2-3 eq) in water (0.4 vol) and the reaction mass was refluxed for approximately 5-6 hours. After the reaction was complete as indicated by thin layer chromatography (TLC), the heating was stopped and the reaction mass cooled to ambient temperature. The reaction mass was washed with ethyl acetate (2×3 vol), and the aqueous layer was collected and acidified with 1:1 conc. HCl:water v/v (3 vol) to pH 3-4. The resultant solid precipitate was filtered with a Buchner funnel under vacuum and then dried on a rotavapor under reduced pressure at 40° C. for 5-6 hours.
[0243] Molar yield=76%.
[0244] HPLC purity=96.45%.
[0245] IR (KBr) cm −1 : 3366 (broad, O—H), 2951, 2922, 2679, 2638, 1654 (C═O), 1647, 1578, 1524, 1508, 1481, 1466, 1449, etc.
[0246] 1 H-NMR (DMSO-d 6 ) δ ppm: 2.05 (s, 3H, —CH 3 ), 2.10 (s, 3H, —CH), 6.36 (s, 1H, ═C—H), 10.79 (s, 1H, NH, D 2 O exchangeable), 11.40 (s, 1H, —OH, D 2 O exchangeable).
[0247] 13 C-NMR (DMSO-d 6 ) δ ppm: 12.70 (1C, — C H 3 , DEPT), 13.60 (1C, — C H 3 , DEPT), 110.09 & 119.82 (2C, 2×— C —CH 3 ), 114.59 (1C, — C H—, DEPT), 135.25 (1C, — C —CO—), 167.11 (1C, — C O—OH).
[0248] Mass (m/z): (M+1) 140 (100%).
Example 1b
N-(2-(diethylamino)ethyl)-2,4-dimethyl-1H-pyrrole-3-carboxamide
[0249] 2,4-Dimethyl-1H-pyrrole-3-carboxylic acid (1 eq) was added to a solution of THF (15 vol), 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (EDC.HCl) (1.5 eq), 1-hydroxybenzotriazole (HOBT) 1.5 eq) and TEA (2 eq) at ambient temperature and stirred for 15-30 minutes. To this solution was added N,N-diethylethylenediamine (3 eq) and the reaction mass was stirred for 8-10 hours. After the reaction was complete as indicated by TLC, THF was distilled out at reduced pressure and the reaction mass was then diluted by adding a saturated sodium bicarbonate solution (any inorganic weak base such as potassium carbonate, potassium bicarbonate, sodium carbonate, etc or even dilute NaOH or KOH solution may be used) (3 vol) and the pH adjusted to 7-10. The whole mass was extracted with ethyl acetate (2×5 vol), which was separated, dried over anhydrous sodium sulfate then filtered. The ethyl acetate was distilled out to obtain a brown viscous mass.
[0250] Molar yield=93%.
[0251] HPLC purity=93.42%.
[0252] IR (KBr) cm −1 : 3241 (broad, N—H), 3063, 2967, 2927, 2872, 2818, 1622 (C═O), 1575, 1530, 1504, 1455, 1401, etc.
[0253] 1 H-NMR (DMSO-d 6 ) δ ppm: 0.96 (t, J=7.1 Hz, 6H, 2×—CH 2 —C H 3 ), 2.08 (s, 3H, —CH 3 ), 2.29 (s, 3H, —CH 3 ), 2.46-2.52 (m, 6H, 3×—N—CH 2 ), 3.21-3.27 (m, 2H, —CO—NH—C H 2 —), 6.33 (s, 1H, ═C—H), 6.78 (s, 1H, amide NH, D 2 O exchangeable), 10.55 (s, 1H, pyrrole NH, D 2 O exchangeable).
[0254] 13 C-NMR (DMSO-d 6 ) δ ppm: 11.90 (2C, 2×—CH 2 — C H 3 , DEPT), 12.04 (1C, — C H 3 , DEPT), 12.81 (1C, — C H 3 , DEPT), 36.59 (1C, — C H 2 —, DEPT), 46.40 (2C, 2×— C H 2 —, DEPT), 51.67 (1C, — C H 2 —, DEPT), 114.14 (1C, — C H—, DEPT), 115.01 & 116.33 (2C, 2×— C —CH 3 ), 130.04 (1C, — C —CO—), 165.85 (1C, C ═O),
[0255] Mass (m/z): (M−1) 238 (100%).
Example 2
Preparation of 2-oxindole with aldehyde substitution at 3-position (5-fluoro-3-formyl-1H-indole-2-one)
Example 2a
2-oxindole from 5-fluoro-isatin
[0256] Hydrazine hydrate (7 eq, 103.2 ml) was charged to a four-neck round-bottomed flask equipped with a reflux condenser, mechanical stirrer and oil bath. To this was added 5-fluoro-isatin (0.4 eq, 20 g) and the mixture was stirred and heated to 100° C. After the desired temperature was reached, more 5-fluoro-isatin was added in four portions (0.15 eq, 7.5 g at each portion). In total 1 eq=50 g of 5-fluoro-isatin was added. After the complete addition of the 5-fluoro-isatin, the reaction mass was maintained at the same temperature for 3 hours and then allowed to cool to ambient temperature (25-30° C.). Acidified water (concentrated HCl 5 vol+water 3.3 vol) was added and stirring continued for about 24 hours. The solid obtained was filtered using a Buchner funnel under vacuum and washed with water twice (2×7.5 vol) and then dried in a vacuum oven at 0.5 kg/cm 2 at 55° C. for 5 hours.
[0257] Molar yield=75%.
[0258] HPLC=98.85%.
[0259] IR (KBr) cm −1 : 3215, 3079, 3053, 2931, 2881, 1699, 1669, 1631, 1484, etc.
[0260] 1 H-NMR (DMSO-d 6 ) δ ppm: 3.50 (s, 2H, —CH 2 —), 6.76-6.80 (dd, J=4.5 Hz, 1H, Ar—H), 6.99 (m, 1H, Ar—H), 7.12 (dd, J=2.5 Hz, 1H, Ar—H), 10.38 (s, 1H, NH, D 2 O exchangeable).
[0261] 13 C-NMR (DMSO-d 6 ) δ ppm: 36.20 (1C, — C H 2 —), 109.52-159.29 (6C, 6×Ar— C ), 176.23 (1C, C ═O).
[0262] Mass (m/z): (M+1) 152 (100%).
Example 2b
5-fluoro-3-formyl-1H-indole-2-one (or 5-fluoro-3-formyl-2-oxindole) from 2-oxindole
[0263] Methanol (5-vol) was charged to a four-neck 250 ml round-bottomed flask equipped with a mechanical stirrer, water bath and reflux condenser. Sodium methoxide (2.1 eq) was added to it and the mixture stirred to obtain a clear solution. To the clear solution, 2-oxindole (1 eq, 15 g) and ethyl formate (2.9 eq, 23.27 ml) were added and then stirring was continued at reflux temperature for about 1 hour. The mixture was allowed to cool to ambient temperature (25-30° C.). The reaction mass was poured in ice-cold water (2 vol, 100 ml) under stirring and the pH adjusted to pH 3 by the addition of 1:1 conc. HCl: water v/v (approximately 35 ml). The stirring was continued for 30 minutes and the resultant solid filtered on a Buchner funnel under vacuum and dried in a vacuum oven at 0.5 kg/cm 2 at 55° C. for 5 hours.
[0264] Molar yield=98%.
[0265] HPLC=98.90%.
[0266] IR (KBr) cm −1 : 3190, 3020, 2721, 1692, 1624, 1601, 1565, 1467, etc.
[0267] 1 H-NMR (DMSO-d 6 ) δ ppm: 6.75-6.79 (dd, J=4.6 Hz, 1H, Ar—H), 6.85-6.92 (m, 1H, Ar—H), 7.24-7.27 (dd, J=2.4 Hz, 1H, Ar—H), 7.86 (bs, 1H, —C H O), 10.20 (s, 1H, NH, D 2 O exchangeable).
[0268] 13 C-NMR (DMSO-d 6 ) δ ppm: 106.04 (1C, — C H—CHO), 108.39-156.42 (6C, 6×Ar— C ), 159.18 (1C, — C HO) 169.90 (1C, C ═O).
[0269] Mass (m/z): (M+1) 180 (100%).
Example 3
Preparation of Example Compound of the Invention (Sunitinib)
Example 3a
N-[2-(diethylamino)ethyl]-5-[(Z)-(5-fluoro-2-oxo-1,2-dihydro-3H-indol-3-ylidene)methyl]-2,4-dimethyl-1H-pyrrole-3-carboxamide (sunitinib)
[0270] N-(2-(Diethylamino)ethyl)-2,4-dimethyl-1H-pyrrole-3-carboxamide (1 eq) and 5-fluoro-3-formyl-2-oxindole (1 eq) were refluxed together in ethanolic hydrogen chloride (5% w/w, 15 vol) for 6-12 hours. After completion of the reaction as indicated by TLC, the reaction mass was diluted with saturated sodium bicarbonate solution (10 vol) and the pH adjusted to pH 9-10. The solid thus obtained was filtered on a Buchner funnel under vacuum and washed with ethanol (5 vol) and dried in a vacuum oven at 0.5 kg/cm 2 at 55° C. for 5 hours to afford a yellow-orange solid.
[0271] Molar yield=75%.
[0272] HPLC purity=93.87%.
[0273] IR (KBr) cm −1 : 3276 (broad, N—H), 3063, 2966, 2925, 2807, 1675 (C═O), 1560, 1475, etc.
[0274] 1 H-NMR (DMSO-d 6 ) δ ppm: 0.97 (t, J=7.1 Hz, 6H, 2×—CH 2 —C H 3 ), 2.42 (s, 3H, —CH 3 ), 2.44 (s, 3H, —CH 3 ), 2.47-2.56 (m, 6H, 3×—N—CH 2 —), 3.25-3.31 (m, 2H, —CO—NH—C H 2 ), 6.83-6.87 (m, 1H, vinyl proton), 6.90-6.94 (t, J=5.9 Hz, 1H, aromatic ortho position), 7.43-7.47 (t, J=5.6 Hz, 1H, aromatic meta position), 7.74-7.78 (dd, J=5.9 Hz, 1H, aromatic ortho position), 7.72 (s, 1H, amide NH, D 2 O exchangeable), 10.90 (s, 1H, pyrrole NH, D 2 O exchangeable), 13.68 (s, 1H, indole NH, D 2 O exchangeable).
[0275] 13 C-NMR (DMSO-d 6 ) δ ppm: 10.64 (1C, — C H 3 , DEPT), 11.92 (2C, 2×—CH 2 — C H 3 , DEPT), 13.38 (1C, — C H 3 , DEPT), 37.02 (1C, — C H 2 —, DEPT), 46.55 (2C, 2×— C H 2 —, DEPT), 51.69 (1C, — C H 2 —, DEPT), 105.90 (1C, d, phenyl carbon, DEPT), 110.10 (1C, d, phenyl carbon, DEPT), 112.45 (1C, d, phenyl carbon, DEPT), 124.94 (1C, vinyl carbon, DEPT), 158.3 (1C, d, C —F, DEPT), 114.60 (bridge-head C of indole ring adjacent to >NH), 120.80, 134.50, 125.80, 136.70 (4C, pyrrole ring), 164.60 (1C, C ═O), 169.63 (1C, C ═O).
[0276] Mass (m/z): (M+1) 399 (100%), [(M+2)+1] 401 (14%).
Example 3b
5-[(Z)-(5-fluoro-2-oxo-1,2-dihydro-3H-indol-3-ylidene)methyl]-2,4-dimethyl-1H-pyrrole-3-carboxylic acid
[0277] 2,4-Dimethyl-1H-pyrrole-3-carboxylic acid (1 eq) and 5-fluoro-3-formyl-2-oxindole (1 eq) were refluxed together in ethanolic hydrogen chloride (5% w/w, 5 vol) for 6 hours. After completion of the reaction as indicated by TLC, the reaction mass was diluted with saturated sodium bicarbonate solution (10 vol) and the pH adjusted to pH 9-10. The solid obtained was filtered and dried under reduced pressure on a rotavapor at 40° C. to afford a yellow-orange solid.
[0278] Molar yield=65%.
[0279] HPLC purity=94.24%.
[0280] IR (KBr) cm −1 : 3437 (broad, N—H, O—H), 3160, 3101, 3041, 2953, 2922, 2873, 1668 (C═O), 1619, 1556, 1474, etc.
[0281] 1 H-NMR (DMSO-d 6 ) δ ppm: 2.33 (s, 3H, —C H 3 ), 2.38 (s, 3H, —C H 3 ), 6.00 (s, 1H, vinyl proton), 6.79-6.82 (m, 2H, aromatic ortho+meta position), 7.15-7.19 (dd, J=5.0 Hz, 1H, aromatic ortho position), 7.33 (s, 1H, NH, D 2 O exchangeable), 7.73 (s, 1H, NH, D 2 O exchangeable), 13.14 (s, 1H, —OH, D 2 O exchangeable),
[0282] 13 C-NMR (DMSO-d 6 ) δ ppm: 11.32 (1C, — C H 3 ), 13.57 (1C, — C H 3 ), 105.33 (1C, d, Ar—C, ortho position), 109.76 (1C, d, Ar— C , meta position), 111.62 (1C, d, Ar—C, ortho position), 112.90 (1C, vinyl carbon), 127.54 (1C, C —F), 111.62-159.71 (7C, 6×Ar— C , —CO— C ═C), 159.71 (1C, C ═O), 169.58 (1C, C ═O).
[0283] Mass (m/z): (M+1) 299 (100%), [(M+1)+2] (13%).
Example 3c
N-[2-(diethylamino)ethyl]-5-[(Z)-(5-fluoro-2-oxo-1,2-dihydro-3H-indol-3-ylidene)methyl]-2,4-dimethyl-1H-pyrrole-3-carboxamide (sunitinib)
[0284] To a stirred solution of 5-[(Z)-(5-fluoro-2-oxo-1,2-dihydro-3H-indol-3-ylidene)methyl]-2,4-dimethyl-1H-pyrrole-3-carboxylic acid (1 eq) in THF (15 vol) was added 1-ethyl-3-(3-dimethylaminopropyl)carbodiimide hydrochloride (EDC.HCl) (1.5 eq), 1-hydroxybenzotriazole (HOBT) (1.5 eq) and TEA (2 eq) and the solution was stirred at room temperature for 30 minutes. To this solution was added N,N-diethylethylenediamine (2 eq) and the whole mass was stirred at room temperature for 8-10 hours. The reaction mass was then diluted with saturated sodium bicarbonate (8-10 vol) and the pH adjusted to pH 10 with the addition of a 50% NaOH aqueous solution (8-10 vol). The whole mass was then extracted with ethyl acetate (3×5 vol). The ethyl acetate layer was separated, dried over anhydrous sodium sulfate, then filtered. Evaporation of the ethyl acetate afforded the corresponding product.
[0285] Molar yield=70%.
[0286] HPLC purity=95.63%.
[0287] IR (KBr) cm −1 : 3276 (broad, N—H), 3063, 2966, 2925, 2807, 1675 (C═O), 1560, 1475, etc.
[0288] 1 H-NMR (DMSO-d 6 ) δ ppm: 0.97 (t, J=7.1 Hz, 6H, 2×—CH 2 — C H 3 ), 2.42 (s, 3H, —CH 3 ), 2.44 (s, 3H, —CH 3 ), 2.47-2.56 (m, 6H, 3×—N—CH 2 —), 3.25-3.31 (m, 2H, —CO—NH—C H 2 —), 6.83-6.87 (m, 1H, vinyl proton), 6.90-6.94 (t, J=5.9 Hz, 1H, aromatic ortho position), 7.43-7.47 (t, J=5.6 Hz, 1H, aromatic meta position), 7.74-7.78 (dd, J=5.9 Hz, 1H, aromatic ortho position), 7.72 (s, 1H, amide NH, D 2 O exchangeable), 10.90 (s, 1H, pyrrole NH, D 2 O exchangeable), 13.68 (s, 1H, indole NH, D 2 O exchangeable).
[0289] 13 C-NMR (DMSO-d 6 ) δ ppm: 10.64 (1C, — C H 3 , DEPT), 11.92 (2C, 2×—CH 2 — C H 3 , DEPT), 13.38 (1C, — C H 3 , DEPT), 37.02 (1C, — C H 2 —, DEPT), 46.55 (2C, 2×— C H 2 —, DEPT), 51.69 (1C, — C H 2 —, DEPT), 105.90 (1C, d, aromatic ortho position, DEPT), 110.10 (1C, d, aromatic meta position, DEPT), 112.45 (1C, d, aromatic meta position, DEPT), 124.94 (1C, vinyl carbon, DEPT), 158.3 (1C, d, C —F, DEPT), 114.60 (bridge-head C of indole ring adjacent to >NH), 120.80, 134.50, 125.80, 136.70 (4C, pyrrole ring), 164.60 (1C, C ═O), 169.63 (1C, C ═O).
[0290] Mass (m/z): (M+1) 399 (100%), [(M+2)+1] 401 (14%).
[0291] It will be readily apparent to one skilled in the art that varying substitutions and modifications may be made to the invention disclosed herein without departing from the scope and spirit of the invention.
[0292] The invention illustratively described herein suitably may be practiced in the absence of any element or elements, limitation or limitations which is not specifically disclosed herein. Thus, it should be understood that although the present invention has been specifically disclosed by preferred embodiments and optional features, modification and variation of the concepts herein disclosed may be resorted to by those skilled in the art, and that such modifications and variations are considered to be within the scope of this invention as defined by the appended claims.
[0293] In addition, where features or aspects of the invention are described in terms of Markush groups, those skilled in the art will recognize that the invention is also thereby described in terms of any individual member or subgroup of members of the Markush group.
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The present invention relates to novel intermediates and further to the use of said intermediates in processes for the preparation of indolinone derivatives, in particular 3-pyrrole substituted 2-indolinones having amide moieties on the pyrrole ring. Such compounds are useful in die treatment of abnormal cell growth, such as cancer, in mammals.
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BACKGROUND OF THE INVENTION
I. Field of the Invention
This invention relates generally to electronic candles used to simulate actual wax candles, and more particularly to a system for recharging a large plurality of such candles.
II. Discussion of the Prior Art
There are artificial candles on the market presently that replicate the look of a burning wax candle, but which incorporate a yellow LED and a suitable electronic controller for imparting a flickering illumination of the LED to simulate the glow of a burning wax candle. However, for the most part, those candles embody a rechargeable battery and a circuit that had to be plugged into a DC current source to effect recharging of the candle, one at a time.
Many restaurants often include a so-called votive candle on each table in the restaurant to add to the ambience of the place. A votive candle is generally 2.0 inches in height by 1.5 inches in diameter and is contained in a suitable holder, such as a glass cup. If one wished to substitute an electronic artificial candle for the real thing, a way would have to be devised to simultaneously recharge a large plurality of such artificial candles so that when fully charged, they may be distributed throughout the restaurant and turned on upon arrival of a patron at a given table.
The prior art, as represented by U.S. Pat. No. 6,819,080 to Barbeau et al, teaches a stand-alone recharging platter capable of charging a set number of artificial candles. Such stand-alone platters have a power cord for supply an electrical charge. If a restaurant needs to charge more candles than the platter is adapted to handle, the restaurant must plug multiple platters into multiple wall sockets.
Another concern on the part of a restaurant owner is the potential loss of such a candle through theft. The artificial candles, being both attractive and of more than negligible cost, loss through theft can be a problem.
A need therefore exists for a decorative artificial candle design that can be used in a restaurant environment as a table decoration and that is adapted to be recharged simultaneously with many other identical candles in unison rather than individually.
A need further exists for an artificial candle design that incorporates features that discourage theft.
A further need is an artificial candle that is more realistic in its operation than existing prior art artificial electronic candles currently available. Specifically, a need exists for an artificial candle that more accurately simulates a real wax candle in that it can be extinguished by a puff of air blown at it at close range.
SUMMARY OF THE INVENTION
The present invention provides a charging stand or tray that can be concatenated with a plurality of identical trays where each tray is capable of supporting a plurality of individual artificial electronic candles as they are simultaneously having their internal batteries recharged. Each of the individual candles may incorporate a position sensitive module capable of detecting whether a candle is otherwise than in an upright position and to provide an audible signal unless the candle is returned to its upright position within a prescribed time interval.
In accordance with a further feature of the invention, a suitable transducer can be incorporated into the individual candles where the transducer is capable of detecting pressure and temperature changes occasioned by a person blowing his/her breath onto the candle and causing the LED light source used to simulate the flame to be extinguished.
DESCRIPTION OF THE DRAWINGS
The foregoing features, objects and advantages of the invention will become apparent to those skilled in the art from the following detailed description of a preferred embodiment especially when considered in conjunction with the accompanying drawings in which like numerals in the several views refer to corresponding parts:
FIG. 1A is a pictorial view showing four charging trays joined together and populated with a plurality of artificial candles;
FIG. 1B is an enlarged view of four charging trays connected together and showing the plug and socket detail;
FIG. 2 is a side elevation view of the artificial candle with the decorative outer shroud removed;
FIG. 3 is a cross-sectional view taken through the artificial candle incorporating an anti-theft feature;
FIG. 4 is a view of a charging tray populated with artificial candles and cross-sectioned to show the engagement between a transformer primary winding forming part of the charging tray and a secondary winding disposed in the artificial candle;
FIG. 5 is an electrical schematic diagram of the artificial candle incorporating the anti-theft feature;
FIG. 6 is a schematic electrical diagram of the artificial candle incorporating the blow-out feature; and
FIG. 7 is an electrical schematic diagram of an inner connected pair of charging trays and a current limiter circuit used therewith.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1A , there is shown a plurality of electrically and mechanically interconnected artificial candle charging trays 2 , 4 , 6 , 8 that are populated with a plurality of battery-operated artificial candles 10 . Without limitation, each charging tray may hold up to a dozen artificial candles in which a rechargeable DC battery is connected through a semiconductor switch to a yellow LED and where the switch is, in turn, controlled by a programmed microprocessor chip such that the LED may be made to flicker much like the light given off by a real wax candle. Just how this is achieved will be explained in greater detail herein below.
With continued reference to FIG. 1A , power for the charging tray is derived from a conventional AC/DC adapter that when plugged into a wall socket at 110 volts produces a 12 volt DC output. Connected in the cable leading from the adapter 12 to the first recharging tray 2 is a current limiter circuit 14 .
FIG. 1B illustrates the manner in which plural trays, 2 , 4 , 6 and 8 , can be concatenated so that each is supplied with power from the AC to DC adapter, via the current limiter circuit 14 . The DC input from the current limiter 14 enters through a plug 15 that projects laterally from a side edge 17 of the tray 2 . Formed inwardly in the opposed side surface 19 of the tray 2 is a female socket dimensioned to accommodate the insertion of a male plug 21 that projects from the side surface of an identical tray 4 . Likewise, tray 6 has a plug 23 mating with a socket in the side surface of the tray 4 , etc. Contained within the hollow interior of the trays 2 , 4 , 6 and 8 are printed circuit boards and wiring that operatively connect the contacts of the plug 15 to corresponding terminals in the socket into which the plug 21 of the tray 4 is inserted. The manner of inner connection is shown in the electrical schematic diagram of FIG. 7 .
Referring next to FIGS. 2 and 3 , each of the battery operated artificial candles comprises a yellow LED 16 that simulates the candle flame. It is surrounded by a translucent bulb 18 ( FIG. 3 ) having the tapered shape of a flame and used to defuse the light emanating there through. The LED 16 projects out through an aperture in the top surface 20 of the molded plastic candle housing 22 or shroud, which is generally a hollow right-circular cylinder that contains the electronic circuitry for powering the LED 16 .
With continued reference to FIGS. 2 and 3 , a rechargeable battery 24 is positioned directly below a socket 26 for the LED 16 and adjacent the underside of a printed circuit board assembly 28 on which much of the circuitry of FIG. 7 is disposed. A pushbutton “on/off” switch 30 is disposed within the housing 22 and is accessible through an aperture formed in the base 32 of the candle. The base also includes a bore 34 and surrounding the bore 34 is an electrical coil 36 or windings which, as will be further explained, acts as the secondary winding of a transformer whose primary winding is disposed about a ferrite core in a hollow post on the charging tray that is adapted to fit within the bore 34 of the artificial candle. The arrangement is more clearly shown in the cross-sectioned view, of FIG. 4 .
As shown in FIG. 4 , the recharging trays for the artificial candles include a hollow, box-like base 38 formed of injection molded plastic. Disposed within the interior of the base 38 is a printed circuit board 40 that contains the circuitry of one of the two recharging trays illustrated in the electrical schematic diagram of FIG. 7 .
Formed into the top surface of the base 38 is a plurality of indented circular sockets dimensioned to receive a bottom portion of an artificial candle in each. Centrally located in each of the sockets and projecting vertically from the center thereof are cylindrical posts 42 . Contained within each such post is a magnetic core 43 encircled by coil windings, as at 44 , and which form the primary winding of a transformer that is inductively coupled to the coil 36 that surround the bore 34 in the candle when the candles are resident in the sockets of the base 38 .
Referring back to FIG. 2 , also contained within the cylindrical housing 22 of the artificial candle is a motion sensor 46 . The motion sensor 46 includes three small tubes 48 , 50 and 52 that contain a conductive ball in the lumens thereof, the balls being free to move between electrical contacts disposed at opposed ends of each of the tubes. Thus, for example, when the artificial candle is resting on a flat horizontal surface, the conductive balls will be at the lower end of each of the tubes 48 , 50 and 52 , but when the candle is tipped from its upright position, gravity will cause the conductive balls to shift in position to close a different set of contacts, thus indicating that the candle is no longer upright.
Also visible in FIG. 2 is a battery-operated buzzer 54 which will be made to sound whenever the artificial candle is not in its upright position for a predetermined length of time. Thus, for example, should a restaurant patron attempt to make off with a candle by placing it in a pocket or purse, the device will give off an audible sound to alert restaurant personnel that a candle is being taken.
FIG. 5 is an electrical schematic diagram of the circuitry contained within the housing 22 of the artificial candle incorporating the anti-theft feature. The transformer T has a center tapped winding where the center tap is connected by conductors 100 and 102 to circuit ground. The opposed outer ends of the secondary winding are connected through rectifier diodes D 201 and D 202 to a junction point VCC. A smoothing capacitor C 201 is connected between that junction and the center tap terminal of the transformer winding, T.
Connected between the junction VCC and ground is a series combination of an NPN transistor Q 4 and a resistor R 14 . Connected between the base electrode of Q 4 and ground is a reference Zenar diode ZD 1 and connected between the junction VCC and the base electrode of Q 4 is a resistor R 1 .
A PNP transistor Q 1 has its emitter electrode coupled to the junction VCC by a current limiting resistor R 2 and the collector electrode of Q 1 is connected through a diode D 1 to a junction point VDD. The base electrode of Q 1 is connected to ground through a series combination of a resistor R 4 and the emitter to collector path of a PNP transistor Q 2 . More particularly, the emitter electrode of Q 2 is connected directly to ground while its collector electrode connects to the base electrode of Q 1 via the resistor R 4 .
A pair of diodes D 4 and D 5 are connected in series between the junction VCC and the base electrode of transistor Q 1 , the purpose of which is to apply an appropriate bias for transistor Q 1 .
Control over the mode of operation of the candle is dictated by a programmed microprocessor U 1 which preferably comprises a Type FS260, an 8-bit microprocessor. A push-button off/on switch for the artificial candle, S 1 , is connected between ground and input pin B 1 of the microprocessor and a capacitor C 6 is connected directly in parallel with the switch S 1 . Connected between input terminals B 0 and B 2 are positioned sensing switches S 301 and S 302 and S 303 . These are the same devices as referred to by reference numerals 48 , 50 and 52 in the drawing of FIG. 2 . A debounce capacitor C 5 is connected in parallel with these three position sensitive switches.
An NPN transistor Q 5 has its emitter electrode tied to ground and its collector electrode connected to the input terminal B 3 of the microprocessor U 1 . The base electrode of Q 5 is connected through a biasing resistor R 3 to the junction point between the emitter electrode of Q 4 and the resistor R 14 . That junction is also connected by means of a conductor 103 , a diode D 2 , and a resistor R 17 to output terminal A 3 of the microprocessor U 1 . The common junction between the diode D 2 and the resistor R 17 is coupled by a resistor R 15 to the reset terminal RETB of the microprocessor and by a conductor 104 to the VDD terminal of the microprocessor U 1 .
A first LED, preferably green in color, has its anode electrode tied to the conductor 104 and its cathode electrode connected, via a resistor R 7 , to the output terminal B 4 of the microprocessor. Likewise, a second LED, preferably red in color, has its anode electrode connected to the conductor 104 and its cathode electrode connected by a resistor R 6 to output terminal B 5 of the microprocessor.
The output terminal B 6 of the microprocessor is connected through a series resistor R 11 to the base electrode of a PNP transistor Q 6 whose emitter electrode connects to the positive terminal of a rechargeable battery BT 1 and whose negative electrode is connected to ground. The rechargeable battery, for example, may be a 3.6 volt 330 ma lithium battery, but limitation to that type of rechargeable cell is not to be inferred.
The collector electrode of a transistor Q 6 connects to ground through a resistor R 12 and a yellow LED, labeled LED 1 , which is the flame LED 16 in FIGS. 2 and 3 of the drawings. The positive battery terminal BT+ is also connected through a diode D 3 to the VDD terminal of the microprocessor thereby supplying its operating voltage. The cathode of the diode D 3 connects to conductor 104 and a capacitor C 3 connects between that conductor and ground. A resistor R 16 couples the VDD terminal of the microprocessor to its OSC 1 terminal.
With continued reference to FIG. 5 , the anode electrode of the diode D 3 connects through a series resistor R 9 and a capacitor C 7 to ground. Connected directly in parallel with the capacitor C 7 is a further resistor R 10 . The common terminal between the resistor C 7 , the resistor R 9 and the resistor R 10 is tied to the input terminal A 1 of the microprocessor.
Programmable shunt regulator U 2 is connected between the microprocessor input terminal A 4 and ground and its reference electrode is connected by means of a capacitor C 4 to ground. The reference electrode is also directly connected to the device's cathode.
Completing the circuit of FIG. 5 is an audible signaling device or buzzer B 1 having a first terminal thereof connected to the VDD terminal, i.e., the battery's positive terminal and the second terminal of the buzzer B 1 connects through an NPN transistor switch Q 3 to ground. The base electrode of Q 3 has a resistor R 8 connecting it to the terminal A 5 of the microprocessor U 1 .
In operation, and assuming that the battery potential BT+ is below a certain potential and it is appropriately mounted on the charging tray with the post 42 located in the bore 34 , transistor Q 1 will be forward biased and a DC current resulting from rectification of the induced voltage across the secondary winding of the transformer T becomes available to charge the battery. When the battery becomes charged to the point where its voltage BT+ is at a predetermined value, the microprocessor is programmed to output a signal on its terminal A 2 to reverse bias the transistor Q 2 which has the effect of shutting off the charging current flow through the transistor Q 1 to the battery.
With the battery fully charged and assuming the candles have been removed from the tray, depression on the on/off switch Si inputs a ground signal to terminal B 1 of U 2 which has the effect of driving the transistor Q 6 into conduction, whereby current flows to the candle lamp LED 1 causing it to glow. The candle flame LED 1 is made to flicker by the microprocessor suitably varying the on/off state of the transistor Q 6 . However, if the on/off switch Si is depressed a second time, the microprocessor is programmed to cause a steady current to flow through transistor Q 6 , such that LED 1 no longer flickers. A third depression of the on/off switch is effective to turn off the candle.
Assuming that the battery is fully charged, the candle has been removed from the base 38 and that the on/off switch has been depressed either once or twice in succession and then the candle set down on a flat, horizontal surface, such as on a patron's table, the LED 1 will continue to glow. However, if the patron should now pick up the candle from the table and, in doing so, tip it so that its top surface 20 is non-horizontal, one or more of the position sensitive switches S 301 , S 302 and S 303 will reverse state and input a signal between microprocessor terminals B 0 and B 2 . Upon detection of this condition for a programmed period, say 5 seconds, the microprocessor will issue a signal on output terminal AS to turn on the transistor Q 3 and complete a circuit from the battery through the buzzer to ground causing the buzzer to emit an audible signal that can attract attention of a restaurant employee. Turning on the buzzer B 1 also results in the LED 2 flashing on and off at one second intervals which is a further attention getter. This state will continue until the candle is returned to the charging tray that is located to be accessible only to restaurant employees.
Turning next to FIG. 6 , it is substantially identical in its construction to that of FIG. 5 except that the buzzer and position sensitive switches S 301 , S 302 and S 303 are eliminated and replaced with circuitry that adds further realism to the artificial candle. Specifically, if the flame LED is glowing in either its blink mode or its steady mode and a patron blows air at the flame, the flame will be extinguished.
As seen in FIG. 6 , connected between the microprocessor input terminals B 0 and B 2 is the circuitry shown enclosed by the broken line box 105 . It includes a PVDF pyro/piezo film transducer CY 1 that possesses the property of being able to convert a temperature change and pressure wave into an electrical signal proportional to the amount of change. This signal is amplified by a two-stage amplifier including the transistors Q 3 and Q 7 and the microprocessor is programmed so that upon receipt of the “blow” signal from the transducer CY 1 , the transistor Q 6 is turned off, thereby extinguishing LED 1 .
FIG. 7 is an electrical schematic diagram of the circuitry used to simultaneously recharge the batteries of a plurality of artificial candles heretofore described. The 110 volt AC to 12 volt DC adapter 12 provides its output to the current limitator circuit 14 contained within the broken line box 110 . The current limitator circuit functions to limit the current draw by the attached charging trays to a maximum of 3.2 amperes and thereby preventing overloading of the adapter 12 . Should the current draw by the connected recharging trays reach the limit of 3.2 amperes, the current limitator automatically cuts off the power being delivered to the recharging trays. The current limitator circuit includes a Type TL431 shunt regulator 112 whose cathode and reference electrode are connected through a jumper selectable voltage divider to the non-inverting input of an LM393 operational amplifier 114 and whose output connects to a Type IRFL024N power MOSFET operatively connected between a wire in the cable that is adapted to plug into the charging tray and ground. The inverting input of the op amp 114 connects through a manually operated reset switch 118 to ground.
The cathode electrode of the shunt regulator 112 is also coupled through a resistor 120 to the non-inverting input of an operational amplifier 122 . The resistor 120 along with a further resistor 123 constitutes a voltage divider. The cathode electrode of the shunt regulator 112 also connects through a parallel RC circuit 124 to the inverting input of the op amp 122 . The op amp 122 has its output electrode connected through a diode 126 to the inverting input of the op amp 114 and through a resistor 128 to the gate electrode of the power MOSFET 116 .
Those skilled in the art will appreciate that the shunt regulator 112 functions much like a Zenar diode to provide a predetermined reference for the op amps 114 and 122 and that when the current being drawn from the AC/DC adapter 12 approaches 3.2 ampere, the power MOSFET 116 is driven into conduction effectively disconnecting the AC/DC adapter source from its load.
The recharging tray circuits are shown enclosed by broken line boxes 130 and 133 . While only two such recharging tray circuits are shown in FIG. 7 , it is to be appreciated that additional trays may be concatenated by operatively joining them to the two conductor cable 132 , via plugs as at 134 and 136 , that are adapted to mate with sockets or jacks 138 and 140 , respectively, in the manner explained with reference to FIG. 1B . In that the two illustrated recharging trays are identical, it will only be necessary to explain the constructional features of one of them and, in this regard, attention will be given to the circuitry shown enclosed by the broken line box 130 .
With the plug 134 mated with the jack 138 , a current path is established to a conductor 142 that connects to the center tap terminals of the primary windings of transformers T 1 through T 12 . It will be recalled that the cores of the transformers T 1 -T 12 are individually disposed within hollow posts projecting upward from the center of the pockets on the charging tray. The “ON” state of the charging tray is indicated by means of a pair of LEDs 144 connected between conductor 142 and ground.
The two outer terminals of the center tapped windings of transformers T 1 through T 12 are connected through, for example, MOSFET switches 146 , 147 , 148 , and 149 , and the ON/OFF state of these switches is controlled by one of the pulse width modulator chips 150 and 152 . Without limitation, they may each comprise a Type SG3525A integrated circuit device available from ST Microelectronics or an ESM6820A dual N-Channel enhancement mode FET. Such circuits are frequently used in the design of various types of switching power supplies. Thus, the duty cycle of the pulsitile current made to flow through the transformer windings of T 1 through T 12 can be controlled. To protect the MOSFET switches 146 - 149 from exposure to peak voltages generated by the coils of the transformer windings, a diode 153 and a parallel RC circuit 155 , 157 is connected between the outer ends of the coils and their center tap.
The switching rate of the MOSFET switches 146 - 149 is controlled by the selection of the RC time constant of the circuit connected to the “R” and “C” input terminals of the integrated pulse width modulator chips 150 and 152 . The RC timing circuit for the pulse width modulator chip 150 is identified by numeral 154 in FIG. 7 .
When the artificial candles are placed on the recharging tray in the manner shown in FIG. 4 , the winding contained within the candle housing is exposed to the magnetic flux generated by the transformer coils of T 1 -T 12 and converted by the rectifiers D 201 and D 202 to a DC current for recharging the candles' batteries 24 .
The microprocessor chip U 1 contained within the candle causes the battery to be charged with only 30% of the maximum set current for a period of 20 minutes. Following that, the batteries in the candles will be charged at 100% of the set current until such time that it is detected that the battery voltage has reached 4.2 volts, indicating a fully charged condition. At this time, the glowing red LED (LED 2 ) will switch off and the green LED (LED 3 ) is illuminated to indicate a fully charged condition of the candle battery. As already mentioned, the microprocessor U 1 in the candle receives a signal when the battery has become fully charged up to 4.3 volts and will cause the transistor Q 1 to become non-conductive, thereby cutting off the charging current.
This invention has been described herein in considerable detail in order to comply with the patent statutes and to provide those skilled in the art with the information needed to apply the novel principles and to construct and use such specialized components as are required. However, it is to be understood that the invention can be carried out by specifically different equipment and devices, and that various modifications, both as to the equipment and operating procedures, can be accomplished without departing from the scope of the invention itself.
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A large plurality of artificial, battery-operated, electronic candles are arranged to be simultaneously recharged upon placement on a series of interconnected charging trays that include a transformer primary winding at defined locations thereon. The primary windings are driven by an AC signal whose duty cycle is controlled by a pulse width modulator IC to induce a voltage across secondary windings contained within the candle housing. This induced signal is rectified to produce the battery charging current and the delivery of the charging current to the rechargeable batteries is controlled by a microprocessor IC.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of U.S. patent application Ser. No. 12/198,129 filed Aug. 26, 2008 and entitled “DETECTING GAS COMPOUNDS FOR DOWNHOLE FLUID ANALYSIS,” which is hereby incorporated in its entirety by this reference.
FIELD OF THE INVENTION
[0002] The invention is generally related to downhole fluid analysis, and more particularly to in situ detection of gaseous compounds in a borehole fluid.
BACKGROUND OF THE INVENTION
[0003] Phase behavior and chemical composition of borehole fluids are used to help estimate the viability of some hydrocarbon reservoirs. For example, the concentration of gaseous components such as carbon dioxide, hydrogen sulfide and methane in borehole fluids are indicators of the economic viability of a hydrocarbon reservoir. The concentrations of various different gasses may be of interest for different reasons. For example, CO 2 corrosion and H 2 S stress cracking are leading causes of mechanical failure of production equipment. CH 4 is of interest as an indicator of the calorific value of a gas well. It is therefore desireable to be able to perform fluid analysis quickly, accurately, reliably, and at low cost.
[0004] A variety of techniques and equipment are available for performing fluid analysis in a laboratory. However, retreiving samples for laboratory analysis are time consuming. Further, some characteristics of borehole fluids change when brought to the surface due to the difference in environmental conditions between a borehole and the surface and other factors. For example, because hydrogen sulfide gas readily forms non-volatile and insoluble metal sulfides by reaction with many metals and metal oxides, analysis of a fluid sample retreived with a metallic container can result in an inaccurate estimate of sulfide content. This presents a technological problem because known fluid analysis techniques that can be used at the surface are impractical in the borehole environment due to size limitations, extreme temperature, extreme pressure, presence of water, and other factors. Another technological problem is isolation of gases, and particular species of gas, from the borehole fluid.
[0005] The technological problems associated with detection of gas in fluids have been studied in this and other fields of research. For example, US20040045350A1, US20030206026A1, US20020121370A1, GB2415047A, GB2363809A, GB2359631A, US6995360B2, US6939717B2, W02005066618A1, W02005017514A1, W02005121779A1, US20050269499A1, and US20030134426A1 describe an electrochemical method for H2S detection using membrane separation. US20040045350A1, GB2415047A, and GB2371621A describe detecting gas compounds by combining infrared spectrophotometry and a membrane separation process. US20060008913 A1 describes the use of a perfluoro-based polymer for oil-water separation in microfluidic system.
SUMMARY OF THE INVENTION
[0006] In accordance with an embodiment of the invention, apparatus for performing in situ analysis of borehole fluid includes a gas separation system and a gas detection system. The gas separation system may include a membrane. The gas separated from the fluid by the membrane may be detected by techniques such as reaction with another material or spectroscopy. When spectroscopy is employed, a test chamber is used to hold the gas undergoing test. Various techniques may be employed to protect the gas separation system from damage due to pressure differential. For example, a separation membrane may be integrated with layers that provide strength and rigidity. The integrated separation membrane may include one or more of a water impermeable layer, gas selective layer, inorganic base layer and metal support layer. The gas selective layer itself can also function as a water impermeable layer. The metal support layer enhances resistance to differential pressure. Alternatively, the test chamber may be filled with a liquid or solid material.
[0007] In accordance with another embodiment of the invention, a method for downhole fluid analysis comprises: sampling a downhole fluid; taking a gas from the downhole fluid by using a gas separation module; and sensing the gas.
[0008] One of the advantages of the invention is that borehole fluid can be analyzed in situ. In particular, gas is separated from the fluid and detected within the borehole. Consequently, time consuming fluid retrieval and errors caused by changes to fluid samples due to changes in conditions between the borehole and the environment are at least mitigated.
BRIEF DESCRIPTION OF THE FIGURES
[0009] FIG. 1 illustrates a logging tool for gas separation and detection in a borehole.
[0010] FIG. 2 illustrates an embodiment of the tool for gas separation and detection in greater detail.
[0011] FIG. 3 illustrates an embodiment of the gas separation and detection tool of FIG. 2 having a gas separation membrane and spectroscopy sensor.
[0012] FIG. 4 illustrates alternative embodiments of the gas separation and detection tool, both with and without sampling chamber.
[0013] FIG. 5 illustrates embodiments of the gas separation and detection tool with different integrated membranes.
[0014] FIG. 6 illustrates embodiments of the integrated membrane in greater detail.
[0015] FIG. 7 illustrates another alternative embodiment of the gas separation and detection tool with an integrated membrane.
[0016] FIG. 8 illustrates an embodiment of the gas separation and detection tool with a fluidic buffer.
[0017] FIG. 9 illustrates a solid state embodiment of the gas separation and detection tool.
[0018] FIG. 10 illustrates an alternative embodiment of the gas separation and detection tool.
DETAILED DESCRIPTION
[0019] Referring to FIG. 1 , a wireline logging tool ( 106 ) is suspended from an armored cable ( 108 ), and may have optional centralizers (not shown). The cable ( 108 ) extends from the borehole ( 104 ) over a sheave wheel ( 110 ) on a derrick ( 112 ) to a winch forming part of surface equipment, which may include an analyzer unit ( 114 ). Well known depth gauging equipment (not shown) may be provided to measure cable displacement over the sheave wheel ( 110 ). The tool ( 106 ) may include any of many well known devices to produce a signal indicating tool orientation. Processing and interface circuitry within the tool ( 106 ) amplifies samples and digitizes the tool's information signals for transmission and communicates them to the analyzer unit ( 114 ) via the cable ( 108 ). Electrical power and control signals for coordinating operation of the tool ( 106 ) may be generated by the analyzer unit ( 114 ) or some other device, and communicated via the cable ( 108 ) to circuitry provided within the tool ( 106 ). The surface equipment includes a processor subsystem ( 116 ) (which may include a microprocessor, memory, clock and timing, and input/output functions—not separately shown), standard peripheral equipment (not separately shown), and a recorder ( 118 ). The logging tool ( 106 ) is representative of any logging device that may be used in accordance with principles described herein. It will be understood by those of skill in the art having the benefit of this disclosure that the gas separation and detection tool described in detail below can be implemented as a wireline, MWD, LWD, or other type of tool, including but not limited to tools mounted in the formation or mounted in a completion of the borehole to perform ongoing measurements over time.
[0020] Referring to FIG. 2 , an embodiment of the gas separation and detection tool includes a separation module ( 200 ) and a detection module ( 202 ). A test chamber ( 204 ) may also be defined between the separation module and detection module. Gas that is present in a borehole fluid in a flowline ( 206 ) enters the chamber via the separation module, i.e., the gas is separated from the fluid in the flowline. Differential pressure between the flow line and the chamber may facilitate gas separation. The detection module subjects the separated gas in the chamber to a testing regime which results in production of an indicator signal ( 208 ). The indicator signal is provided to interpretation circuitry ( 210 ) which characterizes the gas sample, e.g., in terms of type and concentration.
[0021] Referring to FIGS. 2 and 3 , the separation module may include a membrane ( 300 ). The membrane has characteristics that inhibit traversal by all but one or more selected compounds. One embodiment of the membrane ( 300 ) is an inorganic, gas-selective, molecular separation membrane having alumina as its base structure, e.g., a DDR type zeolite membrane. Nanoporous zeolite material is grown on the top of the base material. Examples of such membranes are described in US20050229779A1, US6953493B2 and US20040173094A1. The membrane has a pore size of about 0.3-0.7 nm, resulting in a strong affinity towards specific gas compounds such as CO2. Further enhancement of separation and selectivity characteristics of the membrane can be accomplished by modifying the surface structure. For example, a water-impermeable layer such as a perfluoro-based polymer (e.g. Teflon AF or its variations), polydimethyl siloxane based polymer, polyimide-based polymer, polysulfone-based polymer or polyester-based polymer may be applied to inhibit water permeation through the membrane. Other variations of the separation membrane operate as either molecular sieves or adsoption-phase separation. These variations can formed of inorganic compounds, inorganic sol-gel, inorganic-organic hybrid compounds, inorganic base material with organic base compound impregnated inside the matrix, and any organic materials that satisfy requirements.
[0022] The chamber ( 204 ), if present, is defined by a rigid housing ( 302 ). The membrane ( 300 ) occupies an opening formed in the housing ( 302 ). The housing and membrane isolate the chamber from the fluid in the flowline, except with respect to compounds that can traverse the membrane. As already mentioned, when partial pressure of gas compounds is greater in the flowline than in the chamber, differential pressure drives gas from the flowline into the chamber. When the partial pressure is greater in the chamber than in the flowline, differential pressure drives gas from the chamber into the flowline. In this manner the chamber can be cleared in preparation for subsequent tests.
[0023] Operation of the detector module ( 202 ) may be based on techniques including but not limited to infrared (IR) absorption spectroscopy. An IR absorption detector module may include an infrared (IR) light source ( 304 ), a monitor photodetector (PD) ( 306 ), an IR detector ( 308 ), and an optical filter ( 310 ). The IR source ( 304 ) is disposed relative to the optical filter ( 310 ) and IR detector ( 308 ) such that light from the IR source that traverses the chamber ( 204 ), then traverses the filter (unless filtered), and then reaches the IR detector. The module may be tuned to the 4.3 micrometer wavelength region, or some other suitable wavelength. The monitor PD ( 306 ) detects the light source power directly, i.e., without first traversing the chamber, for temperature calibration. If multi-wavelength spectroscopy is used, e.g., for multi-gas detection or baseline measurement, several LEDs or LDs can be provided as light sources and a modulation technique can be employed to discriminate between detector signals corresponding to the different wavelengths. Further, spectroscopy with NIR and MIR wavelengths may alternatively be employed. In each of these variant embodiments the absorbed wavelength is used to identify the gas and the absorption coefficient is used to estimate gas concentration.
[0024] FIG. 4 illustrates embodiments of the invention both with and without a test chamber. These embodiments may operate on the principle of measuring electromotive force generated when the gas reacts with a detecting compound, i.e., the gas sensor module ( 202 ) includes a compound that reacts with the target gas. Because the electromotive force resulting from the reaction is proportional to the gas concentration, i.e., gas partial pressure inside the system, gas concentration in the flowline can be estimated from the measured electromotive force. Alternatively, these embodiments may operate on the principle of measuring resistivity change when the gas reacts with the detecting compound. Because the resistivity change is proportional to the gas concentration, i.e., gas partial pressure inside the system, gas concentration in the flowline can be estimated from the measured resistivity change.
[0025] Other features which enhance operation may also be utilized. For example, a water absorbent material ( 400 ) may be provided to absorb water vapor that might be produced from either permeation through the membrane or as a by product of the reaction of the gas with a detecting compound. Examples of water absorbant material include, but are not limited to, hygroscopic materials (silica gel, calcium sulfate, calcium chloride, montmorillonite clay, and molecular sieves), sulfonated aromatic hydrocarbons and Nafion composites. Another such feature is a metal mesh ( 402 ) which functions as a flame trap to help mitigate damage that might be caused when gas concentration changes greatly over a short span of time. Another such feature is an O-ring seal ( 404 ) disposed between the housing and the flowline to help protect detection and interpretation electronics ( 406 ). Materials suitable for construction of components of the gas sensor module include SnO2, doped with copper or tungsten, gold epoxy, gold, conductive and non-conductive polymer, glass, carbon compounds and carbon nanotube compounds for the purpose of proper sealing, maintaining good electrical connection, increasing sensitivity and obtaining stable measurements. The housing may be made of high performance thermoplastics, PEEK, Glass-PEEK, or metal alloys (Ni).
[0026] Referring to FIGS. 5 and 6 , various features may be employed to help protect the membrane from damage, e.g., due to the force caused by the pressure differential where the chamber contains only gas. One such feature is an integrated molecular separation membrane. The integrated membrane can include a water impermeable protective layer ( 500 ), a gas selective layer ( 502 ), an inorganic base layer ( 504 ) and a metal support layer ( 506 ). The metal support layer increases the mechanical strength of the membrane at high-pressure differentials. Gas permeates through the molecular separation layer and goes into the system via small holes in the metal support. In another embodiment the integrated molecular separation membrane includes a molecular separation membrane/layer bonded to a metal support layer and sealed with epoxy ( 508 ) or any other sealant. The epoxy can be a high temperature-resistant, non-conductive type of epoxy or other polymeric substances. The molecular separation layer can act as a water/oil separation membrane. Gas permeates through the molecular separation layer and goes into the system via small holes in the metal support. In another embodiment the integrated separation membrane includes a molecular separation membrane/layer bonded to a metal support layer and sealed with epoxy. The metal support is designed to accommodate insertion of the molecular separation membrane. The epoxy or sealant can be a high temperature, non-conductive type of epoxy or other polymeric substances. Gas permeates through the molecular separation layer and goes into the system via small holes in the metal support.
[0027] Referring to FIG. 7 , in an alternative embodiment the integrated membrane includes a molecular separation membrane/layer ( 700 ) bonded between porous metal plates ( 702 , 704 ). In addition to integrating the gas separation and pressure balancing functions into one mechanical assembly, this alternative embodiment provides support for the membrane both at a pressure differential where flowline pressure is greater than chamber pressure and at a pressure differential where chamber pressure is greater than flowline pressure.
[0028] Referring to FIG. 8 , an alternative embodiment utilizes an incompressible liquid buffer ( 800 ) to help prevent membrane damage due to pressure differential. The liquid buffer may be implemented with a liquid material that does not absorb the target gas. Because the liquid buffer is incompressible, buckling of the membrane due to the force caused by higher pressure in the flowline than in the chamber is inhibited when the chamber is filled with liquid buffer. A bellows can be provided to compensate for small changes in compressibility within the chamber due to, for example, introduction or discharge of the target gas. FIG. 8 illustrates a membrane and a spectrometer module, to which the above embodiments of FIGS. 2-7 can be applied either alone or in combination.
[0029] FIG. 9 illustrates an alternative embodiment that is different from the above embodiments of FIGS. 2-7 in utilizing a solid state chamber ( 900 ). The solid state chamber is formed by filling the cavity defined by the housing with a nanoporous solid material. Suitable materials include, but are not limited to, TiO 2 , which is transparent in the NIR and MIR range. The target gas which traverses the membrane enters the nanospace of the solid material. Since the chamber is solid state, buckling of the membrane due to higher pressure in the flowline than in the chamber is inhibited. However, because the chamber is porous, gas can be accommodated.
[0030] FIG. 10 illustrates another alternative embodiment of the gas separation and detection tool. The tool includes a non H2S-scavenging body ( 1000 ) with a gas separation module ( 200 ) which may include a membrane unit ( 1002 ) as illustrated in FIGS. 2-9 . The separated gas enters a test chamber defined by the body and membrane unit due to differential pressure. Optical fibre is used to facilitate gas detection. In particular, light from a lamp source ( 1004 ) is inputted to an optical fibre ( 1006 ), which is routed to one side of the chamber. A corresponding optical fibre ( 1008 ) is routed to the opposite side of the chamber, and transports received light to a receiver ( 1010 ). A microfluidic channel fibre alignment feature ( 1012 ) maintains alignment between the corresponding fibres ( 1006 , 1008 ). The arrangement may be utilized for any of various gas detection techniques based on spectroscopy, including but not limited to infrared (IR) absorption spectroscopy, NIR and MIR. In each of these variant embodiments the absorbed wavelength is used to identify the gas and the absorption coefficient is used to estimate gas concentration.
[0031] While the invention is described through the above exemplary embodiments, it will be understood by those of ordinary skill in the art that modification to and variation of the illustrated embodiments may be made without departing from the inventive concepts herein disclosed. Moreover, while the preferred embodiments are described in connection with various illustrative structures, one skilled in the art will recognize that the system may be embodied using a variety of specific structures. Accordingly, the invention should not be viewed as limited except by the scope and spirit of the appended claims.
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A gas separation and detection tool for performing in situ analysis of borehole fluid is described. The tool comprises a sampling chamber for a downhole fluid. The sample chamber comprises a detector cell with an opening. The tool also comprises a gas separation module for taking a gas from the downhole fluid. The gas separation module comprises a membrane located in the opening, a support for holding the membrane, and a sealant applied between the housing and the membrane or support. Moreover, the tool comprises a gas detector for sensing the gas.
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BACKGROUND OF THE INVENTION
The invention relates to a method for improving the vibration absorbtion of a railway track supported on a bed of ballast, more especially a ballast bed lying in a tunnel, on a fly-over or on another artificial construction, said track consisting of rails supported by sleepers extending in lateral direction. A ballast bed generally has the advantage that much sound is absorbed and moreover that the sound is not reflected. If the bed is not too much settled, it takes vibrations itself which are not conducted further. A disadvantage, especially when such a ballast bed is lying on an artificial construction is that when such a ballast bed is settled after some time, the vibrations at the under surface are transmitted to the supporting part of the artificial construction.
The invention has for its aim to provide a method with which the vibration absorbtion can be approved in a simple way.
BRIEF SUMMARY OF THE INVENTION
According to the invention the track is lifted some centimeters, around the edge of the supporting surface of the sleepers the ballast above the level of said surface is removed, a plate of vibration energy absorbing material is shifted between the supporting surface of the ballast bed and the sleepers and thereafter the track is lowered again and as far is required the ballast around the sleepers is brought in the original position or there is supplied new ballast. Owing to the inserted plate of vibration energy material the vibrations can not be transmitted to the support of the track structure. The reflecting action of the ballast remains completely the same.
According to the invention one can make use of plates of vibration energy absorbing material, which at their upper surface are provided with a layer which adheres quickly to the sleeper. As soon as the plate is inserted under the sleeper and the track is lowered again, the plate will adhere immediately to the sleeper and form a unity with the sleeper.
According to the invention plates can be used of vibration energy absorbing material, which at the surface directed to the ballast are provided with a monolithic layer which resists the reaction of the ballast. The lifetime of the plate is increased strongly by this measure.
In an advantageous embodiment according to the invention cork rubber or a similar material can be used as a vibration energy absorbing material.
According to the invention the ballast can be removed at the end face of each sleeper. Then the plate of vibration energy absorbing material can be inserted under the sleeper from the end face. It is only necessary to remove a small amount of ballast, as the end face is short.
Also according to the invention on both sides of the track in the compartments between the sleepers in every other compartment the ballast can be removed at the side of the supporting surface of the sleepers directed to said compartment. In each compartment one can serve two sleepers so that the next compartment can be left.
According to the invention the space between the under surface of the sleeper and the ballast bed around the plate of vibration energy absorbing material can be filled with a soft material. In such a way it is prevented that loose parts of ballast can shift between the sleeper and the ballast bed, which could have for effect that the supporting action of the plate vibration energy absorbing material could be influenced.
For providing the soft material use can be made of soft material that in the shape of the plate form a unity with the plate of vibration energy absorbing material.
According to the invention it is also possible that said space is filled by means of injecting a plastic foam.
The invention also relates to a track structure consisting of rails supported by sleepers on a ballast bed, more especially a ballast bed lying on a fly-over, in a tunnel or on another artificial construction.
According to the invention the sleepers are supported on the ballast bed through plates consisting of a vibration energy absorbing material, more especially cork rubber.
According to the invention the plates at their under surface can be provided with a hard wearing resistant layer forming a unity with said surface, said layer being in contact with the ballast bed. Finally the invention also relates to a sleeper for use on a ballast bed having no or only a little damping properties.
According to the invention such a sleeper at its under surface is provided with a layer of vibration energy absorbing material, which at its under surface has a layer of a hard wearing resistant material forming a unity with said absorbing material.
The invention will be elucidated in the following description of some embodiments shown in the drawing.
In the drawing is:
FIG. 1 a track in a plan view,
FIG. 2 the track of FIG. 1 in a sectional view according to the line II--II,
FIG. 3 a sectional view of FIG. 2 in a further phase,
FIG. 4 a section according to the lines IV--IV in FIG. 1,
FIG. 5 a sectional view of a track in another embodiment,
FIG. 6 schematically a track in a plan view,
FIG. 7 a plan view corresponding with FIG. 6,
FIG. 8 an embodiment of a track in a plan view,
FIG. 9 a track in another embodiment also in a plan view.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a track lying on a ballast bed 1, consisting of rails 2 and 3, which with clamps 4 are attached to sleepers 5. The ballast bed is lying on an artificial construction, for example on the floor of a tunnel. When the ballast bed 1 has been settled too much the vibration absorbing characteristics of the ballast are significantly impaired.
According to the invention the track consisting of the rails 2 and 3 and the sleepers 5 is lifted some centimeters. Between the layers 5 and the settled ballast is then formed a space 6. Between the sleepers 5, as is indicated at 7, the ballast which is lying above the level of the supporting surface of the sleepers can be removed. The space 6 is now accessible from the side and under the sleepers can now be shifted the plates 8, said plates consisting of vibration energy absorbing material. At its upper surface the plates 8 can be provided with an adhesive layer 9 and at its under surface with a hard layer 10 which resists the influence of the ballast bed. When the track thereafter has been lowered the plates 8 adhere to the sleepers 5 and these sleepers 5 are supported by the plates 8.
As can be seen in FIG. 3 between the plates 8 below the layers 5 can be provided a layer of a soft material 11. This layer 11 takes care that no ballast can take over the supporting action of the plates 8. Also at the outer side of the plates 8 a same layer 12 and 13 can be provided. Thereafter the ballast can be placed again at the side of the sleepers. FIG. 4 shows on a greater scale a sleeper and a plate in cross section and better illustrates the layers 8, 9, 10. FIG. 5 shows a modified form of sleeper which consists of two blocks 14 and 15 supporting the rails 16 and 17, the blocks being connected by tubes or rods 18. Here also the track can be lifted and vibration energy absorbing plates 19 can be provided between the sleeper and the ballast bed, each plate as before having the upper wearing resistant layer 20, an upper surface adhesive layer 21 and the intermediate layer 19 of cushioning material.
FIGS. 6, 7, 8 and 9 show a track in plan view in which the rails 22 and 23 are supported by sleepers 24, 25, 26, 27, 28 and 29. FIG. 6 illustrates how the ballast can be removed in order to make the spaces below all of the sleepers accessable. When for example said ballast is removed at 30 and 31 over the whole length of the sleepers, it is possible to slip the plates of elastic material under the sleepers 25, 26 from the compartment 30 whereas the plates can be slipped below the sleepers 27, 28 from the compartment 31.
FIG. 7 shows an alternate manner of inserting the plates, in which the ballast is removed at 32 from between the sleepers 24 and 25 and from between the sleepers 25 and 26 at 33. It is then possible to insert a plate below each of the sleepers 24 and 25 from the compartment 32 whereas a plate can be inserted beneath the other end of the sleeper 25 from the compartment 33, and so on for the entire track section. The material 11, as in FIG. 3, can for example be provided by injecting.
FIG. 8 shows a further alternative for inserting the plates. The ballast at one of the end faces of the sleepers 24 to 29 is removed as at 34. Then the plates of vibration energy absorbing material for each sleeper can be inserted from the corresponding compartment.
FIG. 9 shows a further embodiment in which the ballast is removed at both ends of the sleepers 24 to 29. Then in contrast to FIG. 8, the sleeper 24 for example can be provided at one end with the supporting plate from the compartment 35 and for the other half from the compartment 36. Although there is more work required in removing the ballast than in FIG. 8, the shifting of the plates under the sleepers is simpler, particularly when the soft layer 11 of FIG. 3 is provided by injecting.
Owing to the method according to the invention the vibration absorbing characteristics of the ballast bed is completely restored and the sound reflecting working of the ballast bed remains completely the same.
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A method for restoring the vibration absorbtion of a railway track supported on a bed of ballast, a track structure obtained by applying such a method and sleepers for use with the method.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of Invention
[0002] The present invention provides methods for analysis of purity and concentration of 2-deoxy-D-glucose (2-DG), especially in preparations intended for therapeutic use, and so relates to the fields of chemistry, biology, pharmacology, and medicine.
[0003] 2. Description of Related Art
[0004] 2-Deoxy-D-glucose (2-DG) has been studied to determine if the compound has potential application as an anticancer agent (see Blough et al., 1979, JAMA 241 (26): 2798, incorporated herein by reference). Recent advances, as described in PCT patent application No. US04/000530 and U.S. Pat. No. 6,670,330, both of which are incorporated herein by reference, that are being implemented in ongoing clinical trials indicate that 2-DG should prove to be a useful anticancer agent. Employing 2-DG as an active pharmaceutical ingredient (API) in a drug product requires an accurate method for determining the concentration and purity of 2-DG.
[0005] HPLC analysis has been used to determine the concentration and purity of glucoase, a 2-DG analog. Columns and chromatographic conditions that have been described for the analysis of glucose using a refractive index (RI) detector are shown in Table 1, below.
[0000]
TABLE 1
Mobile
Vendor
Column
Temperature
Phase
Flow rate
Alltech
Astec Amino
Ambient
ACN:water
1
mL/min
250-4.6 mm
(75:25)
5-μm
Alltech
Hypersil
Ambient
ACN:water
0.5
mL/min
APS-2
(80:20)
100 × 3.2 mm
5-μm
Phenomenex
Luna Amino
40° C.
ACN:water
3
mL/min
250 × 4.6 mm
(80:20)
5-μm
Phenomenex
Rezex
85° C.
Water
0.6
mL/min
RCM-Mono-
saccharide
300 × 7.8 mm
[0006] One of the methods used for determining the purity of 2-DG in a sample is gas chromatography (GC; see Blough et al., supra, page 2799). However, 2-DG is a non volatile, high melting solid and needs to be transformed chemically into a volatile derivative that can be evaporated for analysis by GC. The transformation procedure involves reacting 2-DG with a trimethylsilylating agent, and the purity of its volatile trimethylsilylated derivative is actually analyzed by GC. The purity of 2-DG in the sample is thus indirectly inferred from the analysis of the derivative. In one approach, 2-DG has been reacted with trimethylsilylimidazole and pyridine for five minutes in an all glass reaction-vessel, prior to GC analysis (Blough et al., supra).
[0007] The drawbacks to this method include the following. Because there are four hydroxy groups in 2-DG that can be trimethylsilylated, each of them has to react with trimethylsilyl chloride (or any other trimethylsilylating agent), thus yielding a single product (which is analyzed in comparison to other components in the chromatogram), to describe the purity of 2-DG accurately. If the silylation reaction is incomplete, the formation of partially silylated derivatives can erroneously diminish the measured purity or concentration of the 2-DG in the sample. Also, the silylation product has to be stable during the process of evaporation and passage through the column at high temperatures, and the reactive 1′-TMS ether may become deprotected during this process.
[0008] In another method, 2-DG in rat serum has been analyzed by HPLC following a post column fluorescence derivatization (see Umegae et al., 1990, Chem. Pharm. Bull. 38 (4): 963-5, incorporated herein by reference). In this method, the sugars are converted into fluorescent derivatives by reaction with meso-1,2-bis(4-methoxyphenyl)ethylenediamine in an alkaline medium after separation on a strong anion exchange column (TSK gel Sugar AXG), and the fluorescent analogs are analyzed by a fluorescent detector. The detection limit in one application was, at a signal-to-noise ratio of 3, 0.52 nmol/mL. Again, the requirement of a reactive step and the measurement of an entity different from the actual analyte are among the drawbacks of this method.
[0009] Another method for analyzing the presence of tritiated 3 H-2-DG in rat muscle using chromatography has been reported (see Wallis et al., 2002, Diabetes, 51:3492, incorporated herein by reference). In this method, free and phosphorylated 3 H-2-DG are separated by ion exchange chromatography using an anion exchange resin (AG1-X8). Biodegradable counting scintillant, BCA (Amersham), is added to each radioactive sample and radioactivity determined using a scintillation counter (LS3801; Beckman). However, the radioactivity of 2-DG is used as a read-out, so the method is useful only for radio-labeled 2-DG.
[0010] Another method for determining 2-DG purity, in topical formulations, that involves HPLC has been employed with ultraviolet detection (UV) at 195 nm (see Hughes et al., 1985, J. Chromatogr. 331(1):183-6, incorporated herein by reference). 2-DG does not possess a chromophore absorbing above 200 nm, and a very low wave-length of 195 was chosen by the scientists reporting the method for the purpose of analysis. Columns that have been used in the method are a μBondapak 10 μm NH 2 column and a Varian Micropak 10 μm NH 2 column. The eluent used was 85% MeCN/H 2 O. The retention time of 2-DG reported in one application was about 4 minutes. Such a retention time is typically too short to observe impurities present in the sample, especially if the impurities are structurally closely related compounds like glucose.
[0011] There remains a need for methods for analyzing the purity and concentration of 2-DG that do not require derivatization, provide accurate results, especially at low concentrations, and are applicable to crystalline 2-DG. The present invention meets these needs.
BRIEF SUMMARY OF THE INVENTION
[0012] The present invention provides a method of separating 2-DG employing anion exchange chromatography wherein the anion exchange chromatography uses a poly(styrene-divinylbenzene) based polymer as a stationary phase. In one embodiment, the poly(styrene-divinylbenzene) based stationary phase contains ammonium groups. In a related embodiment, the ammonium group is a trimethylammonium group. In one embodiment, a poly(methylacrylamido propyl trimethylammonium salt) based polymer provides the trimethylammonium employed in the stationary phase. Examples for separating 2-DG employing anion exchange chromatography wherein the anion exchange chromatography uses poly(styrene-divinylbenzene) based stationary phases includes anion exchange chromatography employing RCX-10, RCX-30, and Aminex HPX-87X anion exchange columns. Examples of separating 2-DG employing anion exchange chromatography wherein the anion exchange chromatography uses poly(styrene-divinylbenzene) based stationary phases containing trimethylammonium groups include anion exchange chromatography employing RCX-10 and RCX-30 anion exchange columns.
[0013] In one aspect, the present invention provides an HPLC-based method for analyzing the purity of crystalline 2-DG, said method comprising the steps of: (a) dissolving said crystalline 2-DG in an aqueous solution; (b) chromatographing a sample of said aqueous 2-DG solution on an ion exchange column using an eluent selected from the group consisting of water, aqueous alkali, and aqueous acid as; (c) measuring an amount of 2-DG and any impurities in said sample after said chromatography by means of a detector that generates a signal proportional to the amount of said 2-DG in said sample; and (d) determining the purity of said crystalline 2-DG by comparing the signal generated by said 2-DG with any signal generated by said impurities in said sample.
[0014] In one embodiment, an anion exchange column and aqueous alkali eluent are employed. In another embodiment, an ion exchange column and aqueous acid eluent are employed. In another embodiment, an ion exchange column and water eluent are employed. In another embodiment, an anion exchange column and aqueous alkali eluent are employed, and an RI detector or a pulsed amperometric detector (PAD) is used to generate the signal. In one embodiment, an RI detector or a pulsed amperometric detector is used to generate the signal, and the crystalline 2-DG solution analyzed contains between about 1 μg/mL and 10 mg/mL of crystalline 2-DG.
[0015] In another aspect, the present invention provides an HPLC method for analyzing the purity of 2-DG in an aqueous solution, said method comprising the steps of: (a) chromatographing a sample of said aqueous 2-DG solution on an ion exchange column using an eluent selected from the group consisting of water, aqueous alkali, and aqueous acid; (b) measuring an amount of 2-DG and any impurities in said sample after said chromatography by means of a detector that generates a signal proportional to the amount of said 2-DG in said sample; (c) determining the purity of said 2-DG by comparing the signal generated by said 2-DG with any signal generated by said impurities in said sample. In one embodiment, the detector is a detector other than a UV detector.
[0016] In one embodiment, an anion exchange column and aqueous alkali eluent are employed. In another embodiment, an ion exchange column and aqueous acid eluent are employed. In another embodiment, an ion exchange column and water eluent are employed. In another embodiment, an anion exchange column and aqueous alkali eluent are employed, and an RI detector or a pulsed amperometric detector PAD is used to generate the signal. In another embodiment, an RI detector or a pulsed amperometric detector is used to generate the signal, and said 2-DG solution contains between about 1 μg/mL and 10 mg/mL of 2-DG.
BRIEF DESCRIPTION OF THE FIGURES
[0017] FIG. 1 shows a chromatogram for 2-DG (2 mg/mL) and glucose (2 mg/mL).
[0018] FIGS. 2A and 2B show chromatograms for blank injections of water ( FIG. 2A ) and mobile phase (see FIG. 2B ).
[0019] FIGS. 3A and 3B show chromatograms. FIG. 3A is a chromotogram for a placebo (1.8 mg/ml methylparaben and 0.2 mg/ml propylparaben); FIG. 3B is a chromatogram for the same sample after degradation by exposure to 70° C. for 1 day.
[0020] FIG. 4 shows a chromatogram for 2-deoxyglucose (2-DG) after 35 days at 60° C.
[0021] FIG. 5 shows a chromatogram for 2-DG after 23 days at 60° C.
[0022] FIGS. 6A and 6B show chromatograms for 2-DG after degradation by incubation for 5 days at 60° C. at pH 2, and pH 5, respectively.
[0023] FIGS. 7A and 7B show chromatograms for oxidized 2-DG samples. The sample in FIG. 7A is 5 ml 2-DG+50 μl H 2 O2 after storage at 60° C. for 17 hours. The sample in FIG. 7B is 5 ml 2-DG+100 μl H 2 O2 after storage at 60° C. for 17 hours.
[0024] FIGS. 8A and 8B are chromatograms for 20 mg/ml 2-DG samples, after being degraded by exposure to intense fluorescent light for 35 days.
[0025] FIG. 9 shows average peak area for 1 to 3 mg/ml samples of 2-DG in water.
[0026] FIGS. 10A and 10B show average peak area for 0.1-1.2 mg/ml glucose in assays run with 10 μl samples ( FIG. 10A ) and for 0.01-0.12 glucose in assays using 80 μl samples ( FIG. 10B ).
[0027] FIG. 11 shows a chromatogram for 10 μg/ml glucose.
DETAILED DESCRIPTION OF THE INVENTION
Example 1
Assay of 2-DG and Related Compounds in API and Drug-Product
[0028] This example illustrates how 2-DG purity was assessed in a mixture containing 2-DG and glucose in accordance with an embodiment of the method of the invention in which aqueous NaOH was the mobile phase, an anion exchange column was the stationary phase, an RI detector was employed, and the concentration of 2-DG in the 2-DG solution analyzed was about 2 mg/mL. A sample of 2-DG drug product was prepared by dissolving API grade 2-DG into an aqueous solution containing methylparaben (0.18%) and propylparaben (0.02%). Chromatographic parameters analyzed to illustrate the method included system linearity, accuracy, system precision, system suitability, limits of detection and quantitation, and robustness and ruggedness.
[0029] The general procedure for HPLC employed an isocratic HPLC method, with an RI detector equipped with an anion-exchange column (Hamilton RCX-10, 250×4.1 mm, 0 7-μm) controlled at 30° C. The mobile phase was 18 mM NaOH in water and a flow rate of 0.7 mL/min yielded baseline resolution of 2-DG and glucose.
[0030] The method was performed using a Shimadzu HPLC system equipped with an automatic data acquisition system (ChromPerfect), a Shimadzu pump (Model LC-10AD), a Shimadzu autosampler (Model SIL-10A) and an RI detector (Agilent model 1100). The materials employed in the analyses, along with their suppliers are listed below:
[0000]
Sodium hydroxide
ACS Grade
2-deoxy-D-glucose
Ferro-Pfanstiehl
2-deoxy-D-glucose
Ferro-Pfanstiehl
2-deoxy-D-glucose*
Sigma
Glucose*
Sigma
Methylparaben
Sigma
Propylparaben
Sigma
Water
Milli-Q water
*The reference standard employed in the experiment.
Determination of Specificity
[0031] The placebo solutions and the solutions used for specificity and stability measurements were prepared as follows. The placebo solution was prepared by warming an appropriate mixture of methylparaben and propylparaben in water to about 70° C. and diluting this solution quantitatively. A solution of API 2-DG was prepared by dissolving crystalline 2-DG in water. A solution of 2-DG drug-product was prepared by dissolving a sample of crystalline 2-DG in the placebo solution.
[0032] A typical chromatogram for 2-DG and glucose, each at 2 mg/mL, is shown in FIG. 1 . Under the conditions of the method, 2-DG eluted at about 8 minutes, and glucose eluted between 9 and 10 minutes. Peaks eluting before 6 min were system peaks, which showed some variability run-to-run. Resolution between 2-DG and glucose was 2.4 with 3100 theoretical plates for both peaks. Both 2-DG and glucose peaks were well-shaped with an asymmetry (tailing) of 1.7.
[0033] The methods of the invention can be useful in measuring the heat stability of an aqueous API 2-DG solution. In one test, heat stability was determined by storing the solution at 60° C. for 35 days in a sealed 2 mL glass vial. The methods of the invention can also be useful in measuring the light stability of an aqueous API 2-DG solution. In one test, light stability was determined by exposing the solution to intense fluorescent light for 35 days in a sealed 2 mL glass vial.
[0034] The chromatograms for blank injections of water (see FIG. 2A ) and mobile phase (see FIG. 2B ), placebo containing methylparaben at 1.8 mg/mL and propylparaben at 0.2 mg/mL (see FIG. 3A ), and placebo degraded at 70° C. for one day (see FIG. 3B ) demonstrated that the background signal did not interfere with the quantitation of 2-DG or glucose peaks. API or drug-product 2-DG was exposed to elevated heat (see FIGS. 4 and 5 respectively), acid/base (see FIGS. 6A and 6B ), oxidation by H 2 O 2 (see FIGS. 7A and 7B ) and intense fluorescence light (see FIGS. 8A and 8B ). The results showed there was no degradation in samples exposed to 60° C. or intense fluorescent light for at least 35 days; that 2-DG was stable in pH 2 or pH 10 solution stored at 60° C. for 5 days; and that there was approximately 23% and 34% degradation in 50 and 100 μL H 2 O 2 added 2-DG solutions stored at 60° C. for 17 days.
System Linearity
[0035] To determine system linearity for 2-DG, a series of 2-DG standard solutions in water, in the concentration range of 50-150% of the expected injectate concentration (2 mg/mL), were prepared. Triplicate injections were made for each solution. Six replicate injections were made for the injected concentration at about 2 mg/mL. Excellent linearity was observed for the measured peak area versus 2-DG concentration in the injectate, with an r 2 value of 0.9999, a slope of 231797 and a y-intercept of 8179 (see Table 2 and FIG. 9 ).
[0036] The system linearity for glucose was performed by preparing a series of glucose standard solutions in water in the concentration range of 0.1-1.2 mg/mL with 10 μL injection (see Table 3A and FIG. 10A ) and 10-120 μg/mL with 80 μL injection (see Table 3B and FIG. 10B ). Excellent linearity was observed for the measured peak area versus glucose concentration in the injectate, with r 2 values of 0.9998 and 0.9997, respectively.
[0000]
TABLE 2
System Linearity of 2-DG
2-DG Concentration
% of Nominal
(mg/mL)
(2 mg/mL)
Peak Area
Mean ± SD
1.001
50.1%
240406
241927 ± 5011
247522
237852
1.603
80.2%
376265
376437 ± 4117
372409
380638
1.982
99.1%
468109
468228 ± 2531
467918
468014
467427
465429
472352
2.412
120.6%
565828
568212 ± 2116
568940
569868
3.030
151.5%
707758
710550 ± 4102
715259
708633
Slope = 231797
Y-intercept = 8179
R 2 = 0.9999
[0000]
TABLE 3A
System Linearity for Glucose (10 μL Injection)
Glucose
Concentration
% of Nominal
(mg/mL)
(2 mg/mL)
Peak Area
Mean
0.1
5%
22483
24661
26838
0.4
20%
93967
94815
95662
0.8
40%
188393
187668
186943
1.2
60%
281154
286404
291653
Slope = 238348
Y-intercept = −104
R 2 = 0.9998
[0000]
TABLE 3B
System Linearity for Glucose (80 μL Injection)
Glucose
Concentration
% of Nominal
(μg/mL)
(2 mg/mL)
Peak Area
Mean
10.21
0.51%
19163
19163
21.35
1.07%
42408
40877
39345
40.07
2.00%
78327
80533
82738
83.00
4.15%
160186
160622
161057
119.5
5.98%
231600
229933
228265
Slope = 1925
Y-intercept = 710
R 2 = 0.9997
Determination of System Precision
[0037] A 2-DG standard solution at 1.98 mg/mL was injected six times and the peak areas (mAU•sec) determined (see Table 4). The relative standard deviation (RSD) was 0.5%.
[0000]
TABLE 4
System Precision
Peak
Sample No.
Area(mAU · sec)
Mean ± SD
RSD
1
468109
2
467918
3
468014
468228 ± 2531
0.5%
4
467427
5
465429
6
472352
Determination of System Suitability
[0038] System suitability was determined by six replicate injections of a system suitability-resolution solution. The RSD of the peak area and retention time of 2-DG were 0.8% and 0.0%, respectively. The RSD of the peak area and the retention time of glucose were 0.7% and 0.0%, respectively (see Table 5). The average resolution between 2-DG and glucose was 2.79±0.01 (n=6).
[0000]
TABLE 5
System Suitability of 2-DG and Glucose
Glucose
2-DG
2-DG
Glucose
Retention
Injection
Peak Area
Retention
Peak Area
Time
Reso-
No.
(mAU · S)
Time (min)
(mAU · S)
(min)
lution
1
458700
8.8
489136
10.6
2.78
2
453843
8.8
493462
10.6
2.78
3
458488
8.8
491759
10.6
2.80
4
454905
8.8
489158
10.6
2.79
5
458445
8.8
492504
10.6
2.80
6
451052
8.8
484803
10.6
2.79
Mean
453347
8.8
490337
10.6
2.79
SD
3821
0.0
3482
0.0
0.01
RSD
0.8%
0.0%
0.7%
0.0%
0.4%
Determination of Accuracy
[0039] A known amount of 2-DG reference standard was dissolved in placebo to yield solutions containing 2-DG at 80, 100, and 120 mg/mL. Triplicate samples were prepared for each concentration. Solutions were diluted to 2 mg/mL with water and assayed. The accuracy of this method was determined by evaluating solutions of 2-DG at concentrations of 80%, 1 00% and 120% of solutions at 100 mg/mL. Recoveries were in the range of 101.3-102.8% (see Table 6).
[0000]
TABLE 6
Accuracy (Nominal Concentration: 100 mg/mL)
% of
2-DG Concentration mg/mL
%
Nominal
Expected
Found
Recovery
Mean ± SD
80%
77.65
81.86
102.8
102.4 ± 0.8
79.07
80.24
101.5
79.47
81.72
102.8
100%
99.02
100.90
101.9
102.2 ± 0.5
98.40
101.15
102.8
99.18
101.14
102.0
120%
118.8
120.98
101.8
101.5 ± 0.3
118.1
119.76
101.4
119.5
121.02
101.3
Determination of Method Precision
[0040] Method precision was assessed by assaying two API lots on four different days in the same laboratory. The same HPLC system and column were used for all assays. The results indicate that the percent purity in both lots was very similar on four assay days, and that the method had good precision (see Table 7).
[0000]
TABLE 7
Method Precision (2-DG API)
% Purity
Assay Date
Lot 28445A
Lot 28506A
Mar. 6, 2003
98.0
98.9
Mar. 7, 2003
97.6
98.7
Mar. 13, 2003
97.9
99.4
Mar. 21, 2003
98.6
99.2
Mean =
98.0
99.1
SD =
0.4
0.3
Limit of Detection and Quantitation of Glucose
[0041] A signal-to-noise (S/N) ratio of 3:1 is generally defined as the limit of detection. The S/N ratio for an 80-μL injection of glucose sample at 10 μg/mL (or 0.5% of 2-DG at 2 mg/mL), was determined to be 6.7 ( FIG. 11 ). Therefore the limit of detection (LOD, defined as 3•S/N) was calculated to be:
10 μg/mL×(3/6.7)=4.5 μg/mL. The limit of quantitation (LOQ, defined as 10•S/N) was 15 μg/mL.
Ruggedness and Robustness
[0043] The 2-DG standard and resolution solutions at a nominal concentration of 2 mg/mL were re-assayed versus a freshly-prepared standard solution. The results showed both solutions were stable after storage at ambient room temperature for 4 days (see Table 8A. 2-DG injectate solutions from two lots were re-assayed after stored at 5° C. for 7 days. The results indicate both solutions were stable (see Table 8B.
[0000]
TABLE 8A
Robustness/Ruggedness: Stability of
Standard and Resolution Solutions
2-DG Concentration (mg/mL and % of Initial)
Initial
4 days RT
Standard Solution
2.026 mg/mL
2.035 mg/mL
(≈2 mg/mL)
(100.0%)
(100.4%)
Resolution Solution
2.158 mg/mL
2.125 mg/mL
(≈2 mg/ml)
(100.0%)
(98.5%)
[0000]
TABLE 8B
Robustness/Ruggedness: Stability of Injectate Solutions
2-DG Concentration (mg/mL and % of Initial)
Initial
7 days at 5° C.
Lot # 28445A
2.07 mg/mL
2.03 mg/mL
(100.0%)
(98.1%)
Lot # 28506A
2.02 mg/mL
1.98 mg/mL
(100.0%)
(98.0%)
[0044] The effects of variation of the NaOH concentration in the mobile phase, column temperature (25° C. and 35° C.), and flow rate (0.6, 0.8 and 1.0 mL/min), on 2-DG retention time, and the resolution between 2-DG and glucose (see Tables 9A and 9B were also determined. Variation in 2-DG retention time was observed with chromatography conditions, but in all cases, the resolution was greater than 2.0.
[0000]
TABLE 9A
Robustness/Ruggedness: Effects of Variation on the
NaOH Concentration in Mobile Phase, Column Temperature
and Flow Rate on 2-DG Retention Time
2-DG Retention Time
Mobile
Column
(min) with Flow Rate at
Phase
Temperature
0.6 mL/min
0.8 mL/min
1.0 mL/min
20 mM NaOH
35° C.
9.09
7.35
6.17
16 mM NaOH
25° C.
11.24
8.32
6.54
[0000]
TABLE 9B
Robustness/Ruggedness: Effects of Variation on the
NaOH Concentration in Mobile Phase, Column Temperature
and Flow Rate on Resolution of 2-DG and Glucose
Mobile
Column
Resolution with Flow Rate at
Phase
Temperature
0.6 mL/min
0.8 mL/min
1.0 mL/min
20 mM NaOH
35° C.
2.55
2.60
2.54
16 mM NaOH
25° C.
2.81
2.61
2.43
Example 2
[0045] This example illustrates how 2-DG purity was assessed in a mixture containing 2-DG, glucose, and tri-O-acetyl-D-glucal (glucal), in accordance with an embodiment of the method of the invention in which aqueous NaOH was the mobile phase, an RCX-10 anion exchange column was the stationary phase, an electrochemical (EC) detector was employed, and the concentration of 2-DG in the 2-DG solution analyzed was about 10 μg/mL. Acceptable separation of 2-DG and glucose was obtained with 10-50 mM NaOH being employed as the mobile phase. An increase in NaOH concentration decreased retention time for 2-DG and glucose. With 47 mM NaOH in the mobile phase, the following result was obtained (see Table 10).
[0000]
TABLE 10
2-DG
glucose
glucal
Concentration
10 μg/mL
1 μg/mL
50 μg/mL
Peak Area
17,683,388
15,033,551
Retention Time
8.6 min
10.2 min
14.8 min
Note
Good sharp peak
Good sharp peak
Slight tailing
Example 3
[0046] This example illustrates how 2-DG purity was assessed in a solution containing 2-DG, glucose, and glucal in accordance with an embodiment of the method of the invention in which aqueous NaOH was the mobile phase, an RCX-30 anion exchange column was the stationary phase and an EC detector was employed (see Table 11). The peak corresponding to glucal dissolved in 30 mM NaOH (50 μg/mL) was a sharp large peak with retention time at about 11 minutes, possibly because of a hydrolysis of the glucal to 2-DG in the alkaline solution. However, the same sample dissolved in water resulted in a poorly-shaped, small peak.
[0000]
TABLE 11
Mobile Phase
Retention Time
Retention Time
(NaOH)
Sample Dissolved in
(2-DG)
(glucose)
40 mM
water
10 min
14 min
30 mM
water
13 min
18 min
40 mM
30 mM NaOH
9-10 min
13 min
Example 4
[0047] This example illustrates how 2-DG purity was assessed in a mixture containing 2-DG and glucose in accordance with an embodiment of the method of the invention in which aqueous acid was the mobile phase, an aminex column was the ion exchange column and an EC detector was employed (see Table 12). This example further illustrates how 2-DG purity was assessed in a solution containing 2-DG and glucal in accordance with an embodiment of the method of the invention in which water was the mobile phase, an aminex column was the ion exchange column, and an EC detector was employed.
[0000]
TABLE 12
Column
Mobile Phase
Retention time
Aminex
0.009N H 2 SO 4
8.4 min (glucose)
HPX-87H
9.5 min (2-DG)
Aminex
water
13.3 min (glucal)
HPX-87N
10.2 min (2-DG)
|
2-Deoxy-2-D-glucose (2-DG) concentration and purity can be measured in a sample of crystalline or liquid by HPLC with accuracy and precision suitable for analysis of active pharmaceutical ingredient and drug product.
| 6
|
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This is a division patent application of co-pending U.S. patent application Ser. No. 10/707,469, filed Dec. 16, 2003.
BACKGROUND OF THE INVENTION
[0002] (1) Field of the Invention
[0003] The present invention generally relates to coating processes. More particularly, this invention is directed to a physical vapor deposition process and apparatus for depositing ceramic coatings containing multiple oxides and elemental carbon and/or a carbon-based gas.
[0004] (2) Description of the Related Art
[0005] Certain components of the turbine, combustor and augmentor sections of a gas turbine engine are typically protected from their harsh thermal environments by a thermal barrier coating (TBC) formed of a ceramic material. Various ceramic materials have been proposed for TBC's, the most notable of which is zirconia (ZrO 2 ) that is partially or fully stabilized by yttria (Y 2 O 3 ). Binary yttria-stabilized zirconia (YSZ) is widely used as a TBC material because of its high temperature capability, low thermal conductivity and erosion resistance in comparison to zirconia stabilized by other oxides. YSZ is also preferred as a result of the relative ease with which it can be deposited by plasma spraying, flame spraying and physical vapor deposition (PVD) techniques. TBC's employed in the highest temperature regions of gas turbine engines are often deposited by PVD, particularly electron beam physical vapor deposition (EBPVD), which yields a columnar, strain-tolerant grain structure that is able to expand and contract without causing damaging stresses that lead to spallation. Similar columnar microstructures can be produced using other atomic and molecular vapor processes, such as sputtering (e.g., high and low pressure, standard or collimated plume), ion plasma deposition, and all forms of melting and evaporation deposition processes (e.g., cathodic arc, laser melting, etc.).
[0006] In order for a TBC to remain effective throughout the planned life cycle of the component it protects, it is important that the TBC material has and maintains a low thermal conductivity. However, the thermal conductivity of YSZ is known to increase over time when subjected to the operating environment of a gas turbine engine. To reduce and stabilize the thermal conductivity of YSZ, ternary YSZ systems have been proposed. For example, commonly-assigned U.S. Pat. No. 6,586,115 to Rigney et al. discloses a TBC of YSZ alloyed to contain certain amounts of one or more alkaline-earth metal oxides (magnesia (MgO), calcis (CaO), strontia (SrO) and barium oxide (BaO)), rare-earth metal oxides (lanthana (La 2 O 3 ), ceria (CeO 2 ), neodymia (Nd 2 O 3 ), gadolinium oxide (Gd 2 O 3 ) and dysprosia (Dy 2 O 3 )), and/or such metal oxides as nickel oxide (NiO), ferric oxide (Fe 2 O 3 ), cobaltous oxide (CoO), and scandium oxide (Sc 2 O 3 ). According to Rigney et al., when present in sufficient amounts these oxides are able to significantly reduce the thermal conductivity of YSZ by increasing crystallographic defects and/or lattice strains. In commonly-assigned U.S. patent application Ser. No. 10/064,785 to Darolia et al., a TBC of YSZ is deposited to contain a third oxide, elemental carbon, and potentially carbides. The resulting TBC is characterized by lower thermal conductivity that remains more stable during the life of the TBC as a result of stable porosity that forms when the elemental carbon and carbides within the TBC oxidize to form carbon-containing gases (e.g., CO).
[0007] While the incorporation of additional oxides and carbon-containing compounds into a YSZ TBC in accordance with Rigney et al. and Darolia et al. has made possible a more stabilized TBC microstructures, it can be difficult to deposit a TBC by an evaporation process to produce a desired and uniform composition if the additional oxide has a significantly different vapor pressure (e.g., an order of magnitude) than zirconia and yttria. For example, co-evaporation of YSZ and zirconium carbide (ZrC) as a source of carbides and/or carbon is complicated by the low partial pressure of ZrC, yielding a TBC that has an unacceptable nonuniform distribution of carbides. To avoid this result, separate ingots of YSZ and ZrC may be evaporated with a single electron beam using a controlled beam jumping technique, with the dwell time on each ingot being adjusted so that the energy output achieves the energy balance required to obtain compositional control of the vapor cloud that condenses on the targeted surface to form the desired coating. Alternatively, multiple electron guns can be operated at power levels suited for the particular material being evaporated by a given gun. Yet another approach disclosed in commonly-assigned U.S. patent application Ser. No. 10/064,887 to Movchan et al. involves regulating when vapors from one or more evaporation sources are permitted to condense on the surface being coated, such that deposition only occurs while the relative amounts of vapors within the vapor cloud are at levels corresponding to the desired coating composition.
[0008] It would be desirable if a process existed that simplified the co-evaporation of materials with different vapor pressures during the deposition of TBC's and other coatings.
BRIEF SUMMARY OF THE INVENTION
[0009] The present invention provides a process and apparatus for depositing a ceramic coating, such as a thermal barrier coating (TBC) for a component intended for use in a hostile thermal environment, particular examples of which include turbine, combustor and augmentor components of a gas turbine engine. The process of this invention is particularly directed to an evaporation technique for depositing a TBC whose composition includes multiple oxide compounds and a carbon-based constituent, which as used herein includes elemental carbon, carbides, and carbon-based gases such as carbon monoxide (CO) and carbon dioxide (CO 2 ).
[0010] The invention generally entails the use of at least one evaporation source so as to provide multiple different oxide compounds and at least one carbide compound comprising carbon and an element. The evaporation source is evaporated to produce a vapor cloud that contacts and condenses on a surface to form a ceramic coating that comprises the oxide compounds, an oxide of the element of the carbide compound, and at least one of elemental carbon, a carbon-containing gas, and precipitates of the carbide compound. Such a process can be carried out with an apparatus comprising a coating chamber in which the one or more evaporation sources are present, and means for evaporating the evaporation source(s) to produce a vapor cloud that contacts and condenses on the surface to form the ceramic coating.
[0011] According to one aspect of the invention, the process is particularly suited for use when the oxide of the carbide compound element has a vapor pressure that is significantly different from the oxide compounds. If a YSZ coating is to be deposited, particularly notable examples of such oxides include ytterbia, neodymia, and lanthana, each of which has a sufficient absolute percent ion size difference relative to zirconium ions to produce significant lattice strains that promote lower thermal conductivities. As a result of their significantly different vapor pressures, it is difficult to produce a ceramic coating having a uniform and desired composition by simultaneously evaporating one or more ingots of YSZ and any one or more of these oxides. In accordance with this invention, these oxides can be codeposited with YSZ by evaporating their corresponding carbides, i.e., YbC 2 , NdC 2 , and LaC 2 , which dissociate during evaporation to form the oxide if sufficient oxygen is present within the vapor cloud to oxide the metal dissociated from the carbide. Furthermore, the process of this invention also advantageously co-deposits one or more carbon-based constituents that also evolve from evaporation of the carbide(s), promoting stable porosity within the coating.
[0012] Other objects and advantages of this invention will be better appreciated from the following detailed description.
BRIEF DESCRIPTION OF THE DRAWINGS
[0013] FIG. 1 is a schematic representation of an EBPVD apparatus using multiple evaporation sources to deposit a ceramic coating containing multiple oxide compounds, one of which has a significantly different vapor pressure than the remaining oxide compounds of the coating, in accordance with an embodiment of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0014] The present invention is generally applicable to components subjected to high temperatures, and are therefore often formed of a superalloy material. The advantages of this invention are particularly applicable to TBC's for gas turbine engine components, such as the high and low pressure turbine nozzles and blades, shrouds, combustor liners and augmentor hardware. However, the teachings of this invention are more generally applicable to processes and apparatuses for depositing a ceramic coating. To provide the required thermal protection for a particular component, TBC's are typically deposited to a thickness of about 75 to about 300 micrometers, though lesser and greater thicknesses are foreseeable. Adhesion of the TBC to a superalloy substrate is typically promoted with the use of a bond coat, preferably an aluminum-rich composition such as an overlay coating of beta-phase NiAI intermetallic or MCrAIX alloy or a diffusion aluminide coating, though it is foreseeable that other bond coat materials and types could be used. These aspects of the invention are generally well known in the art, and therefore will not be discussed in further detail.
[0015] To achieve a strain-tolerant columnar grain structure, TBC's are deposited using a physical vapor deposition technique, such as EBPVD, though other evaporation techniques are possible and within the scope of this invention. The EBPVD process requires the presence of at least one evaporation source of the coating composition desired, and an electron beam at an appropriate power level to create a vapor of the evaporation source in the presence of the surface to be coated. FIG. 1 schematically represents a portion of an EBPVD coating apparatus 10 , including a coating chamber 12 in which a component 14 is suspended for coating. A TBC 16 is represented as having been deposited on the component 14 as a result of melting and vaporizing a pair of ingots 18 and 20 that, in combination, provide the constituents of the desired coating material. The ingots 18 and 20 are depicted as being evaporated with electron beams 28 produced by a single electron beam gun 30 , though multiple guns could be used for this purpose. The intensities of the beams 28 are sufficient to produce a vapor cloud that contacts and then condenses on the component 14 to form the TBC 16 . The vapor cloud evaporates from pools 22 and 24 of molten ingot material contained within reservoirs formed by crucibles 26 that surround the upper ends of the ingots 18 and 20 .
[0016] According to a preferred aspect of the invention, the thermal-insulating material of the TBC 16 is based on binary yttria-stabilized zirconia (preferably zirconia stabilized by about 3 to about 8 weight percent yttria), and further alloyed to contain at least a third metal oxide. The invention particularly pertains to the deposition by evaporation of YSZ-based coatings in which one or more of the additional metal oxides have a vapor pressure that differs significantly from zirconia and yttria, defined herein as at least an order of magnitude higher or lower than zirconia and yttria. Though not a necessary feature of the invention, the third oxide preferably has the effect of reducing and/or stabilizing the thermal conductivity of the TBC 16 . For this purpose, and in accordance with commonly-assigned U.S. Pat. No. 6,586,115 to Rigney et al., the third oxide preferably has a sufficient absolute percent ion size difference relative to zirconium ions to produce significant lattice strains that promote lower thermal conductivities. In accordance with commonly-assigned U.S. patent application Ser. No. 10/064,785 to Darolia et al., the TBC 16 also contains entrapped carbon-containing gases (e.g., carbon monoxide (CO) and/or carbon dioxide (CO 2 )) and possibly elemental carbon and/or carbides in the form of precipitate clusters, the thermal decomposition of which yields additional carbon-containing gas. In combination, the presence of entrapped CO and/or CO 2 , elemental carbon and/or carbide clusters, and one or more of the above-specified third metal oxides are believed to reduce the density and thermal conductivity of the YSZ TBC 16 .
[0017] According to the present invention, the ingots 18 and 20 can be evaporated to simultaneously deposit YSZ (or another base material), the third oxide, and the carbon-based constituent(s) in controllable desired proportions as a result of the third oxide and the carbon-based constituent(s) evolving during evaporation from a carbide of the metallic component of the third oxide. In preferred examples, one or more oxides of ytterbium, neodymium, and lanthanum (Yb 2 O 3 , Nd 2 O 3 , and La 2 O 3 ) are co-deposited with YSZ by simultaneously evaporating the ingots 18 and 20 , one of which may be formed of YSZ while the other may be formed of one or more of YbC 2 , NdC 2 , and LaC 2 . During evaporation, the carbide dissociates and the dissociated metal oxidizes to deposit as the desired oxide on the component 14 to form the TBC 16 . In so doing, elemental carbon released as a result of dissociation of the carbide (and possibly the carbide itself) also deposits within the TBC 16 . During deposition, the third oxide preferably solutions into the YSZ to increase crystallographic defects and/or lattice strains that reduce thermal conductivity of the TBC 16 .
[0018] In accordance with Darolia, the presence of elemental carbon and/or carbide precipitates within the TBC 16 increases the porosity of the TBC 16 apparently as a result of a shadowing effect that occurs when two insoluble phases are deposited by PVD. More particularly, “primary” porosity is believed to be created surrounding deposited elemental carbon clusters (and possibly clusters of carbides, oxycarbides, etc., all of which are insoluble in YSZ) during EBPVD as a result of zirconia vapor flux being blocked from the immediate vicinity of the second phase clusters. Another benefit of co-deposition of carbon clusters (and possibly carbide clusters) by EBPVD has been observed to be the formation of many additional interfaces associated with sub-grain boundaries, possibly due to what appears to be related to the presence of carbon promoting the nucleation of new sub-grains and inhibiting diffusion processes of grain growth. The result is a continuous nucleation of new grains, which produces a fine sub-grained TBC structure with numerous interfaces that reduce thermal conductivity through the TBC grains. Open porosity levels observed within TBC deposited in accordance with this invention are well in excess of TBC deposited under identical conditions from only a YSZ source.
[0019] Fine “secondary” porosity occurs as a result of elemental carbon (and possibly carbides) precipitates within the TBC 16 reacting with oxygen to form carbon monoxide and/or another carbon-containing gas (e.g., carbon dioxide) during high temperature excursions (e.g., above about 950° C.). As a result of the primary porosity surrounding the deposited carbon, there is sufficient pore volume for carbon-containing gases to evolve and produce very fine pores (“micropores”) within the TBC 16 . As these gases form and some of the original primary porosity is lost as a result of shrinkage of smaller pores and growth of larger pores at the expense of smaller pores (pore coarsening and redistribution) during sintering, some of the gases are entrapped within the micropores. The entrapped gases are believed to counteract surface tension energies that are the driving force for the shrinkage of small pores during sintering. Therefore, in addition to reducing the density and thermal conductivity of the TBC 16 , the added fine porosity is thermally stable, i.e., less susceptible to shrinkage.
[0020] While not wishing to be held to any particular theory, the above-noted carbides are believed to provide a source of carbon within the slightly oxidizing atmosphere maintained within the EBPVD chamber 12 as a result of a controlled amount of oxygen being introduced into the chamber 12 above that necessary to ensure the deposition of ZrO 2 . Using the neodymium-based carbide (NdC 2 ) as an example, the coating reaction is believed to be:
[0000] [ZrO 2 +Y 2 O 3 ] matrix +2NdC 2 +7O→[ZrO 2 +Y 2 O 3 ] matrix +Nd 2 O 3 +4CO
[0021] In this reaction, carbon monoxide is indicated as evolving during dissociation of neodymium carbide (NdC 2 ), so as to be co-deposited with YSZ and neodymia (Nd 2 O 3 ). In addition or alternatively, clusters of elemental carbon and/or neodymium carbide may be co-deposited with YSZ, such that primary porosity forms around these clusters as a result of the shadowing effect during the EBPVD process. During subsequent heating, gaseous carbon monoxide then forms in situ as a result of oxidation of the carbon and/or neodymium carbide, resulting in new secondary porosity within the TBC 16 and its grains, as well as carbon monoxide (and/or carbon dioxide or another carbon-containing gas) entrapped within micropores that are remnants of the original primary porosity. Oxycarbides are also potential byproducts of the above reaction, and may serve to stabilize the micropore structure of the TBC 16 by anchoring and pinning the grain boundaries and pores of the TBC 16 .
[0022] If a significant amount of carbon monoxide forms as a result of oxidation of carbide precipitates within the TBC 16 , the carbides of the Group III metals of the Periodic Table can be more beneficial as compared to other carbides, such as ZrC, as these carbides tend to be relatively less stable. The basis for this belief is that carbide stability correlates with melting point, ZrC has a melting point of about 3427° C., while the melting points of the Group III carbides are believed to be in the range of about 2215° C. to about 2500° C. During the transformation of the carbide into the third oxide, a volume change is likely to occur that may lead to the formation of additional porosity during aging of the TBC 16 . For obtaining this benefit, the carbides of lanthanum, tantalum and neodymium are believed to be preferred as a result of their oxides being about 50 volume percent smaller than their carbides.
[0023] Additional benefits are possible with the present invention by co-evaporating carbides having vapor pressures and evaporation rates similar to zirconia, such that the evaporation process can be more readily controlled to yield a desired composition. For example, ZrC has a vapor pressure of one order of magnitude lower than ZrO 2 in the temperature range of 2500° C. to 3000° C., which appears to correlate with their different melting points (about 2701° C. for ZrO 2 and about 3427° C. for ZrC). As noted above, the melting points of carbides of the Group III metals are comparable to that of zirconia, such that the vapor pressures of these carbides are closer to zirconia than ZrC (i.e., less than one order of magnitude), making co-evaporation of zirconia and one or more of these carbides easier than co-evaporation of zirconia and ZrC. Such circumstances permit the carbide and zirconia (along with yttria) to be contained within a single ingot, so that multiple ingots are not required to deposit the TBC 16 .
[0024] While the invention has been described in terms of a preferred embodiment, it is apparent that other forms could be adopted by one skilled in the art. For example, instead of depositing the TBC by EBPVD, other vapor deposition processes could be used. Accordingly, the scope of the invention is to be limited only by the following claims.
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A process and apparatus for depositing a ceramic coating, such as a thermal barrier coating (TBC) for a gas turbine engine component. The process deposits a coating whose composition includes multiple oxide compounds and a carbon-based constituent, e.g., elemental carbon, carbides, and carbon-based gases. The process uses at least one evaporation source to provide multiple different oxide compounds and at least one carbide compound comprising carbon and an element. The evaporation source is evaporated to produce a vapor cloud that contacts and condenses on the component surface to form the ceramic coating, and particularly so that the coating comprises the oxide compounds, an oxide of the element of the carbide compound, and the carbide compound and/or a carbon-containing gas. The process is carried out with an apparatus comprising a coating chamber in which the evaporation source is present, and a device for evaporating the evaporation source.
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CROSS-REFERENCE TO RELATED APPLICATIONS
This application claims the benefit of U.S. Provisional Ser. No. 60/846,429, filed Sep. 22, 2006, which is incorporated by reference herein.
GOVERNMENT FUNDING
The present invention was funded under U.S. Army TARDEC Contract No. DAAE07-00-C-L075. The U.S. government may have certain rights to this invention.
BACKGROUND
This invention relates generally to composites and more particularly to a composite structure having a specific fiber or shape configuration.
It is known to employ prepreg composites with stacked material layers. Each layer typically has resin and fibers, with the fibers being oriented at 45°/0°/−45°/90°, 30°/90°/0°/90° or 30°/60°/90°/0° for relative adjacent layers. For example, traditional constructions are disclosed in Ambur et al., “Effect of Curvature on the Impact Damage Characteristics and Residual Strength of Composite Plates,” American Institute of Aeronautics and Astronautics, AIAA 98-1881 (Apr. 20-23, 1998); Z. Cui et al., “Buckling and Large Deformation Behaviour of Composite Domes Compressed Between Rigid Platens,” Composite Structures 66 (2004), pp. 591-599 (Elsevier); and S. Spottswood et al., “Progressive Failure Analysis of a Composite Shell,” Composite Structures 53 (2001), pp. 117-131 (Elsevier). Such conventional fiber patterns, however, are prone to severe delamination, cracking and fiber breakage upon projectile impact.
SUMMARY
In accordance with the present invention, a composite structure is provided. In another aspect of the present invention, a composite structure has relative layer-to-layer fiber orientations of between approximately 5° and 15°, inclusive. A further aspect of the present invention employs relative fiber offset angles less than 30° on a curved section. Yet another aspect of the present invention provides a three-dimensionally woven configuration where the first sheet is interwoven or mechanically linked with both the adjacent second layer and the opposite third or deeper layer. A method of making a composite structure is also provided.
The composite structure of the present invention is advantageous over traditional constructions in that the present invention allows for fiber bridging spanning the curved shape, generally without significant delamination, upon projectile impact. This allows for up to 90% energy absorption of the impact without significant structural composite failure. The present invention is thereby ideally suited for use in armor plating without the conventional weight of metallic materials and with the ease of forming curved yet thin shapes. Additional advantages and features of the present invention will become apparent from the following description, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view showing the composite structure of the present invention employed on an airplane;
FIG. 2 is a side elevational view showing the composite structure of the present invention employed on a military tank;
FIG. 3 is a cross-sectional view, taken along line 3 - 3 of FIG. 1 , showing a first preferred embodiment of the composite structure;
FIG. 4 is a fragmentary and perspective view, taken from FIG. 2 , showing a second preferred embodiment of the composite structure;
FIG. 5 is a cross-sectional view, taken along lines 5 - 5 of FIG. 4 , showing the second preferred embodiment composite structure;
FIG. 6 is a perspective view showing a third preferred embodiment of the composite structure;
FIG. 7 is an exploded and diagrammatic, perspective view showing the preferred embodiments of the composite structure prior to shaping;
FIG. 8 is a diagrammatic side view showing the preferred embodiments of the composite structure prior to shaping;
FIG. 9 is an exaggerated and diagrammatic top view showing the preferred embodiments of the composite structure, employing a two-dimensional fabric weave, prior to shaping;
FIG. 10 is a diagrammatic side view showing a weaving pattern of the preferred embodiments of the composite structure, employing a two-dimensional fabric weave, prior to shaping;
FIG. 11 is a perspective view showing the second preferred embodiment composite structure after a projectile impact;
FIG. 12 is a fragmentary perspective view showing a first alternate embodiment of the composite structure;
FIG. 13 is a fragmentary perspective view showing a second alternate embodiment of the composite structure;
FIG. 14 is a fragmentary perspective view showing a third alternate embodiment of the composite structure;
FIG. 15 is a perspective view showing a fourth alternate embodiment of the composite structure;
FIG. 16 is a cross-sectional view, taken along line 16 - 16 of FIG. 15 , showing the fourth alternate embodiment composite structure;
FIG. 17 is a diagrammatic perspective view showing a first alternate embodiment of a weaving pattern employed with the composite structure; and
FIG. 18 is a diagrammatic perspective view showing a second alternate embodiment of a weaving pattern employed with the composite structure.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
A first preferred embodiment topologically controlled composite structure 21 of the present invention is shown in FIGS. 1 and 3 . Composite structure 21 includes multiple curved composite layers 23 , outer skin composite layers 25 and inner skin composite layers 27 , all permanently joined together. Curved composite layers 23 have a repeating corrugated shape. Skin layers 25 and 27 span between and bridge the corrugations such that the skins only contact tangents, in other words the peaks and valleys, of curved composite layers 23 . Outer skin layers 25 act as an aerodynamic surface on an aerospace craft or vehicle such as a leading edge of an airplane wing 29 , the underside of a helicopter, or an outer shield for a satellite; alternately outer skin layers 25 can be used as an outer surface of a ship hull, other marine vehicle, or the like.
A second preferred embodiment composite structure 41 is employed as armor on a land vehicle such as a military tank 43 , personnel carrier or automobile. This is shown in FIGS. 2 , 4 and 5 . Each composite structure 41 has a curved middle segment 45 bordered by flanges 47 which are attached to an underlying skin 49 . Skin 49 can be made from a composite, steel or other material. Middle segment 45 has a generally semi-cylindrically curved shape. Referring to FIG. 5 , exemplary dimensions for composite structure 41 are as follows: d 1 is approximately 3.0 inches, d 2 is approximately 1.0 inches and d 3 is approximately 0.3-0.8 inches. It should be appreciated, however, that these dimensions may vary depending upon the actual aerospace, land vehicle or watercraft application.
A third preferred embodiment composite structure 61 of the present invention can be observed in FIG. 6 . A curved segment 63 has a generally semi-spherical curved shape or dome shape projecting from a generally planar base segment 65 . It should be appreciated that inner and outer skins such as those shown in FIG. 3 may also be employed with any of these preferred embodiments disclosed herein depending upon whether aerodynamic or aesthetic covering of the curved shape is desired.
All of the presently disclosed preferred embodiment composite structures are made by: (1) stacking and overlapping sheets or layers made of fibers and resin as shown in FIGS. 7 and 8 ; or (2) a “two-dimensional” weave between two adjacent fiber bundles, with each woven layer or ply then being stacked upon each other in an overlapping manner with resin applied before or after the weaving to join the fabric layers, such as is shown in FIG. 10 . With either approach, the adjacent layer-to-layer fiber orientation is approximately 0° and the immediately adjacent fiber orientation is between 5° and 29°, inclusive, and more preferably about 0° and between 5°-15°, inclusive. It should be appreciated that the desired fiber orientation is the primary or average fiber orientation as the fibers may not be perfectly straight and may have a slight tolerance variation during manufacturing. Furthermore, the 0° orientation is simply a base reference angle from which the adjacent layer orientation is measured. This fiber orientation is shown in an exaggerated fashion in FIGS. 7 and 9 wherein a first layer 81 has a reference orientation of 0° and the immediately adjacent layer 83 has a relative reference fiber orientation of 5°. Similarly, in the woven scenario of FIG. 10 , a warp fiber 85 has a reference orientation of 0° while a woven and interlinking weft fiber 87 has a reference orientation of about 5°.
FIG. 11 illustrates composite structure 41 after the curved segment is impacted by a bullet-type projectile P. In this scenario, the fibers tear out of the resin matrix and bridge across the back, concave side of the curved segment without significant layer-to-layer delamination. Improved results are expected for larger radii or a greater curved height dimension d 3 . The combination of small fiber angle offsets between immediately adjacent layers and the curved shape provides significant energy absorption without complete composite structure failure.
The laminated version of the present invention can be made from a prepreg tape or fabric, or a fiber preform. Glass fibers, fabrics and braided preforms are preferred for land vehicles and marine structures due to their high specific strength properties. Polymeric fibers, fabrics and braided preforms, such as Kevlar® aramid, Spectra® polyethylene or Dyneema® polyethylene, are preferred for military applications due to their high specific energy absorption characteristics. Furthermore, carbon fibers, fabrics and braided preforms are preferred for aerospace vehicles due to their high specific stiffness properties. Toughened epoxy resins are desirable in the specific curing temperatures is dependent on the type of epoxy resin used. For example, if manufacturing convenience is of primary concern, then a low temperature and low viscosity epoxy resin should be employed. If the structure is to be used in high temperature environments, however, a high temperature epoxy would be desirable.
The following preferred manufacturing steps are employed with the laminated versions of the preferred embodiment composite structures. First, the fiber preform is prepared by selecting laminated fabrics or sheets with small relative offset angles between adjacent layers or two-dimensional fabrics with small angle differences between warp and weft yarns, or three-dimensional fabrics with small angular differences between linked layers. Second, a clean mold with the designated curved geometry is made. Third, the mold is waxed, and fourth, a sealant tape is applied around a perimeter of the mold. Fifth, the operator cuts a peel ply and places it on the mold surface. Sixth, the operator places the fiber preform over the peel ply and marks its outline on the peel ply before removing it from the mold. Seventh, the user prepares the epoxy matrix by mixing a hardener and the resin into the designated ratio. Furthermore, eighth, the user applies the mixed epoxy to the peel ply on the marked area for the fiber preform. Ninth, the user places the fiber preform on the epoxy and tenth, adds a second layer of peel ply over the fiber preform. Eleventh, the user adds a bleeder/breather fabric on the top of the second peel ply. Twelfth, a vacuum bag is applied to the sealant tape on the mold and thirteenth, a vacuum gauge is inserted at one end of the mold. Fourteenth, the user sets up the vacuum pump and piping, and fifteenth, turns on the pump to impregnate the fiber preform with the epoxy matrix and cures the epoxy. Sixteenth, the composite structure is trimmed and seventeenth, the user inspects the composite structure for design compliance. Eighteenth, the composite component is applied to a secondary assembly with adhesive bonding and nineteenth, the operator conducts a final assembly inspection. Finally, the composite structure assembly is packaged and shipped.
FIG. 12 illustrates an alternate embodiment composite structure 91 . In this embodiment, a corrugated curved shape segment 93 , including multiple joined fiber and resin sheets, is attached between outer composite skin layers 95 and middle composite skin layers 97 . Additionally, a second corrugated curved composite segment 99 , having peaks and valleys offset from the first corrugated segment 93 , is affixed between middle skin layers 97 and inner composite skin layers 101 . The skin layers bridge and span between the peaks and valleys of each corrugation segment, essentially only contacting the corrugated segments at the tangents of their respective curves.
FIG. 13 discloses a series of elongated, tube-like curved composite segments 111 affixed between spanning composite outer and inner skins 113 and 115 , respectively. Tubular segments 111 each have a generally cylindrical shape. Each of the composite segments and skins includes multiple sheets of fiber and resin layers. The tubular segments 111 only contact each other along outer tangents and only contact the bridging skins at their corresponding tangents thereby leaving somewhat triangular gaps defined by adjacent pairs of tubular segments 111 and the adjacent skin 113 or 115 . The inside of each tubular segment 111 is also open or hollow. The tubular segments 111 are further generally parallel to each other. Referring to FIG. 14 , another alternate composite structure 121 is similar to that shown in FIG. 13 , however, a smaller elongated and tubular curved segment 123 is located in each of the gaps between the much larger diameter tubular segments 111 ′ and the adjacent skins 113 ′ or 115 ′. The smaller diameter tubular segments 123 are also of a multi-layer fiber and resin composite structure. This exemplary embodiment creates a hollow and multi-cellular curved configuration.
Moreover, referring to FIGS. 15 and 16 , another alternate embodiment composite structure 131 has a central curved segment 133 and a pair of outboard flanges 135 . Three or more fiber and resin layers 137 , 139 and 141 are joined together in an overlapping and contacting manner at flanges 135 , however, these layers are spaced away from each other and have air gaps 143 and 145 therebetween at the curved segment 133 . It should also be appreciated that each layer 137 , 139 and 141 may include multiple laminated or woven sheets therein.
FIGS. 17 and 18 illustrate alternate embodiments of “three-dimensionally” woven composite structures 161 and 171 . With the embodiment of FIG. 17 , a first warp fiber 163 is woven around first and second weft fibers 165 and 167 in a repeating manner. Thus, a first ply is woven with a third ply, a third ply is woven with a fifth ply, a fifth ply is woven with a seventh ply, a seventh ply is woven with a ninth ply, a ninth ply is woven with an eleventh ply, and the eleventh ply is woven with a twelfth ply. With the embodiment of FIG. 18 , a first ply is woven with a second ply, a second ply is woven with a fourth ply, a fourth ply is woven with a sixth ply, a sixth ply is woven with an eighth ply, an eighth ply is woven with a tenth ply and a tenth ply is woven with a twelfth ply. Accordingly, there is no need for a separate transverse stitch to sew together multiple ply layers as the present invention integrally links multiple depth plies together during the initial weaving process. These composite structures 161 and 171 also contain an epoxy or other polymeric resin. These three-dimensionally woven composite structures 161 and 171 are preferably employed with small angular offsets between adjacent ply layers and within a curved segment after shaping and curing, however, they do not necessarily need to have small fiber angle offsets and curved final shapes if they are employed in other non-impact final use applications.
While various aspects of the present invention have been disclosed, it should be appreciated that other variations may fall within the scope of the present invention. For example, a single very large dome-shaped composite structure can be employed on the side of an armored land vehicle with multiple underlying smaller dome, corrugated or tubular curved composite structures thereunder. It should also be appreciated that various numbers of composite layers have been shown by way of example, but a greater or lesser number of composite layers may actually be employed depending upon the end use applications and specific materials chosen. It is intended by the following claims to cover these and any other departures from the disclosed embodiment which falls within the true spirit of this invention.
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A composite structure is provided. In another aspect of the present invention, a composite structure has relative layer-to-layer fiber orientations of between approximately 5° and 15°, inclusive. A further aspect of the present invention employs relative fiber offset angles less than 30° on a curved section. Yet another aspect of the present invention provides a three-dimensionally woven configuration where the first sheet is interwoven or mechanically linked with both the adjacent second layer and the opposite third or deeper layer.
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FIELD OF THE INVENTION
[0001] The invention relates to the general field of magnetic disk storage with particular reference to read heads and specifically to longitudinal bias stabilization thereof.
BACKGROUND OF THE INVENTION
[0002] The principle governing the operation of most current magnetic read heads is the change of resistivity of certain materials in the presence of a magnetic field (magneto-resistance or MR). Magneto-resistance can be significantly increased by means of a structure known as a spin valve or SV. The resulting increase (known as Giant Magneto-Resistance or GMR) derives from the fact that electrons in a magnetized solid are subject to significantly less scattering by the lattice when their own magnetization vectors (due to spin) are parallel (as opposed to anti-parallel) to the direction of magnetization of their environment.
[0003] The key elements of a spin valve are a low coercivity (free) ferromagnetic layer, a non-magnetic spacer layer, and a high coercivity ferromagnetic layer. The latter is usually formed out of a soft ferromagnetic layer that is pinned magnetically by a nearby layer of antiferromagnetic material. Alternatively, a synthetic antiferromagnet (formed by sandwiching an antiferromagnetic coupling layer between two antiparallel ferromagnetic layers) may be used to replace the ferromagnetic pinned layer.
[0004] When the free layer is exposed to an external magnetic field, the direction of its magnetization is free to rotate according to the direction of the external field. After the external field is removed, the magnetization of the free layer will stay at a direction, dictated by the minimum energy state, which is determined by the crystalline and shape anisotropy, current field, coupling field and demagnetization field. If the direction of the pinned field is parallel to the free layer, electrons passing between the free and pinned layers, suffer less scattering. Thus, the resistance in this state is lower. If, however, the magnetization of the pinned layer is anti-parallel to that of the free layer, electrons moving from one layer into the other will suffer more scattering so the resistance of the structure will increase. The change in resistance of a spin valve is typically 8-20%.
[0005] First generation GMR devices were designed so as to measure the resistance of the free layer for current flowing in the, plane (CIP) of the film. However, as the quest for ever greater densities continues, devices that measure current flowing perpendicular to the plane (CPP) have begun to emerge. For devices depending on in-plane current, the signal strength is diluted by parallel currents flowing through the other layers of the GMR stack, so these layers should have resistivities as high as possible while the resistance of the leads into and out of the device need not be particularly low. By contrast, in a CPP device, the resistivity of both the leads and the other GMR stack layers dominate and should be as low as possible.
[0006] A device that is particularly well suited to the CPP design is the magnetic tunneling junction (MTJ) in which the layer that separates the free and pinned layers is a non-magnetic insulator, such as alumina or silica. Its thickness needs to be such that it will transmit a significant tunneling current. The principle governing the operation of the MTJ is the change of resistivity of the tunnel junction between two ferromagnetic layers. When the magnetization of the two ferromagnetic layers is in opposite directions, the tunneling resistance increases due to a reduction in the tunneling probability. The change of resistance is typically about 40%. The device is also referred to as a TMR (tunnel magneto-resistance) device
[0007] Although the layers enumerated above are all that is needed to produce the GMR or TMR effects, additional problems remain. In particular, there are certain noise effects associated with these structures. Magnetization in a layer can be irregular because of reversible breaking of magnetic domain walls, leading to the phenomenon of Barkhausen noise. The solution to this problem has been to provide a device structure conducive to ensuring that the free layer is a single domain so that the domain configuration remains unperturbed after fabrication and under normal operation.
[0008] A typical prior art arrangement for longitudinal biasing is illustrated in schematic cross-section in FIG. 1. Seen there are seed layer 17 , pinning layer 16 , pinned layer 15 , free layer 13 , non-magnetic layer 14 , and capping layer 18 . If layer 14 is conductive, the device is a GMR unit while if it is a dielectric, the device is a TMR unit. Two opposing permanent magnets (PM) 11 a and 11 b, magnetized in the direction shown by arrows 12 , are located at the sides of the device.
[0009] As track widths grow very small (<0.2 microns), the above biasing configuration has been found to no longer be suitable since the strong magnetostatic coupling at the track edges also pins the magnetization of the free layer (symbolically illustrated by arrows 19 a, 19 b, and 19 c ) which drastically reduces the GMR or TMR sensor sensitivity. Even for read track widths as high as 0.1-0.2 um, the bias field strength is significant at the track center where it interferes with the free-layer magnetization change. Additionally, this reduced sensitivity at the track center leads to a poor track profile shape at the output. This in turn leads to side reading so the magnetic read width (MRW) becomes too wide.
[0010] The present invention provides a solution to this problem.
[0011] A routine search of the prior art was performed with the following references of interest being found:
[0012] Kanbe et al. in U.S. Pat. No. 6,383,574 and Knapp et al. in U.S. Pat. No. 6,417,999, describe a bias layer in addition to the permanent magnetic layer while U.S. Pat. Nos. 5,745,978 and 5,713,122 (Aboaf et al.) disclose a soft film biased sensor layer and hard bias stabilizing magnets. Additionally, U.S. Pat. Nos. 5,508,866 and 5,492,720 (Gill et al.) show transverse and longitudinal bias layers.
SUMMARY OF THE INVENTION
[0013] It has been an object of at least one embodiment of the present invention to provide a magnetic read head device whose output is both stable as well as unaffected by the steps taken to achieve said stability.
[0014] Another object of at least one embodiment of the present invention has been that said device be a CIP GMR device, a CPP GMR device, or a TMR device.
[0015] Still another object of at least one embodiment of the present invention has been to provide a process for manufacturing said devices.
[0016] These objects have been achieved by adding to existing designs of GMR and TMR devices an additional, compensatory, bias layer. This layer, which may be located either above or below the free layer, is permanently magnetized in the same direction as the permanent magnets (or antiferromagnetically pinned soft magnets) used to achieve longitudinal stability. Through control of the magnetization strength and location of the compensatory bias layer, cancellation of the field induced in the free layer by the main bias layers is achieved. This field cancellation is due to the presence of a return flux associated with the compensatory bias layer. The return field that the compensatory bias layer provides may also be produced by the exchange field of an antiferromagnetic layer that is stacked on top of the free layer, and coupled to it either directly or indirectly, the coupled direction being opposite to that produced by the permanent magnets.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] [0017]FIG. 1 shows how, as taught by the prior art, longitudinal stabilization is achieved by means of a pair of permanent magnet layers that flank the device in question.
[0018] [0018]FIGS. 2 a, 2 b, and 2 c show how signal loss from the free layer of a device stabilized as shown in FIG. 1 can be eliminated.
[0019] [0019]FIG. 3 shows three field strength plots vs. off-track position for a compensatory bias field, a prior art bias field, and a combination of the first two fields.
[0020] [0020]FIGS. 4-9 show process steps for manufacturing a CIP GMR device that incorporates the teachings of the present invention.
[0021] [0021]FIGS. 10-15 show process steps for manufacturing a CPP GMR device or a TMR device that incorporates the teachings of the present invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0022] The basic principle of the present invention is schematically illustrated in FIG. 2 a. As can be seen, the structure shown in FIG. 1 has been modified by the addition of compensatory bias layer 21 located on seed layer 25 ; it has been magnetized in direction 22 and has been placed near the GMR or TMR sensor. As illustrated in FIG. 2 a, it is most conveniently located below the sensor unit.
[0023] The compensatory bias layer could, instead, be located a similar distance above the sensor unit, should this be preferred. This is shown in FIG. 2 b where the compensatory bias layer has been given the designation 121 .
[0024] A third possibility is illustrated in FIG. 2 c. Here, the return field that the compensatory bias layer provides is produced by the exchange field of an antiferromagnetic layer 26 , such as IrMn, that is stacked on top of the free layer, and coupled to it either directly or indirectly, the coupled direction being opposite to that produced by the permanent magnets.
[0025] Returning now to FIG. 2 a, since bias compensatory layer 21 has been given magnetization 22 , there is a return flux 23 whose direction is the opposite to that of 12 (the PM magnetization). The result is the cancellation of the PM field, particularly at the center of the free layer. This is illustrated in FIG. 3 which shows the longitudinal bias field distribution for a free layer with a 0.1 μm track width. Curve 31 is for the original PM field. Although it is greatest at the track edge, there still remains a field of over 100 Oe even in the track center. Curve 32 is the field due to return flux 23 while curve 33 is the result of combining curves 31 and 32 . As can be seen, the field is almost zero out to the track edge but rises steeply thereafter so the stabilizing effect of the PM is not diminished, making this an ideal bias distribution since it provides a large output, a stable reading operation and a narrow magnetic track width
[0026] For any particular device, fine tuning of the bias field distribution is readily achieved through adjustment of one or more of the following:
[0027] 1. Compensatory bias layer thickness (typically between about 0.005 and 0.02 microns).
[0028] 2. Compensatory bias layer magnetization (typically between about 600 and 1,600 emu/cc).
[0029] 3. Compensatory bias layer width (typically between about 0.6 and 1.3 times that of the free layer).
[0030] 4. Distance between the compensatory bias layer and the free layer (typically between about 0.005 and 0.04 microns).
[0031] We now describe processes for the manufacture of three embodiments of the present invention. Since the detailed layer structure needed to produce the GMR or TMR effects are not part of the invention, we will refer in each case simply to GMR or TMR stacks instead of listing the full set of layers. The description of these processes will also serve to disclose the structure of the present invention.
1 st Embodiment
[0032] Referring now to FIG. 4, the process of the first embodiment begins with the provision of lower magnetic shield 41 and depositing thereon dielectric layer 42 .
[0033] Now follows a key feature of the invention, namely the deposition onto dielectric layer 42 of compensatory bias layer 43 . Dielectric layer 44 is now deposited onto compensatory bias layer 43 followed by the deposition onto layer 43 of GMR stack 45 whose top layer is a conductive non-magnetic layer (not shown), this being followed by the deposition of free layer 46 and capping layer 47 .
[0034] Referring next to FIG. 5, photoresist mask 51 is now formed on capping layer 47 in order to define the width of the read head. Then, as shown in FIG. 6, a pedestal, consisting of layers 43 through 47 , is formed by means of ion beam etching (IBE). This pedestal rests on sloping dielectric base 62 (originally layer 42 prior to being reshaped).
[0035] Moving on to FIG. 7, with mask 51 , still in place, dielectric layer 71 is deposited onto layer 62 so that it abuts the vertical sidewalls of the afore-mentioned pedestal. This is followed by the deposition of seed layer 80 over which is deposited permanent magnet layer 81 . As can be seen in FIG. 8, the thickness of layer 81 (typically between about 0.01 and 0.03 microns) is such that its top surface is almost flush with free layer 46 (actually, slightly below it). Also shown in FIG. 8 is in-plane conductive lead layer 82 that precisely abuts the edges of free layer 46 . Following deposition of 82 , photoresist 51 is lifted off.
[0036] Then, as shown in FIG. 9, the process of the first embodiment concludes with the deposition of dielectric layer 91 onto which is deposited upper magnetic shield 92 , thereby forming a CIP GMR device. At this point, permanent magnets 81 and compensatory bias layer 43 are magnetized in the same longitudinal direction.
2 nd Embodiment
[0037] Referring now to FIG. 10, the process of the second embodiment begins with the provision of lower magnetic shield 41 and depositing thereon lower conducting lead layer 101 .
[0038] Now follows a key feature of the invention, namely the deposition onto conducting lead layer 101 of compensatory bias layer 43 . Next is the deposition onto layer 43 , of GMR stack 45 whose top layer is a conductive non-magnetic layer (not shown), this being followed by the deposition of free layer 46 and capping layer 47 .
[0039] Referring next to FIG. 11, photoresist mask 111 is now formed on capping layer 47 in order to define the width of the read head. Then, as shown in FIG. 12, a pedestal, consisting of layers 43 through 47 , as well as 102 , is formed by means of IBE. This pedestal rests on sloping dielectric base 122 (originally layer 101 prior to being reshaped).
[0040] Moving on to FIG. 13, with mask 111 , still in place, dielectric layer 131 is deposited onto layer 41 , as well as the sloping sidewalls of layer 122 , so that it abuts the vertical sidewalls of the afore-mentioned pedestal. This is followed by the deposition of permanent magnet layer 132 and then additional dielectric layer 133 . As can be seen in FIG. 13, the thickness of layer 131 (typically between about 0.007 and 0.025 microns) is such that its top surface is flush with upper conducting lead layer 102 .
[0041] As seen in FIG. 14, photoresist mask 111 is now fully removed (along with any material that had been deposited thereon). As shown in FIG. 15, the process of the second embodiment concludes with the deposition of upper magnetic shield 152 on all exposed surfaces.
3 rd Embodiment
[0042] This embodiment is identical to the process described above for the second embodiment with the important difference that element 45 in FIGS. 10-15 now represents a TMR, as opposed to a GMR, stack. Consequently, the topmost layer of the stack (see layer 14 in FIG. 1, for example) is now a dielectric (whose thickness is low enough to allow tunneling) rather than a conductor.
[0043] We conclude by noting that the magnetic properties of thin films are known to be very sensitive to a number of factors in addition to their composition. Said factors include, but may not be limited to, thickness, deposition conditions, annealing treatments (particularly in the presence of a magnetic field), immediate underlayer, and immediate over-coating. Thus, as a general rule, the parameters that characterize the layers named in the claims to be recited below should be regarded as critical rather than merely optimal.
[0044] While the invention has been particularly shown and described with reference to the preferred embodiments described above, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit and scope of the invention.
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It is necessary to stabilize the free layer of GMR or TMR devices by providing a longitudinal bias field. As read tracks become very narrow, this field can drastically reduce the strength of the output signal. This problem has been overcome by adding an additional, compensatory, bias layer. This layer is permanently magnetized in the same direction as the main bias magnet. Through control of the magnetization strength and location of the compensatory bias layer, cancellation of the field induced in the free layer, by the main bias layers, is achieved. A process for manufacturing the devices is also described.
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CROSS REFERENCE TO RELATED APPLICATION
The present application is a continuation of U.S. application Ser. No. 11/281,457, filed on Nov. 18, 2005, now issued U.S. Pat. No. 7,093,929, which is a continuation of U.S. application Ser. No. 11/048,823 filed on Feb. 3, 2005, now issued as U.S. Pat. No. 6,986,563, which is a continuation of U.S. application Ser. No. 10/893,375 filed on Jul. 19, 2004, now issued as U.S. Pat. No. 6,955,424 which is a Continuation of U.S. application Ser. No. 10/102,699 filed on Mar. 22, 2002, now issued as U.S. Pat. No. 6,767,076, the entire contents of which are herein incorporated by reference.
FIELD OF THE INVENTION
This invention relates to a printhead assembly. More particularly, this invention relates to a printhead assembly with ink chamber defining structures.
CO-PENDING APPLICATIONS
Various methods, systems and apparatus relating to the present invention are disclosed in the following co-pending applications filed by the applicant or assignee of the present invention:
U.S. Pat. Nos. 6,428,133, 6,526,658, 6,795,215, application No. 09/575,109.
The disclosures of these co-pending applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The overall design of a printer in which capping can be utilized revolves around the use of replaceable printhead modules in an array approximately 8½ inches (21 cm) long. An advantage of such a system is the ability to easily remove and replace any defective modules in a printhead array. This would eliminate having to scrap an entire printhead if only one chip is defective.
A printhead module in such a printer can be comprised of a “Memjet” chip, being a chip having mounted thereon a vast number of thermo-actuators in micro-mechanics and micro-electromechanical systems (MEMS). Such actuators might be those as disclosed in U.S. Pat. No. 6,044,646 to the present applicant, however, might be other MEMS print chips.
In a typical embodiment, eleven “Memjet” tiles can butt together in a metal channel to form a complete 8½-inch printhead assembly.
The printhead, being the environment within which the capping device of the present invention is to be situated, might typically have six ink chambers and be capable of printing four color process (CMYK) as well as infra-red ink and fixative. An air pump would supply filtered air through a seventh chamber to the printhead, which could be used to keep foreign particles away from its ink nozzles.
Each printhead module receives ink via an elastomeric extrusion that transfers the ink. Typically, the printhead assembly is suitable for printing A4 paper without the need for scanning movement of the printhead across the paper width.
The printheads themselves are modular, so printhead arrays can be configured to form printheads of arbitrary width.
Additionally, a second printhead assembly can be mounted on the opposite side of a paper feed path to enable double-sided high-speed printing.
OBJECTS OF THE INVENTION
It is an object of the present invention to provide a printhead assembly-capping device.
Another object of the present invention is to provide a printhead assembly including a capping device providing an air flow path during operation of the printer and serving to prevent ingress of foreign particles to printhead nozzles during non-operational period of the printer.
SUMMARY OF THE INVENTION
According to a first aspect of the invention, there is provided a printhead assembly for an ink jet printer, the printhead assembly comprising
an elongate ink supply structure that defines at least one longitudinally extending ink passage and at least one set of holes in fluid communication with the at least one ink passage;
a first ink chamber defining structure that defines at least one ink chamber formation on one side and at least one set of ink inlet openings on an opposite side in fluid communication with the at least one ink chamber formation, the first ink chamber structure being engageable with the ink supply structure so that each ink inlet opening is in fluid communication with a respective hole of the ink supply structure;
a second ink chamber defining structure that defines at least one ink chamber formation on one side and at least one set of exit holes on an opposite side in fluid communication with the at least one ink chamber, the first and second ink chamber structures being engaged with each other so that respective ink chamber formations define at least one ink chamber; and
at least one elongate printhead chip, having a plurality of ink inlets, that is mounted on the second ink chamber defining structure so that each ink inlet is in fluid communication with a respective exit hole of the second ink chamber structure.
The printhead assembly may include a film layer that is interposed between the first and second ink chamber defining structures. The film layer may define a number of openings for the passage of ink through the film layer. The film layer may be of a substantially inert polymer.
The first and second ink chamber defining structures may be micro-moldings.
The second ink chamber defining structure may be of a liquid crystal polymer blend.
The elongate ink supply structure may define a number of passages, each passage corresponding with a respective ink, and a number of sets of holes, each set in fluid communication with a respective passage. The first ink chamber defining structure may define a number of ink chamber formations and a number of corresponding sets of ink inlet openings, each set corresponding with a respective set of holes. The second ink chamber defining structure may define a number of ink chamber formations and a number of corresponding sets of exit holes, each set corresponding with a respective set of ink inlets of the at least one elongate printhead chip.
The printhead assembly may include an elongate channel member that defines a channel. The ink supply structure and the ink chamber defining structures may be positioned in the channel, such that the channel imparts structural rigidity to the printhead assembly. The channel member may be of a nickel iron alloy.
According to a second aspect of the invention, there is provided a printhead assembly for a drop on demand ink jet printer, comprising:
a printhead module having a printhead including ink jet nozzles, the module being affixed to the assembly,
a capping device affixed to the assembly and movable linearly with respect thereto, the capping device at least partially surrounding the printhead module and movable between a capped position whereby the nozzles are capped by the capping device and an uncapped position whereby the nozzles are uncapped.
Preferably a plurality of printhead modules is situated along a channel, the modules and channel extending substantially across a pagewidth.
Preferably the capping device partly surrounds the channel.
Preferably the capping device has an onsert molded elastomeric pad which bears onto one or more of the printhead modules.
Preferably each printhead module includes a nozzle guard to protect the nozzles and wherein the elastomeric pad clamps against the nozzle guard in the capped position.
Preferably the elastomeric pad includes air ducts via which air is pumped to the printhead modules when the capping device is in the uncapped position.
Preferably a camshaft bears against the capping device and serves to move the capping device between said capped and uncapped positions.
Preferably the capping device includes a spring to bias the device with respect to the printhead modules against the camshaft.
Preferably the capping device is formed of stainless spring steel.
Preferably each printhead module includes a ramp and wherein the capping device includes a boss that rides over the ramp when the capping device is moved between the capped and uncapped positions, the ramp serving to elastically distort the capping device as it is moved between said capped and uncapped positions so as to prevent scraping of the device against the nozzle guard.
Preferably each printhead module has alternating air inlets and outlets cooperating with the elastomeric pad so as to be either sealed off or grouped into air inlet/outlet chambers depending on the position of the capping device, the chambers serving to duct air to the printhead when the capping device is uncapped.
Preferably the capping device applies a compressive force to each printhead module and an underside of the channel.
Preferably rotation of the camshaft is reversible.
As used herein, the term “ink” is intended to mean any fluid which flows through the printhead to be delivered to print media. The fluid may be one of many different colored inks, infrared ink, a fixative or the like.
BRIEF DESCRIPTION OF THE DRAWINGS
A preferred form of the present invention will now be described by way of example with reference to the accompanying drawings wherein:
FIG. 1 is a schematic overall view of a printhead;
FIG. 2 is a schematic exploded view of the printhead of FIG. 1 ;
FIG. 3 is a schematic exploded view of an ink jet module;
FIG. 3 a is a schematic exploded inverted illustration of the ink jet module of FIG. 3 ;
FIG. 4 is a schematic illustration of an assembled ink jet module;
FIG. 5 is a schematic inverted illustration of the module of FIG. 4 ;
FIG. 6 is a schematic close-up illustration of the module of FIG. 4 ;
FIG. 7 is a schematic illustration of a chip sub-assembly;
FIG. 8 a is a schematic side elevational view of the printhead of FIG. 1 ;
FIG. 8 b is a schematic plan view of the printhead of FIG. 8 a;
FIG. 8 c is a schematic side view (other side) of the printhead of FIG. 8 a;
FIG. 8 d is a schematic inverted plan view of the printhead of FIG. 8 b;
FIG. 9 is a schematic cross-sectional end elevational view of the printhead of FIG. 1 ;
FIG. 10 is a schematic illustration of the printhead of FIG. 1 in an uncapped configuration;
FIG. 11 is a schematic illustration of the printhead of FIG. 10 in a capped configuration;
FIG. 12 a is a schematic illustration of a capping device;
FIG. 12 b is a schematic illustration of the capping device of FIG. 12 a , viewed from a different angle;
FIG. 13 is a schematic illustration showing the loading of an ink jet module into a printhead;
FIG. 14 is a schematic end elevational view of the printhead illustrating the printhead module loading method;
FIG. 15 is a schematic cut-away illustration of the printhead assembly of FIG. 1 ;
FIG. 16 is a schematic close-up illustration of a portion of the printhead of FIG. 15 showing greater detail in the area of the “Memjet” chip;
FIG. 17 is a schematic illustration of the end portion of a metal channel and a printhead location molding;
FIG. 18 a is a schematic illustration of an end portion of an elastomeric ink delivery extrusion and a molded end cap; and
FIG. 18 b is a schematic illustration of the end cap of FIG. 18 a in an out-folded configuration.
DETAILED DESCRIPTION OF THE INVENTION
In FIG. 1 of the accompanying drawings there is schematically depicted an overall view of a printhead assembly. FIG. 2 shows the core components of the assembly in an exploded configuration. The printhead assembly 10 of the preferred embodiment comprises eleven printhead modules 11 situated along a metal “Invar” channel 16 . At the heart of each printhead module 11 is a “Memjet” chip 23 ( FIG. 3 ). The particular chip chosen in the preferred embodiment has a six-color configuration.
The “Memjet” printhead modules 11 are comprised of the “Memjet” chip 23 , a fine pitch flex PCB 26 and two micro-moldings 28 and 34 sandwiching a mid-package film 35 . Each module 11 forms a sealed unit with independent ink chambers 63 ( FIG. 9 ) which feed the chip 23 . The modules 11 plug directly onto a flexible elastomeric extrusion 15 which carries air, ink and fixative. The upper surface of the extrusion 15 has repeated patterns of holes 21 which align with ink inlets 32 ( FIG. 3 a ) on the underside of each module 11 . The extrusion 15 is bonded onto a flex PCB (flexible printed circuit board).
The fine pitch flex PCB 26 wraps down the side of each printhead module 11 and makes contact with the flex PCB 17 ( FIG. 9 ). The flex PCB 17 carries two busbars 19 (positive) and 20 (negative) for powering each module 11 , as well as all data connections. The flex PCB 17 is bonded onto the continuous metal “Invar” channel 16 . The metal channel 16 serves to hold the modules 11 in place and is designed to have a similar coefficient of thermal expansion to that of silicon used in the modules.
A capping device 12 is used to cover the “Memjet” chips 23 when not in use. The capping device is typically made of spring steel with an onsert molded elastomeric pad 47 ( FIG. 12 a ). The pad 47 serves to duct air into the “Memjet” chip 23 when uncapped and cut off air and cover a nozzle guard 24 ( FIG. 9 ) when capped. A camshaft 13 that typically rotates throughout 180 o actuates the capping device 12 .
The overall thickness of the “Memjet” chip is typically 0.6 mm which includes a 150-micron inlet backing layer 27 and a nozzle guard 24 of 150-micron thickness. These elements are assembled at the wafer scale.
The nozzle guard 24 allows filtered air into an 80-micron cavity 64 ( FIG. 16 ) above the “Memjet” ink nozzles 62 . The pressurized air flows through microdroplet holes 45 in the nozzle guard 24 (with the ink during a printing operation) and serves to protect the delicate “Memjet” nozzles 62 by repelling foreign particles.
A silicon chip backing layer 27 ducts ink from the printhead module packaging directly into the rows of “Memjet” nozzles 62 . The “Memjet” chip 23 is wire bonded 25 from bond pads on the chip at 116 positions to the fine pitch flex PCB 26 . The wire bonds are on a 120-micron pitch and are cut as they are bonded onto the fine pitch flex PCB pads ( FIG. 3 ). The fine pitch flex PCB 26 carries data and power from the flex PCB 17 via a series of gold contact pads 69 along the edge of the flex PCB.
The wire bonding operation between chip and fine pitch flex PCB 26 may be done remotely, before transporting, placing and adhering the chip assembly into the printhead module assembly. Alternatively, the “Memjet” chips 23 can be adhered into the upper micro-molding 28 first and then the fine pitch flex PCB 26 can be adhered into place. The wire bonding operation could then take place in situ, with no danger of distorting the moldings 28 and 34 . The upper micro-molding 28 can be made of a Liquid Crystal Polymer (LCP) blend. Since the crystal structure of the upper micro-molding 28 is minute, the heat distortion temperature (180° C.-260° C.), the continuous usage temperature (200° C.-240° C.) and soldering heat durability (260° C. for 10 seconds to 310° C. for 10 seconds) are high, regardless of the relatively low melting point.
Each printhead module 11 includes an upper micro-molding 28 and a lower micro-molding 34 separated by a mid-package film layer 35 shown in FIG. 3 .
The mid-package film layer 35 can be an inert polymer such as polyimide, which has good chemical resistance and dimensional stability. The mid-package film layer 35 can have laser-ablated holes 65 and can comprise a double-sided adhesive (i.e. an adhesive layer on both faces) providing adhesion between the upper micro-molding, the mid-package film layer and the lower micro-molding.
The upper micro-molding 28 has a pair of alignment pins 29 passing through corresponding apertures in the mid-package film layer 35 to be received within corresponding recesses 66 in the lower micro-molding 34 . This serves to align the components when they are bonded together. Once bonded together, the upper and lower micro-moldings form a tortuous ink and air path in the complete “Memjet” printhead module 11 .
There are annular ink inlets 32 in the underside of the lower micro-molding 34 . In a preferred embodiment, there are six such inlets 32 for various inks (black, yellow, magenta, cyan, fixative and infrared). There is also provided an air inlet slot 67 . The air inlet slot 67 extends across the lower micro-molding 34 to a secondary inlet which expels air through an exhaust hole 33 , through an aligned hole 68 in fine pitch flex PCB 26 . This serves to repel the print media from the printhead during printing. The ink inlets 32 continue in the under surface of the upper micro-molding 28 as does a path from the air inlet slot 67 . The ink inlets lead to 200-micron exit holes also indicated at 32 in FIG. 3 . These holes correspond to the inlets on the silicon backing layer 27 of the “Memjet” chip 23 .
There is a pair of elastomeric pads 36 on an edge of the lower micro-molding 34 . These serve to take up tolerance and positively located the printhead modules 11 into the metal channel 16 when the modules are micro-placed during assembly.
A preferred material for the “Memjet” micro-moldings is a LCP. This has suitable flow characteristics for the fine detail in the moldings and has a relatively low coefficient of thermal expansion.
Robot picker details are included in the upper micro-molding 28 to enable accurate placement of the printhead modules 11 during assembly.
The upper surface of the upper micro-molding 28 as shown in FIG. 3 has a series of alternating air inlets and outlets 31 . These act in conjunction with the capping device 12 and are either sealed off or grouped into air inlet/outlet chambers, depending upon the position of the capping device 12 . They connect air diverted from the inlet slot 67 to the chip 23 depending upon whether the unit is capped or uncapped.
A capper cam detail 40 including a ramp for the capping device is shown at two locations in the upper surface of the upper micro-molding 28 . This facilitates a desirable movement of the capping device 12 to cap or uncap the chip and the air chambers. That is, as the capping device is caused to move laterally across the print chip during a capping or uncapping operation, the ramp of the capper cam detail 40 serves to elastically distort the capping device as it is moved by operation of the camshaft 13 so as to prevent scraping of the device against the nozzle guard 24 .
The “Memjet” chip assembly 23 is picked and bonded into the upper micro-molding 28 on the printhead module 11 . The fine pitch flex PCB 26 is bonded and wrapped around the side of the assembled printhead module 11 as shown in FIG. 4 . After this initial bonding operation, the chip 23 has more sealant or adhesive 46 applied to its long edges. This serves to “pot” the bond wires 25 ( FIG. 6 ), seal the “Memjet” chip 23 to the molding 28 and form a sealed gallery into which filtered air can flow and exhaust through the nozzle guard 24 .
The flex PCB 17 carries all data and power connections from the main PCB (not shown) to each “Memjet” printhead module 11 . The flex PCB 17 has a series of gold plated, domed contacts 69 ( FIG. 2 ) which interface with contact pads 41 , 42 and 43 on the fine pitch flex PCB 26 of each “Memjet” printhead module 11 .
Two copper busbar strips 19 and 20 , typically of 200-micron thickness, are jigged and soldered into place on the flex PCB 17 . The busbars 19 and 20 connect to a flex termination which also carries data.
The flex PCB 17 is approximately 340 mm in length and is formed from a 14 mm wide strip. It is bonded into the metal channel 16 during assembly and exits from one end of the printhead assembly only.
The metal U-channel 16 into which the main components are placed is of a special alloy called “Invar 36 ”. It is a 36% nickel iron alloy possessing a coefficient of thermal expansion of 1/10 th that of carbon steel at temperatures up to 400° F. The Invar is annealed for optimal dimensional stability.
Additionally, the Invar is nickel plated to a 0.056% thickness of the wall section. This helps further to match it to the coefficient of thermal expansion of silicon which is 2×10 −6 per ° C.
The Invar channel 16 functions to capture the “Memjet” printhead modules 11 in a precise alignment relative to each other and to impart enough force on the modules 11 so as to form a seal between the ink inlets 32 on each printhead module and the outlet holes 21 that are laser ablated into the elastomeric ink delivery extrusion 15 .
The similar coefficient of thermal expansion of the Invar channel to the silicon chips allows similar relative movement during temperature changes. The elastomeric pads 36 on one side of each printhead module 11 serve to “lubricate” them within the channel 16 to take up any further lateral coefficient of thermal expansion tolerances without losing alignment. The Invar channel is a cold rolled, annealed and nickel-plated strip. Apart from two bends that are required in its formation, the channel has two square cut-outs 80 at each end. These mate with snap fittings 81 on the printhead location moldings 14 ( FIG. 17 ).
The elastomeric ink delivery extrusion 15 is a non-hydrophobic, precision component. Its function is to transport ink and air to the “Memjet” printhead modules 11 . The extrusion is bonded onto the top of the flex PCB 17 during assembly and it has two types of molded end caps. One of these end caps is shown at 70 in FIG. 18 a.
A series of patterned holes 21 are present on the upper surface of the extrusion 15 . These are laser ablated into the upper surface. To this end, a mask is made and placed on the surface of the extrusion, which then has focused laser light applied to it. The holes 21 are evaporated from the upper surface, but the laser does not cut into the lower surface of extrusion 15 due to the focal length of the laser light.
Eleven repeated patterns of the laser-ablated holes 21 form the ink and air outlets 21 of the extrusion 15 . These interface with the annular ring inlets 32 on the underside of the “Memjet” printhead module lower micro-molding 34 . A different pattern of larger holes (not shown but concealed beneath the upper plate 71 of end cap 70 in FIG. 18 a ) is ablated into one end of the extrusion 15 . These mate with apertures 75 having annular ribs formed in the same way as those on the underside of each lower micro-molding 34 described earlier. Ink and air delivery hoses 78 are connected to respective connectors 76 that extend from the upper plate 71 . Due to the inherent flexibility of the extrusion 15 , it can contort into many ink connection mounting configurations without restricting ink and air flow. The molded end cap 70 has a spine 73 from which the upper and lower plates are integrally hinged. The spine 73 includes a row of plugs 74 that are received within the ends of the respective flow passages of the extrusion 15 .
The other end of the extrusion 15 is capped with simple plugs which block the channels in a similar way as the plugs 74 on spine 17 .
The end cap 70 clamps onto the ink extrusion 15 by way of snap engagement tabs 77 . Once assembled with the delivery hoses 78 , ink and air can be received from ink reservoirs and an air pump, possibly with filtration means. The end cap 70 can be connected to either end of the extrusion, i.e. at either end of the printhead.
The plugs 74 are pushed into the channels of the extrusion 15 and the plates 71 and 72 are folded over. The snap engagement tabs 77 clamp the molding and prevent it from slipping off the extrusion. As the plates are snapped together, they form a sealed collar arrangement around the end of the extrusion. Instead of providing individual hoses 78 pushed onto the connectors 76 , the molding 70 might interface directly with an ink cartridge. A sealing pin arrangement can also be applied to this molding 70 . For example, a perforated, hollow metal pin with an elastomeric collar can be fitted to the top of the inlet connectors 76 . This would allow the inlets to automatically seal with an ink cartridge when the cartridge is inserted. The air inlet and hose might be smaller than the other inlets in order to avoid accidental charging of the airways with ink.
The capping device 12 for the “Memjet” printhead would typically be formed of stainless spring steel. An elastomeric seal or onsert molding 47 is attached to the capping device as shown in FIGS. 12 a and 12 b . The metal part from which the capping device is made is punched as a blank and then inserted into an injection molding tool ready for the elastomeric onsert to be shot onto its underside. Small holes 79 ( FIG. 12 b ) are present on the upper surface of the metal capping device 12 and can be formed as burst holes. They serve to key the onsert molding 47 to the metal. After the molding 47 is applied, the blank is inserted into a press tool, where additional bending operations and forming of integral springs 48 takes place.
The elastomeric onsert molding 47 has a series of rectangular recesses or air chambers 56 . These create chambers when uncapped. The chambers 56 are positioned over the air inlet and exhaust holes 30 of the upper micro-molding 28 in the “Memjet” printhead module 11 . These allow the air to flow from one inlet to the next outlet. When the capping device 12 is moved forward to the “home” capped position as depicted in FIG. 11 , these airways 32 are sealed off with a blank section of the onsert molding 47 cutting off airflow to the “Memjet” chip 23 . This prevents the filtered air from drying out and therefore blocking the delicate “Memjet” nozzles.
Another function of the onsert molding 47 is to cover and clamp against the nozzle guard 24 on the “Memjet” chip 23 . This protects against drying out, but primarily keeps foreign particles such as paper dust from entering the chip and damaging the nozzles. The chip is only exposed during a printing operation, when filtered air is also exiting along with the ink drops through the nozzle guard 24 . This positive air pressure repels foreign particles during the printing process and the capping device protects the chip in times of inactivity.
The integral springs 48 bias the capping device 12 away from the side of the metal channel 16 . The capping device 12 applies a compressive force to the top of the printhead module 11 and the underside of the metal channel 16 . An eccentric camshaft 13 mounted against the side of the capping device governs the lateral capping motion of the capping device 12 . It pushes the device 12 against the metal channel 16 . During this movement, the bosses 57 beneath the upper surface of the capping device 12 ride over the respective ramps 40 formed in the upper micro-molding 28 . This action flexes the capping device and raises its top surface to raise the onsert molding 47 as it is moved laterally into position onto the top of the nozzle guard 24 .
The camshaft 13 , which is reversible, is held in position by two printhead location moldings 14 . The camshaft 13 can have a flat surface built in one end or be otherwise provided with a spline or keyway to accept gear 22 or another type of motion controller.
The “Memjet” chip and printhead module are assembled as follows: 1. The “Memjet” chip 23 is dry tested in flight by a pick and place robot, which also dices the wafer and transports individual chips to a fine pitch flex PCB bonding area. 2. When accepted, the “Memjet” chip 23 is placed 530 microns apart from the fine pitch flex PCB 26 and has wire bonds 25 applied between the bond pads on the chip and the conductive pads on the fine pitch flex PCB. This constitutes the “Memjet” chip assembly. 3. An alternative to step 2 is to apply adhesive to the internal walls of the chip cavity in the upper micro-molding 28 of the printhead module and bond the chip into place first. The fine pitch flex PCB 26 can then be applied to the upper surface of the micro molding and wrapped over the side. Wire bonds 25 are then applied between the bond pads on the chip and the fine pitch flex PCB. 4. The “Memjet” chip assembly is vacuum transported to a bonding area where the printhead modules are stored. 5. Adhesive is applied to the lower internal walls of the chip cavity and to the area where the fine pitch flex PCB is going to be located in the upper micro-molding of the printhead module. 6. The chip assembly (and fine pitch flex PCB) are bonded into place. The fine pitch flex PCB is carefully wrapped around the side of the upper micro-molding so as not to strain the wire bonds. This may be considered as a two-step gluing operation if it is deemed that the fine pitch flex PCB might stress the wire bonds. A line of adhesive running parallel to the chip can be applied at the same time as the internal chip cavity walls are coated. This allows the chip assembly and fine pitch flex PCB to be seated into the chip cavity and the fine pitch flex PCB allowed to bond to the micro-molding without additional stress. After curing, a secondary gluing operation could apply adhesive to the short side wall of the upper micro-molding in the fine pitch flex PCB area. This allows the fine pitch flex PCB to be wrapped around the micro-molding and secured, while still being firmly bonded in place along on the top edge under the wire bonds. 7. In the final bonding operation, the upper part of the nozzle guard is adhered to the upper micro-molding, forming a sealed air chamber. Adhesive is also applied to the opposite long edge of the “Memjet” chip, where the bond wires become ‘potted’ during the process. 8. The modules are ‘wet’ tested with pure water to ensure reliable performance and then dried out. 9. The modules are transported to a clean storage area, prior to inclusion into a printhead assembly, or packaged as individual units. This completes the assembly of the “Memjet” printhead module assembly. 10. The metal Invar channel 16 is picked and placed in a jig. 11. The flex PCB 17 is picked and primed with adhesive on the busbar side, positioned and bonded into place on the floor and one side of the metal channel. 12. The flexible ink extrusion 15 is picked and has adhesive applied to the underside. It is then positioned and bonded into place on top of the flex PCB 17 . One of the printhead location end caps is also fitted to the extrusion exit end. This constitutes the channel assembly. The laser ablation process is as follows: 13. The channel assembly is transported to an excimir laser ablation area. 14. The assembly is put into a jig, the extrusion positioned, masked and laser ablated. This forms the ink holes in the upper surface. 15. The ink extrusion 15 has the ink and air connector molding 70 applied. Pressurized air or pure water is flushed through the extrusion to clear any debris. 16. The end cap molding 70 is applied to the extrusion 15 . It is then dried with hot air. 17. The channel assembly is transported to the printhead module area for immediate module assembly. Alternatively, a thin film can be applied over the ablated holes and the channel assembly can be stored until required. The printhead module to channel is assembled as follows: 18. The channel assembly is picked, placed and clamped into place in a transverse stage in the printhead assembly area. 19. As shown in FIG. 14 , a robot tool 58 grips the sides of the metal channel and pivots at pivot point against the underside face to effectively flex the channel apart by 200 to 300 microns. The forces applied are shown generally as force vectors F in FIG. 14 . This allows the first “Memjet” printhead module to be robot picked and placed (relative to the first contact pads on the flex PCB 17 and ink extrusion holes) into the channel assembly. 20. The tool 58 is relaxed, the printhead module captured by the resilience of the Invar channel and the transverse stage moves the assembly forward by 19.81 mm. 21. The tool 58 grips the sides of the channel again and flexes it apart ready for the next printhead module. 22. A second printhead module 11 is picked and placed into the channel 50 microns from the previous module. 23. An adjustment actuator arm locates the end of the second printhead module. The arm is guided by the optical alignment of fiducials on each strip. As the adjustment arm pushes the printhead module over, the gap between the fiducials is closed until they reach an exact pitch of 19.812 mm. 24. The tool 58 is relaxed and the adjustment arm is removed, securing the second printhead module in place. 25. This process is repeated until the channel assembly has been fully loaded with printhead modules. The unit is removed from the transverse stage and transported to the capping assembly area. Alternatively, a thin film can be applied over the nozzle guards of the printhead modules to act as a cap and the unit can be stored as required. The capping device is assembled as follows: 26. The printhead assembly is transported to a capping area. The capping device 12 is picked, flexed apart slightly and pushed over the first module 11 and the metal channel 16 in the printhead assembly. It automatically seats itself into the assembly by virtue of the bosses 57 in the steel locating in the recesses 83 in the upper micro-molding in which a respective ramp 40 is located. 27. Subsequent capping devices are applied to all the printhead modules. 28. When completed, the camshaft 13 is seated into the printhead location molding 14 of the assembly. It has the second printhead location molding seated onto the free end and this molding is snapped over the end of the metal channel, holding the camshaft and capping devices captive. 29. A molded gear 22 or other motion control device can be added to either end of the camshaft 13 at this point. 30. The capping assembly is mechanically tested. Print charging is as follows: 31. The printhead assembly 10 is moved to the testing area. Inks are applied through the “Memjet” modular printhead under pressure. Air is expelled through the “Memjet” nozzles during priming. When charged, the printhead can be electrically connected and tested. 32. Electrical connections are made and tested as follows: 33. Power and data connections are made to the PCB. Final testing can commence, and when passed, the “Memjet” modular printhead is capped and has a plastic sealing film applied over the underside that protects the printhead until product installation.
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A modular printhead assembly includes an elongate carrier. An elongate ink conduit is positioned in the carrier and is configured to feed ink along a length of the carrier. A plurality of printhead modules is serially arranged along and engaged with the ink conduit. The ink conduit is in fluid communication with the printhead modules and each printhead module includes a printhead integrated circuit for carrying out a printing operation. A pair of supports is fastenable to respective ends of the carrier. The printhead modules are located between the supports. At least one capping mechanism is arranged to cap the printhead integrated circuits. A camshaft is operatively engaged with the supports and extends between the supports and is arranged to move the, or each, capping mechanism so that the printhead integrated circuits can be capped.
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REFERENCE TO EARLIER FILED APPLICATIONS
This application is a continuation of U.S. Ser. No. 932,561 filed Nov. 19, 1986 entitled Penetration Enhancers for Transdermal Delivery of Systemic Agents now U.S. Pat. No. 4,808,414 which is a Continuation-in-part of U.S. Ser. No. 912,947, entitled Compositions Comprising N,N-Dialkylakanamides, filed on Sep. 29, 1986, now U.S. Pat. No. 4,902,676. U.S. Ser. Nos. 932,561 and 912,947 are to be totally incorporated, including drawings, if any, into the present application by this specific reference hereto.
BACKGROUND OF THE INVENTION
1) Field of the Invention
The invention generally relates to an improved method of drug delivery. More particularly, the invention relates to an improved membrane penetration enhancers for use in the transdermal delivery of systemically active drugs to humans and animals.
2) Background of the Prior Art
For some years, pharmaceutical researchers have sought an effective means of introducing drugs into the bloodstream by applying them to unbroken skin. Among other advantages, such administration can provide a comfortable, convenient, and safe way of giving many drugs now taken orally or infused into veins or injected intramuscularly.
Using skin as the portal for drug entry offers unique potential, because transdermal delivery permits close control over drug absorption. For example, it avoids factors that can cause unpredictable absorption from the gastrointestinal tract, including: changes in acidity, motility, and food content. It also avoids initial metabolism of the drug by the liver. Thus, controlled drug entry through skin can achieve a high degree of control over blood concentrations of drug.
Close control over drug concentrations in blood can translate readily into safer and more comfortable treatment. When a drug's adverse effects occur at higher concentrations than its beneficial ones, rate control can maintain the concentrations that evoke only--or principally the drug's desired actions. This ability to lessen undesired drug actions can greatly reduce the toxicity hazards that now restrict or prevent the use of many valuable agents.
Transdermal delivery particularly benefits patients with chronic disease. Many such patients have difficulty following regimens requiring several doses daily of medications that repeatedly cause unpleasant symptoms. They find the same drugs much more acceptable when administered in transdermal systems that require application infrequently--in some cases, only once or twice weekly--and that reduce adverse effects.
Transdermal delivery is feasible for drugs effective in amounts that can pass through the skin area and that are substantially free of localized irritating or allergic effects. While these limitations may exclude some agents, many others remain eligible for transdermal delivery. Moreover, their numbers will expand as pharmaceutical agents of greater potency are developed. Particularly suitable for transdermal delivery are potent drugs with only a narrow spread between their toxic and safe blood concentrations, those having gastrointestinal absorption problems, or those requiring frequent dosing in oral or injectable form.
Transdermal therapy permits much wider use of natural substances such as hormones. Often the survival times of these substances in the body are so short that they would have to be taken many times daily in ordinary dosage forms. Continuous transdermal delivery provides a practical way of giving them, and one that can mimic the body's own patterns of secretion.
At present, controlled transdermal therapy appears feasible for many drugs used for a wide variety of ailments including, but not limited to, circulatory problems, hormone deficiency, respiratory ailments, and pain relief.
Percutaneous administration can have the advantage of permitting continuous administration of drug to the circulation over a prolonged period of time to obtain a uniform delivery rate and blood level of drug. Commencement and termination of drug therapy are initiated by the application and removal of the dosing devices from the skin. Uncertainties of administration through the gastrointestinal tract and the inconvenience of administration by injection are eliminated. Since a high concentration of drug never enters the body, problems of pulse entry are overcome and metabolic half-life is not a factor of controlling importance.
U.S. Pat. Nos. 3,989,815; 3,989,816; 3,991,203; 4,122,170; 4,316,893; 4,415,563; 4,423,040; 4,424,210; and 4,444,762 generally describe a method for enhancing the topical (as contrasted to the systemic) administration of physiologically active agents by combining such an agent with an effective amount of a penetration enhancer and applying the combination topically to humans or animals, in the form of creams, lotions, gels, etc.
Penetration enhancers for enhancing systemic administration of therapeutic agents transdermally are cited in U.S. Pat. Nos. 4,405,616; 4,562,075; 4,031,894, 3,996,934; and 3,921,636.
SUMMARY OF THE INVENTION
It has been discovered that the penetration enhancers previously disclosed in U.S. patent application Ser. No. 912,947 to enhance topical delivery of physiologically active agents also enhance the transdermal delivery of systemically active agents through the skin or other body membranes of humans and animals directly into the bloodstream.
The invention therefore provides a method for topically administering systemically active agents through the skin or mucosal membranes of humans and animals, utilizing a transdermal device or formulation, wherein the improvement in said method comprises topically administering with said systemic agent an effective amount of a membrane penetration enhancer having the structural formula ##STR2## wherein R 1 and R 2 are independently selected from the group consisting of alkyl radicals and cycloalkyl radicals, comprising from 1 to 20 carbon atoms, preferably from 2 to 14 carbon atoms and R is selected from the group consisting of alkyl radicals and cycloalkyl radicals comprising from 1 to 30 carbon atoms, preferably from 1 to 20 carbon atoms; provided, however, that the total number of carbon atoms in said compound is 15 or more and the total number of carbon atoms in R 1 and R 2 is 5 or more.
The invention also provides an improved method for administering systemically active therapeutic agents topically through the skin of humans in a transdermal device or formulation to obtain therapeutic blood levels of the therapeutic agent, wherein the improvement in said method comprises the use of an effective skin penetration enhancing amount of the above membrane penetration enhancer, with said therapeutic agent.
In a more preferred embodiment of the present invention, R 1 and R 2 are normal alkyl radicals or cycloalkyl radicals having from 3 to 12 carbon atoms, e.g. n-propyl, n-dodecyl or cyclohexyl radicals, and R is represented by the general formula
--CH.sub.2).sub.n CH.sub.3
wherein n is an integer of from 0 to 19, more preferably from 0 to 12, e.g. n is 0 or 10.
DETAILED DESCRIPTION OF THE INVENTION
The compounds useful as membrane penetration-enhancers in the formulations or devices of the instant invention may be made as described in U.S. patent application Ser. No. 855,497 hereby incorporated by reference. Topical examples of compounds represented by the above structural formula include:
N,N-dipropyloctanamide
N-butyl,-N-dodecylacetamide
N,N-didodecylacetamide
N-cyclohexyl,-N-dodecylacetamide
N,N-di-propyldodecanamide
N,N-dibutyloctadecanamide
N,N-dihexylheptanamide
N,N-dipropyleicosanamide
N,N-dipropylheneicosanamide
N,N-dipropylpentadecanamide
N,N-dipropylheptadecanamide
N,N-dipropyloctadecanamide
N,N-dipropylnonadecanamide
N,N-dihexyloctanamide
N,N-dipropyltetradecanamide
N,N-dipropyltridecnamide
N,N-dipropylundecanamide
N,N-dipropylnonanamide
N,N-dibutyltetradecanamide
N,N-dipentylheptanamide
N,N-dipentyloctanamide
N,N-dipropylhexadecanamide
N,N-dibutylnonanamide
N,N-dibutyldecanamide
N,N-dibutylundecanamide
N,N-dibutyltridecanamide
N,N-dibutylheptanamide
N,N-dibutyloctanamide
N,N-dihexyloctadecanamide
N,N-dipropyldecanamide
N,N-dibutylhexadecanamide
N,N-dibutyloctadecanamide
Typical systemically active agents which may be delivered transdermally are therapeutic agents which are sufficiently potent such that they can be delivered through the skin or other membrane to the bloodstream in sufficient quantities to produce the desired therapeutic effect. In general, this includes therapeutic agents in all of the major therapeutic areas including, but not limited to, anti-infectives, such as antibiotics and antiviral agents, analgesics and analgesic combinations, anorexics, anthelmintics, antiarthritics, antiasthma agents, anticonvulsants, antidepressants, antidiabetic agents, antidiarrheals, antihistamines, anti-inflammatory agents, antimigraine preparations, antimotion sickness, antinauseants, antineoplastics, antiparkinsonism drugs, antipruritics, antipsychotics, antipyretics, antispasmodics, including gastrointestinal and urinary; anticholinergics, sympathomimetics, xanthine derivatives, cardiovascular preparations including calcium channel blockers, beta-blockers, antiarrhythmics, antihypertensives, diuretics, vasodilators including general, coronary, peripheral and cerebral; central nervous system stimulants, cough and cold preparations, decongestants, diagnostics, hormones, hypnotics, immunosuppressives, muscle relaxants, parasympatholytics, parasympathomimetics, psychostimulants, sedatives and tranquilizers.
Dosage forms for application to the skin or other membranes of humans and animals include creams, lotions, gels, ointments, suppositories, sprays, aerosols, buccal and sub-lingual tablets and any one of a variety of transdermal devices for use in the continuous administration of systemically active drugs by absorption through the skin, oral mucosa or other membranes, see, for example, one or more of U.S. Pat. Nos. 3,598,122; 3,598,123; 3,731,683; 3,742,951; 3,814,097; 3,921,636; 3,972,995; 3,993,072; 3,993,073, 3,996,934; 4,031,894; 4,060,084; 4,069,307; 4,201,211; 4,230,105; 4,292,299 and 4,292,303. U.S. Pat. No. 4,077,407 and the foregoing patents also disclose a variety of specific systemically active agents which may also be useful in transdermal delivery, which disclosures are hereby incorporated herein by this reference.
Typical inert carriers which may be included in the foregoing dosage forms include conventional formulating materials, such as, for example, water, isopropyl alcohol, gaseous fluorocarbons, ethyl alcohol, polyvinyl pyrrolidone, propylene glycol, fragrances, gel-producing materials such as "Carbopol", stearyl alcohol, stearic acid, spermaceti, sorbitan monooleate, "Polysorbates", "Tweens", sorbital, methylcellulose, etc.
Systemically active agents are used in amounts calculated to achieve and maintain therapeutic blood levels in a human or animal over the period of time desired. These amounts vary with the potency of each systemically active substance, the amount required for the desired therapeutic or other effect, the rate of elimination or breakdown of the substance by the body once it has entered the bloodstream and the amount of penetration-enhancer in the formulation. In accordance with conventional prudent formulating practices, a dosage near the lower end of the useful range of a particular agent is usually employed initially and the dosage increased or decreased as indicated from the observed response, as in the routine procedure of the physician.
The amount of penetration enhancer which may be used in the invention varies from about 1 to 100 percent although adequate enhancement of penetration is generally found to occur in the range of about 1 to about 10 percent by weight of the formulation to be delivered. The penetration-enhancer disclosed herein may be used in combination with the active agent or may be used separately as a pre-treatment of the skin or other body membrane through which the systemically-active agent is intended to be delivered.
The invention is further illustrated by the following examples which are illustrative of a specific mode of practicing the invention and is not intended as limiting the scope of the appended claims.
EXAMPLE 1
A composition, in the form of a gel, suitable for transdermal delivery of haloperidol, an antidyskinetic or antipsychotic drug, is prepared by mixing the following components in the given concentrations.
______________________________________Component Weight %______________________________________Haloperidol 1-5N,N-di-n-dodecylacetamide 1-10Carbopol 934 P 0.5-2(Available fromB. F. Goodrich)Neutralizing Agent q.s.(NaOH)Tween-20 1-10(Available fromAtlas Chemical, aDiv. of I.C.I.)Preservative q.s.(Sorbic Acid)Antioxidant q.s.(Ascorbic Acid)Chelating Agent q.s.(Disodium salt ofethylenediaminetetraaceticacid)Deionized Water q.s to 100______________________________________
This composition is topically applied to the skin of a human subject and after the passage of a suitable period of time haloperidol is found in the bloodstream of said subject.
EXAMPLE 2
When an amine, e.g. triethylamine or triethanolamine, is substituted for NaOH the results are substantially similar, i.e. a topical composition suitable for transdermally delivering haloperidol to the bloodstream is obtained.
EXAMPLE 3
When potassium sorbate, or a lower alkyl paraben, e.g. methyl, ethyl, propyl or butyl paraben are substituted for the preservative of the composition of Example 1, the results are substantially similar, i.e. a topical composition suitable for the transdermal delivery of haloperidol to the bloodstream is obtained.
EXAMPLE 4
When ascorbyl palmitate, Vitamin E, thioglycerol, thioglycolic acid, sodium formaldehyde sulfoxylate, BHA, BHT, propyl gallate or sodium metabisulfite are substituted for the antioxidant of the composition formulated in Example 1, the results are substantially similar in that a topical composition suitable for transdermally delivering haloperidol to the bloodstream is obtained.
EXAMPLE 5
The composition of Example 1 is prepared in the form of a sodium alginate gel by mixing the following components in the following given concentrations:
______________________________________Component Weight %______________________________________Haloperidol 1-5N,N-di-n-dodecylacetamide 1-10Sodium Alginate 0.5-5Calcium Salts q.s.Tween-20 1-10Preservative* q.s.Antioxidant** q.s.Chelating Agent*** q.s.Deionized Water to 100______________________________________ *Suitable preservatives are those used in Example 3 as well as sorbic acid. **Suitable antioxidants are those used in Example 4 including ascorbic acid. ***The chelating agent is the disodium salt of ethylenediaminetetraacetic acid.
This composition when applied topically is found to transdermally deliver haloperidol to the bloodstream of a subject.
EXAMPLE 6
The composition of Example 1 is prepared in the form of a hydrophilic cream by mixing the following components.
______________________________________Component Weight %______________________________________Oil PhaseCetyl Alcohol 5-15Stearyl Alcohol 1-5N,N-di-n-dodecylacetamide 0.5-10Glycerol Monostearate 2-7Water PhaseSodium Laurylsulfate 0.1Solvent* 2-20Tween-20 1-5Water q.s. to 100______________________________________ *Suitable solvents are propylene glycol, glycerin, alcohols, for example, ethyl alcohol, isopropyl alcohol, etc. and polyethylene glycols.
The oil phase and the water phase is made up separately, and then agitated to form an emulsion. (When, as in Example 8, the active ingredient, is other than haloperidol, depending on its lipophilicity, it will be distributed in the oil or water phase.) This hydrophilic cream, when applied topically to the skin of a human, is found to transdermally delivery haloperidol into the bloodstream.
EXAMPLE 7
The composition of the instant invention may also be delivered by use of a polymeric matrix. For example, a solid polymer such as cellulose triacetate, polyvinyl acetate, terpolymers and copolymers of vinyl chloride and vinyl acetate, copolymers of polyvinyl alcohol and polyvinyl acetate, and silicon elastomers is imbibed with a liquid having the following components in the given concentrations.
______________________________________Component Weight %______________________________________Polymer 5-40Haloperidol q.s.N,N-di-n-dodecylacetamide 0.5-80Solvent* 5-90Surfactant** 1-10Preservative*** q.s.Antioxidant**** q.s.______________________________________ *Solvents may be the solvents used in Example 6 above. *The Surfactant may be Tween20, glycerol monostearate or sodium laurylsulfate, etc. ***The preservative may be any of the preservatives used in Example 3 above. ****The antioxidants may be any of those used in Example 4 above.
When solid matrix, containing the active ingredients formulated above, is contacted with the skin of a human subject, after a period of time the active agent is found in the bloodstream of said subject.
EXAMPLE 8
Examples 1 to 7 are repeated except that the following active ingredients in the given concentrations are substituted for haloperidol:
______________________________________Active Ingredient Weight %______________________________________Isosorbide Dinitrate 5-15Nitroglycerin 1-5Estradiol 1-5Clonidine 0.5-3Propranolol 1-5Indomethacine 5-15Nifedipine 1-5Nicardipine 1-5Diclorofenac 5-15Metaproterenol 1-5______________________________________
Similar results are obtained in that the active ingredient is transdermally delivered to the bloodstream of an animal.
EXAMPLE 9
Examples 1 to 8 are repeated except that the compounds exemplified on page 7 (except for N,N-di-n-dodecylacetamide) are substituted for N,N-di-n-dodecylacetamide. Similar results are obtained in that the active ingredients are transdermally delivered to the bloodstream of an animal.
N-n-butyl, N-n-dodecylacetamide, N-cycloheptyl, -N-n-dodecylacetamide and N,N-n-di-n-propyldodecanamide are especially suitable for substitution for N,N-di-n-dodecylacetamide in Examples 1 to 8.
While particular embodiments of the invention have been described it will be understood of course that the invention is not limited thereto since many obvious modifications can be made and it is intended to include within this invention any such modifications as will fall within the scope of the appended claims.
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This invention relates to a method administering systemically active agents including therapeutic agents through the skin or mucosal membranes of humans and animals in a transdermal device or formulation comprising topically administering with said systemic agent an effective amount of a membrane penetration enhancer having the structural formula ##STR1## wherein R 1 and R 2 are independently selected from the group consisting of alkyl radicals and cycloalkyl radicals comprising from 1 to 20 carbon atoms and R is selected from the group consisting of alkyl radicals and cycloalkyl radicals comprising from 1 to 30 carbon atoms; provided, however, that the total number of carbon atoms in said compound is 15 or more and the total number of carbon atoms in R 1 and R 2 is 5 or more.
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BACKGROUND OF THE INVENTION
The present invention relates generally to drag or braking mechanisms for fishing reels; and, more specifically, the invention concerns fishing reels of the type consisting of a rotary-mounted spool for the fishing line, means of braking the rotation of the spool manually adjustable through an hydraulic cylinder containing a first piston kinematically connected with the adjustment means and a second piston kinematically connected with the braking means.
In known devices of this kind, such as exemplified in U.S. Pat. No. 3,322,369, the second piston acts on ramps, each integral with one of the jaws of a drum brake. The hydraulic cylinder serves to transmit the diplacement of the manually adjustable piston to the second piston and to the brake jaws. Therefore, once the different elements constituting the braking means are brought in contact with each other, the braking force is applied abruptly, since nothing is provided to reduce the displacement of the manually adjusted piston. In fact, for a relatively slight displacement of the adjustment piston, a very rapid increase of braking force occurs. This is undersirable for a number of reasons, one of which being line breakage upon abrupt braking.
The fishing reel according to the present invention avoids the aforesaid problem since the force exerted on the braking means by the adjustment means is applied very gradually.
SUMMARY OF THE INVENTION
A fishing reel in accordance with the present invention comprises a housing rotatably supporting a line spool; brake means constructed and arranged to apply frictional braking forces to the sides of said spool; a first hydraulic cylinder housed within said housing having first and second pistons, said first piston being manually operative and said second piston being operative by fluid pressure applied thereto to apply said braking forces; and a second cylinder housed within said housing in fluid connection with said first cylinder; a third piston arranged in said second cylinder, said third piston being elastically biased to constantly maintain fluid in said cylinders under pressure whereby said braking force may be gradually applied by manually displacing said first piston.
There has thus been outlined, rather broadly, the more important features of the present invention in order that the detailed description thereof that follows may be better understood and in order that the present contribution to the art may be appreciated. There are, of course, additional features of the invention that will be described hereinafter and which will form the subject of the claims appended hereto. Those skilled in the art will appreciate that this invention may be utilized for designing other structures for carrying out the several purposes of the invention. It is, therefore, important that the claims be regarded as including such equivalent constructions as do not depart from the spirit and scope thereof.
BRIEF DESCRIPTION OF THE DRAWINGS
One embodiment of the invention has been chosen for purposes of illustration and description, and is shown in the accompanying drawing wherein:
FIG. 1 is a cross-section view taken along the longitudinal axis of a fishing reel according to the invention.
DESCRIPTION OF THE INVENTION
As illustrated in FIG. 1, a fishing reel incorporating the invention has a conventional body formed of two lateral flanges or side plates 1 and 2 spaced apart by crosspieces 3 and by a crosspiece 4 having a contoured area 9 for attachment thereof to a rod (not shown). Between flanges 1 and 2 a central shaft 5 is mounted, on which a spool 6 is supported for rotation. A washer 7 is moulded in flange 1 and contains a hole provided with two flats, the dimensions of which correspond with two matching flats 8 provided on the end of shaft 5. The shaft is thus immobilized from rotation and is also immobilized axially by a nut 10 screwed on a threaded terminal part 11. Progressing from left to right on the drawing, after washer 7, there is, threaded on shaft 5, a first ball bearing generally indicated by the numeral 12, one race of which is integral with a first brake plate 13. A first compression spring 14 is positioned between brake plate 13 and a thrust washer 15 abutting spool 6. Two bearings 16 support spool 6 on shaft 5 and a second thrust washer 17 abuts the opposite side of spool 6 for a second compression spring 18. The latter bears on one side of a pinion 19 integral with a second brake plate 20. Brake plates 13 and 20 each include an inwardly facing friction gasket 24 and 25 arranged to engage the lateral faces 26 and 27 of spool 6. The first spring 14 constantly tends to separate face 26 axially from gasket 24. Similarly, the second spring 18 constantly tends to separate face 27 axially from gasket 25.
Pinion 19 supports ratchet 28 which bears on a second ball bearing generally indicated by the numeral 29, which, in turn, bears on a first, inward face of a piston 30 through which shaft 5 extends. Piston 30 is mounted within a housing defined by lateral flange 2 to slide axially around shaft 5. On the inward face of flange 2, a pawl 36, pivoted on a screw 37, is mounted to engage ratchet 28 to prevent the latter from turning in the direction of arrow 38. Similarly on the inward face of flange 1, another pawl 39, pivoted on a screw 40, is mounted to engage a ratchet 41 provided on the periphery of brake plate 13 to also prevent the latter from turning in the direction of arrow 38.
Pinion 19 is driven by a toothed wheel 31 integral with a shaft 32 of a crank 33. Shaft 32 is mounted for rotation in two bearings 34 and 35 supported within a housing defined by lateral flange 2. The end of shaft 5, adjacent to crank 33, is threaded at 45 to accept a nut 46 integral with an operating lever 47. Nut 46 has an outer cylindrical periphery 42 housed, at least partially, in a cylindrical housing 48 of corresponding diameter defined in flange 2. Housing or cylinder 48 is filled with hydraulic fluid and constitutes a first hydraulic cylinder. Face 49 of nut 46 constitutes the face of a first piston which is axially displaceable by the rotation of lever 47. Piston 30 has a face 50 directed into cylinder 48 and thus comprises a second piston axially displaceable by hydraulic pressure. In the illustrated embodiment, the second piston 30, has a smaller section than that of the first piston, nut 46. Fluid tightness of hydraulic cylinder 48 is assured by O-rings 52, 53 and 54.
A third piston 55 is set in a second cylinder 43 within lateral flange 2 in fluid connection with the first cylinder 48. O-ring 56 assures fluid tightness of piston 55 which is subjected to the action of a helical compression spring 57 keeping it in pressure against the hydraulic fluid in the cylinders. This third piston 55 is placed in flange 2 perpendicular to the axis of cylinder 48. A cap 58 threaded to the end of cylinder 43 permits regulation of the tension of spring 57 exerted on piston 55. The section of the third piston 55 is, for example, less than that of the second piston 30. In a particularly preferred embodiment, the first, second and third pistons 46, 30 and 55 have sections equal to 600 mm 2 , 300 mm 2 and 40 mm 2 respectively.
Operation of a reel embodying the present invention is as follows. When line is being let out of the reel in the direction of arrow 38, operating lever 47 occupies a first position such that spool 6 is entirely free or very slightly braked, spring 57 then being completely released or very slightly compressed. Pawls 36 and 39 do not interfere with this rotation of spool 6 in this direction.
When a fish has taken the bait, it is necessary to work the brake so as to tire the fish, while letting spool 6 turn in the direction of 38. For that purpose, lever 47 is rotated, which causes the displacement of nut 46 in the direction of arrow 44 so that the hydraulic fluid contained in cylinders 48 and 43 drives back piston 30 in the direction of arrow 44 and the third piston 55 in the direction of arrow 59. The displacement of the second piston 30 causes frictional engagement of gasket 25 and face 27 of spool 6, by means of ball bearing 29, pinion 19 and brake plate 20. Spool 6 is, itself, then displaced in the direction of arrow 44, its opposite side face 26 thus engaging gasket 24 of brake plate 13. The more nut 46 is displaced in the direction of 44, the more the third piston 55 recedes in the direction of arrow 59 against the action of spring 57 and the greater the braking pressure is exerted on the second piston 30. At all times the pressures exerted on nut 46, piston 30 and the third piston 55 are identical. The braking force exerted on piston 30 and the force exerted on nut 46 are always in the same ratio as their respective sections. With the preferred sections identified above, the forces would be in the ratio of 300 to 600 mm 2 . The force exerted by spring 57 on the third piston has no effect on the braking force, but does act on the effect of nut 46 and, therefore, of lever 47 in order to obtain a given braking effort. Thus, for example, if spring 57 is extremely rigid, everything occurs roughly as if the third piston did not exist; the braking force changes from a minimum value to a maximum value with a very slight displacement of nut 46. On the other hand, the more flexible spring 57 is, the greater displacement of nut 46 must be in order to obtain a given braking force. It is thus possible to choose a spring 57, the characteristics of which are such that a whole range of adjustment of operating lever 47 can be used, which allows for a very gradual braking effort. In the illustrated embodiment, spring 57 is a helical spring. Therefore, the force it exerts is proportional to the distance it is compressed. As a result, the braking force is linked with the displacement of nut 46 by a function of the first degree; and the braking obtained is thus even more gradual throughout the range of rotation of lever 47, since, for each angular displacement of lever 47 by a given unit value, the braking force grows by a constant value.
When the brake is thus operated, brake plates 13 and 20 are prevented from turning in the direction of 38 by pawls 39 and 36 respectively.
When the crank is turned in the direction of 62, spool 6 is driven into rotation in the direction of 60 by means of toothed wheel 31, toothed pinion 19 and brake plates 13 and 20. Pawls 36 and 39 do not interfere such rotation. The line is thus wound on spool 6.
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A fishing reel, of the type having a rotating line spool, includes an hydraulic braking system for the spool. The braking system comprises a manually operable lever associated with a piston in a first hydraulic cylinder through which fluid forces are applied to a second piston operating friction plates bearing upon the reel spool. A third, spring loaded, piston is located in a second cylinder in fluid connection with the first cylinder.
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STATEMENT REGARDING FEDERAL RIGHTS
This invention was made with government support under Contract No. W-7405-ENG-36 awarded by the U.S. Department of Energy. The government has certain rights in the invention.
FIELD OF THE INVENTION
The present invention relates generally to electron multipliers and, more particularly, to electron multipliers used in photomultipliers and particle detectors such as channel electron multipliers and microchannel plates that are used extensively in electron spectrometers, mass spectrometers, and photonic detectors.
BACKGROUND OF THE INVENTION
Two types of conventional electron multipliers are routinely used. A first type, pictorially illustrated in FIG. 1 , consists of discrete dynode multipliers, which comprise dynodes stages 10 that initiate and amplify a cascade of electrons. U.S. Pat. No. 4,668,890, issued May 26, 1987, details this type of electron multiplier. Typically, dynode stages 10 are biased using resistor divider string 20 such that front dynode 12 of the multiplier is biased to a high negative voltage (e.g., several kilovolts) relative to last dynode 14 and anode 16 of the multiplier. Thus, an electric field is imposed between each of the dynodes. As incoming particle 30 strikes the front dynode 12 it generates an average of γ I secondary electrons 32 from the impact surface of front dynode 12 . These secondary electrons are accelerated by the imposed electric field toward the next successive dynode, where they impact and generate more secondary electrons. This cascade of electrons continues throughout the entire series of dynode stages with the cumulative charge of the electron avalanche growing at each stage. After last dynode 14 , the electron avalanche charge is collected on anode 16 .
The gain (G D ) of a discrete dynode multiplier, which equals the cumulative output electron charge per incident particle, corresponds to:
G D =γ I γ SE N−1 (Equation 1)
where γ SE equals average number of secondary electrons emitted by an electron from one dynode impacting on the next sequential dynode and N equals the number of dynodes used in the detector. To maximize the gain, the dynode material is often selected for high secondary electron emission yield (γ SE ) properties (See U.S. Pat. No. 5,680,008, issued Oct. 21, 1997).
The second type of multiplier is a continuous electron multiplier, pictorially illustrated in FIG. 2 . Channel electron multipliers and microchannel plate (MPC) detectors are specific examples of this type. MPCs employ one or more high resistivity glass channels or tubes 40 , each of which acts as a series of continuous dynodes. Patented examples of this type of electron multiplier include: U.S. Pat. No. 4,095,132, issued Jun. 13, 1978; U.S. Pat. No. 4,073,989, issued Feb. 14, 1978; U.S. Pat. No. 5,086,248, issued Feb. 4, 1992; U.S. Pat. No. 6,015,588, issued Jan. 18, 2000; and U.S. Pat. No. 6,045,677, issued Apr. 4, 2000.
As with the discrete dynode, channel front 42 is negatively biased several kilovolts relative to the channel back 44 and anode 50 , so that an electric field is imposed inside of the channel from the front (entrance) to the rear (exit). Incident particle 60 impacts channel front 42 and generates secondary electrons 62 , which are then accelerated further into tube 40 by the imposed electric field. Secondary electrons 62 impact channel wall 41 and generate even more secondary electrons. The cumulative charge of the electron avalanche grows as it traverses tube 40 . The avalanche of secondary electrons 62 exits tube 40 , and is collected on anode 70 . The gain of a continuous electron multiplier can be modeled as a series of discrete dynodes and can therefore be represented by Equation 1. A variation of this concept uses a porous media having irregular channels; e.g., U.S. Pat. No. 6,455,987, issued Sep. 24, 2002.
A foil electron multiplier, in accordance with the present invention, encompasses the next generation design of electron multipliers. In a preferred embodiment, a series of extremely thin, in-line foils are used to create secondary electrons. The in-line orientation of the foils coupled with their thinness not only creates secondary electrons, but allows the incident primary particles, and the secondary electrons generated by the primary particles, to continue to the next and subsequent foils. It is believed that this design not only creates a larger avalanche of electrons when compared to historical designs, but also allows for obtaining position-sensitive information on where an incident particle impacted the first stage of the foil electron multiplier. The ability to provide position-sensitive information enables improvements on articles such as flat television screens, computer screens, night vision devices, and the like.
Advantages of the foil electron multiplier design over other types of electron multipliers include:
(1) A higher gain per multiplication stage that results in an increased multiplication efficiency since fewer stages are required to obtain the same charge as other multipliers.
(2) Simplicity of fabrication, since the foil fabrication process (evaporation of a foil material onto a glass slide covered with a surfactant and a subsequent aqueous transfer to a support grid or aperture plate) is simpler than fabrication of continuous multipliers, such as MCPs. The MCP fabrication process requires high purity materials, high precision, a high level of cleanliness, and involves using cladded fibers that must be bundled, stretched, and sintered in cycles, and then cut, etched, and chemically activated.
(3) A lower cost of fabrication, as the fabrication process complexity is reflected in the relevant cost. Twenty commercial foils cost about $500 whereas MCP detectors cost about $5,000 to $10,000.
(4) An ability to cover a larger area, as foils can be evaporated over large surface areas, whereas MCPs require additional bundling and sintering to increase the surface area. Also, large area foils are much more robust as they can be dropped without breaking, whereas MCPs shatter.
(5) Finally, the foil electron multiplier exhibits an intrinsic rejection of ion feedback at each stage. Continuous electron multipliers require a curved or zigzag path to prevent ions from being accelerated back toward the entrance where they can initiate a second pulse. In the foil electron multiplier, ions generated at one foil may be accelerated back to the previous foil, but cannot be re-transmitted back because the ion energy is too low. Therefore, ions can only reach one stage back, and a pulse that they generate will be indistinguishable from the main pulse.
Additional objects, advantages and novel features of the invention will be set forth in part in the description which follows, and in part will become apparent to those skilled in the art upon examination of the following or may be learned by practice of the invention. The objects and advantages of the invention may be realized and attained by means of the instrumentalities and combinations particularly pointed out in the appended claims.
SUMMARY OF THE INVENTION
In accordance with the purposes of the present invention, as embodied and broadly described herein, the present invention includes an apparatus for electron multiplication by transmission that is designed with at least one foil having a front side for receiving incident particles and a back side for transmitting secondary electrons that are produced from the incident particles transiting through the foil. The foil thickness enables the incident particles to travel through the foil and continue on to an anode or to a next foil in series with the first. The foil, or foils, and anode are contained within a supporting structure that is attached within an evacuated enclosure. An electrical power supply is connected to the foil, or foils, and the anode to provide an electrical field gradient effective to accelerate negatively charged incident particles and the generated secondary electrons through the foil, or foils, to the anode for collection.
BRIEF DESCRIPTION OF THE DRAWINGS
The accompanying drawings, which are incorporated in and form a part of the specification, illustrate the embodiments of the present invention and, together with the description, serve to explain the principles of the invention. In the drawings:
FIG. 1 is a pictorial illustration of a prior art discrete dynode electron multiplier
FIG. 2 is a pictorial illustration of a prior art continuous dynode electron multiplier
FIGS. 3 a and 3 b are pictorial illustrations of embodiments of the present invention foil electron multiplier.
FIGS. 4 a and 4 b , a cross-sectional view and face view, respectively, of one embodiment of foil, grid, and foil holder.
FIG. 5 graphically shows the gain produced with a foil electron multiplier having 2, 3, and 4 foil stages as a function of the applied voltage-per-stage.
FIG. 6 graphically shows the gain of a foil electron multiplier at an applied voltage-per-stage in the range of −650 V to −750 V.
DETAILED DESCRIPTION
A foil electron multiplier, in accordance with the present invention, uses a sequential series of thin foils in an evacuated enclosure that act to multiply electrons in a series of transmission stages. A voltage is applied to each foil to accelerate electrons emitted from the back of one foil to an energy level that effectively transmits the electrons through the next foil in the series, as well as generating secondary electrons that add on to the transmitted electrons and continue on to the next foil in the series. Thus, the present invention may be used for amplification of an incident electron flux or for detection of particles (e.g., photons, ions, electrons, and the like). Therefore, the present invention may be used in photomultiplier tubes and particle detectors, such as channel electron multipliers and microchannel plates. Channel electron multipliers and microchannel plates are used extensively in electron spectrometers, mass spectrometers, and photonic detectors, such as night vision devices.
Referring to FIGS. 3 a and 3 b , the foil electron multiplier comprises a series of thin foils 100 held by foil holders 105 in an evacuated enclosure 110 that form discrete multiplication stages. In a preferred embodiment, foils 100 are arranged collinearly, although it will be understood that foils 100 can be arranged in an array that is along an arc as shown in FIG. 3 b . Voltage 120 is applied to each foil 100 , so that secondary electrons 155 created by incident particle 150 are accelerated in a direction from first stage 102 of the multiplier through last stage 108 and collected onto anode 130 . The voltage on each stage can be applied, for example, by attaching electrical resistors 140 between adjacent stages to form a resistor divider string across the multiplier, or by attaching separate power supplies (not shown) to each stage. This results in an electric field having a positive gradient between adjacent foils that accelerates secondary electrons between successive stages in the multiplier.
If the foil electron multiplier is used in photomultiplier device, the anode could, for example, be a made from a scintillator material that converts electron energy to light. When using the foil electron multiplier as a detector, the anode is electrically connected to sensing electronics that measure the output charge or current deposited onto the anode. For example, a pulse of electrons resulting from a single particle that is incident on the foil multiplier can be directed into an electronic amplifier, whereupon the amplified pulse can be measured using detection electronics. As another example, an ammeter can measure the amplified current of a particle flux incident on the foil electron multiplier. Since the foil electron multiplier can span a large active area, a position-sensitive anode could provide position-sensitive information on where an incident particle impacted a stage of the foil electron multiplier.
Foil electron multipliers, as shown in FIGS. 3 a and 3 b , are defined as having N foils and a resistor divider between each foil with an applied voltage V APP , for N>1, such that the potential between individual stages is V S =V APP /(N−1). An incident particle (electron, ion, or photon) transits through the first foil and generates an average of γ I secondary electrons at the rear surface. The secondary electrons are then accelerated by the voltage V S between the first and second stages toward the second foil and are transmitted with a probability T SE through the second foil, where T SE depends on the foil thickness τ and accelerating potential V S . If an electron from the first stage successfully transits through the second foil and exits at an energy E, it will generate a second set of electrons at an average secondary electron emission yield equal to γ SE , where γ SE is a function of E, and, therefore, a function of foil thickness τ and accelerating potential V S . This electron multiplication process continues at each foil stage, resulting in a growing avalanche of electrons, which are finally deposited onto the anode.
The mean gain, G N , of the foil electron multiplier with N stages resulting from impact of a particle with the first stage is:
G N =T I T G γ I [T SE T G [γ SE +1]] N−1 (Equation 2)
where T I is the probability of incident particle transmission through the first foil. Often, the foil can be thin enough to require a supporting grid for structural integrity, and T G equals the transmission through such a grid of a single stage. The term T I T GγI corresponds to the mean number of secondary electrons generated at the first stage by the incident particle. The term T SE T G corresponds to the probability that a secondary electron successfully transits the second or subsequent stage, and the term (γ SE +1) corresponds to the mean number of secondary electrons exiting the second or subsequent stage.
Generally, the gain of a foil electron multiplier is maximized by:
1) maximizing the electron transmission T SE of electrons through the foil by operating at an applied bias V S such that the imposed electric field accelerates electrons to an energy level sufficient to allow the electrons to transit through the foil;
2) maximizing the transmission through the support grid T G by selecting a grid that provides required structural support but maximizes the grid open area; and
3) maximizing γ SE by optimizing the voltage per stage V S such that electrons transmitted through a foil exit the foil at an optimal energy for high secondary electron emission yield and by selection of a foil material having high secondary electron emission yield.
A preferred embodiment uses as thin of a foil as possible to minimize the required stage bias V S for electrons to transit a foil. However, a trade-off exists since an extremely thin foil may require a grid for structural support, which results in T G <1 and therefore a reduced gain.
Electrons are negatively charged as they traverse the foil electron multiplier. However, the charge on incident ions may change, because ions can exit a foil with a positive, neutral, or negative charge. If an incident particle exits a stage negatively-charged, the particle is accelerated by the imposed electric field to the next stage similar to an electron. If an incident particle exits a stage positively-charged, the particle will be decelerated by the imposed electric field, and may not transit the foil of the next stage absent sufficient momentum.
For the case of a negatively charged ion, positively charged ion with sufficient momentum, or electron incident on the foil electron multiplier, the ion or electron can transit several or all of the foils, initiating a new electron avalanche at each foil. The pulse of electrons deposited onto the anode therefore consists of all of the avalanches initiated by the ion or electron at each foil. Mathematically, the average total gain for incident particles that can transit all foils in the multiplier (T I =1) and can generate secondary electrons at each stage is represented by:
G = ∑ n = 0 N - 1 T G n G N - n ( Equation 3 )
where T G n equals the probability that the incident particle transits all grids before stage N−n. Therefore, Equation 2 can be rewritten as:
G = T G N T I γ I ∑ n = 0 N - 1 ( T SE ( γ SE + 1 ) ) n ( Equation 4 )
Equation 4 represents a series of N terms of increasing magnitude corresponding to additional stages of multiplication, such that each term increases by a factor equal to T SE (γ SE +1) relative to its previous term. For the limiting case in which the incident particle impacts only the first stage (n=N−1 only), Equation 4 reduces to Equation 2.
The gain advantage of the foil electron multiplier, which utilizes secondary electrons emitted from the rear surface of a foil, over conventional multipliers, which utilize secondary electrons emitted from the same surface that an incident electron impacts, lies in the term γ SE +1. First, the secondary electron yield from a primary electron exiting a foil typically should be greater than the secondary electron yield from a primary electron entering a surface, similar to ions transmitted through foils. Therefore, γ SE for a foil electron multiplier is likely to be larger than the secondary electron yield for a conventional electron multiplier. Second, a primary electron that generates secondary electrons at the exit surface of a foil stage also continues to the next stage with the secondary electrons that it generated. The continuation of the primary electron with the secondaries that it produces is represented as “+1” in the term γ SE +1 in Equation 4. This contrasts with conventional electron multipliers in which electrons that impact a dynode are typically absorbed in the dynode material and cannot contribute to further gain in the multiplier.
Ion feedback in electron multipliers, which is important primarily for continuous electron multipliers, results when an ion is created by the electron avalanche and the ion is accelerated in a direction opposite to that of the propagation direction of the electron avalanche due to the imposed electric field. The ion traverses a significant distance of the channel length toward the entrance end of the channel, impacts the channel wall, and initiates another electron avalanche. This results in two avalanches that collectively are observed at the anode as two individual pulses or a single pulse that is temporally long, both of which are generally not desired when the multiplier is used as a particle detector. This limitation can be resolved using curved channels such that an ion generated in a channel cannot travel far within the channel before it impacts the wall of the channel, so that the resulting ion-induced avalanche is nearly indistinguishable in time from the initial electron avalanche.
The present invention does not experience ion feedback. In the electron foil multiplier, ions generated at the input surface of a particular stage are accelerated toward the previous stage, but cannot penetrate the foil. These ions can initiate another avalanche, but this avalanche is generally indistinguishable in time from the initial avalanche.
Foil Electron Multiplier Design
The range of foil dimensions practiced for the present invention is from about 0.5 cm diameter (round) to 2×4 cm 2 (rectangular); although this range may be expanded or reduced depending on the application sought. In a preferred embodiment a round 1 cm diameter foil is used. The foil areal thickness can range from about 0.2 μg/cm 2 to about 2 μg/cm 2 . In a preferred embodiment the range is 0.2 to 1 μg/cm 2 .
Foil dimension and thickness characteristics are directly related to the material selected for foil composition. Using currently available commercial foils, such as those provided by ACF Metals, carbon provides the thinnest and most uniform foils; therefore, carbon is the preferred foil material. However, other materials can also be used, to include: silver, gold, chromium, and hydrocarbons such as Lexan®, and the like.
There is a trade-off between foil thickness and applied voltage: the thinner the foil, the lower the voltage required for the secondary electrons to transit the subsequent foil. In a preferred embodiment, an applied voltage of about −650 V per stage was found to be optimal for a 0.6 μg/cm 2 carbon foil. A thinner foil would require a lower applied voltage. The distance between foil stages is minimized to save volume, but must be large enough to withstand the applied voltage (i.e. no arcing between adjacent foil stages). A typical, conservative design for high voltage standoff is 1 mm per kV.
At the preferred foil areal thickness (0.2 to 1 μg/cm 2 ) it is not currently possible to span a commercial foil across an aperture without a supporting grid. Thus, a support grid attached to the foil holder and spanning the aperture is required. FIG. 4 displays a preferred embodiment of foil 100 , grid 103 , and foil holder 105 . The foil holder and grid, if required, may be made from any conductive material, such as metals or metal alloys, or semiconductors, or insulators with a finite resistance. Grid 103 may be attached to foil holder 105 by spot welding or may be designed as an integral part of foil holder 105 by using a standard lithography process to etch the grid windows into a sheet of foil holder 105 material. An exemplary embodiment of a support grid is a conductive frame with an attached 200 line-per-inch nickel grid.
For a self-supporting foil, the foil would need to be thicker and, therefore, the applied voltage per stage would need to be higher. However, as commercial fabrication techniques continue to improve, it may be possible to procure very thin, self-supporting foils.
Since a beam of energetic ions transmitted through a thin foil will scatter, and the magnitude of angular scattering increases with increasing foil thickness, measurement of the angular scattering distribution of a narrow beam of ions provides a simple and accurate method to estimate of the foil thickness. The foil electron multiplier was demonstrated using nominal 0.6 μg/cm 2 areal thickness carbon foils that are typically measured using angular scatter distributions of keV H + that relate approximately to a 1.5 μg/cm 2 areal thickness. A foil stage consisted of a conductive frame having a 5-mm-diameter aperture on which was attached a 200 line-per-inch nickel grid, which was used for structural support of the foil and had a transmission of approximately 78%. The commercially available grid was procured from Buckbee-Mears, Inc. A nominal 0.6 μg/cm 2 areal thickness carbon foil was affixed to the grid.
As shown in FIG. 3 a , the foil electron multiplier was constructed using a series of foil stages 100 followed by conductive anode 130 . Foil stages 100 were aligned in evacuated chamber 110 such that their apertures were collinear. Foil stages 100 were separated by a dielectric material (not shown) such that the spacing between adjacent foil stages was 5-mm. Anode 130 , which consisted of a conductive aluminum plate behind last stage 108 , collected electrons transmitted through and generated at last stage 108 .
Resistors 140 having a resistivity value of 450 MΩ were attached between adjacent foil stages and between last stage 108 and anode 130 . Note that the value of resistor 140 between last stage 108 and anode 130 can be much lower without change in detector performance, because the imposed electric field between last stage 108 and anode 130 is only used to direct the electrons from the exit of last stage 108 to anode 130 . However, a resistor equal in value to the other resistors in the resistor divider string was chosen for simplicity of calculating the voltage applied per stage. The input end of the multiplier was biased to a negative bias V APP 120 of 650 volts, and referenced to ground. Anode 130 was connected to an ammeter (not shown) that measured the output current of the multiplier.
In an evacuated chamber, a 2.7-mm-diameter 50 keV O + ion beam was first directed into a Faraday cup apparatus to measure the incident O + beam current I IN , and then directed into the input end of the foil electron multiplier. The output current I OUT from the foil electron multiplier was measured as a function of the applied voltage V APP . This was performed for foil electron multipliers configurations having 2, 3, and 4 foil stages.
The multiplier gain, which is defined as the ratio I OUT /I IN , is shown in FIG. 5 as a function of the applied voltage V APP for the multiplier configurations. As the applied voltage is increased, the multiplier gain increases to a maximum at an applied voltage of approximately 650 V per stage. This voltage corresponds to an energy sufficient for secondary electrons to transit a foil and exit with an energy at which they can efficiently generate secondary electrons at the exit surface. At V APP =0 V, only electrons generated at the exit surface of the last foil from incident O + that transits the last foil are measured, and the decrease in the gain for an increasing number of stages results from attenuation of the incident O + beam by the structural support grid in each stage.
FIG. 6 shows the maximum gain, that occurs at a voltage per stage of V S =V APP /N≈−650 V as a function of the number N of stages. On a semi-log plot, the data generally follow a straight line that infers a gain behavior described by Equations 1 through 4. The data was fit to Equation 4 using, for simplicity, the largest two terms n=N−1 and n=N−2 in the fitted equation. For T G =0.78, the fit resulted in T IγI =3.83 and T SE (γ SE +1)=1.88, which is shown as the solid line in FIG. 5 . The fit agreed well with the data, and the gain per stage T SE (γ SE +1)=1.88 is higher than the equivalent gain-per-stage equal to ˜1.37 of a microchannel plate detector. This higher gain per stage results in fewer required stages in a foil electron multiplier than a conventional electron multiplier.
These results demonstrate that the foil electron multiplier performs as described in Equations 1-4 and that a foil electron multiplier has a higher gain efficiency than conventional electron multipliers.
The foregoing description of the invention has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise form disclosed, and obviously many modifications and variations are possible in light of the above teaching.
The embodiments were chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and with various modifications as are suited to the particular use contemplated. It is intended that the scope of the invention be defined by the claims appended hereto.
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An apparatus for electron multiplication by transmission that is designed with at least one foil having a front side for receiving incident particles and a back side for transmitting secondary electrons that are produced from the incident particles transiting through the foil. The foil thickness enables the incident particles to travel through the foil and continue on to an anode or to a next foil in series with the first foil. The foil, or foils, and anode are contained within a supporting structure that is attached within an evacuated enclosure. An electrical power supply is connected to the foil, or foils, and the anode to provide an electrical field gradient effective to accelerate negatively charged incident particles and the generated secondary electrons through the foil, or foils, to the anode for collection.
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FIELD OF THE INVENTION
This invention relates generally to polarized connectors and, more particularly, to a keying element for configuring a connector to one of several allowed polarizations.
BACKGROUND OF THE INVENTION
Fiber Distributed Data Interface (FDDI) connectors are used for data transmission in, among other things, computer systems and particularly local area networks. Typical FDDI connectors include a connector body having an entrance at one end for receiving a fiber optic cable. The fiber optic cable breaks out inside the connector body into two separate optical fibers that are attached to, and terminate in, two ferrules. The connector body mates with one of several different receptacles including, for example, an active device receptacle, a transceiver adaptor, a dual ST-coupling, or an FDDI to FDDI coupling.
The receptacles typically include a spline cooperating with a connector key or polarizing element to ensure that the particular receptacle being used is compatible with the mated connector. See U.S. Pat. No. 5,166,995 to Weber, the teachings of which are specifically incorporated herein by reference. There are generally four basic keying formats in the American National Standards Institute (ANSI) protocol, that is the A, B, M ("Master")and S ("Slave") polarizations as disclosed in FDDI:X3.166-1990; ISO/IEC 9314-3 and X3T9.5/88-155 the teachings of which are hereby incorporated by reference. The polarizations are achieved by the size and placement the spline in the cooperating receptacle. For example, a connector polarized in the S configuration has a centrally disposed full width channel. The "A" polarization is a partial width channel located to the right of center, while the "B" polarization is a partial width channel located to the left of center. The "M" polarization is a partial width channel located at the center of the connector.
In order to avoid molding different connector bodies to accommodate the four different polarization possibilities, prior connectors have been designed with three separate and different keying elements that fit into the connector to configure the connector to the desired polarization. The connector housing itself has a full width central channel for the S polarization. To configure the connector to the A, B, or M polarizations, a polarizing key having an appropriately sized and placed channel is placed in the full width channel in the connector body. See, for example, U.S. Pat. No. 4,979,792, Weber et al. the teachings of which are incorporated herein by reference.
The keying system disclosed in the Weber patent requires multiple keys for each connector kit. In order to accommodate the possibility of changing connector polarizations, multiple unused keys must be retained together with the associated connector. See for example U.S. Pat. No. 4,979,792 to Weber et al. Keying systems having a single keying element for each polarization obviate the need to retain multiple unused parts. Single keys tend to be small making them difficult to manipulate. There is a need, therefore, for a single key polarization system that is easily manipulated for changing polarization modes.
SUMMARY OF THE INVENTION
It is an object of the present invention to provide a single polarization key that may be retained with the connector for all polarization positions.
It is an object of the present invention to provide a polarization key that is easily manipulated to change connector polarizations.
A polarized connector comprises a connector body having an opening. The opening receives a polarization key. The key comprises a substantially circular polarizing member having a longitudinal axis. The key is rotatable about the longitudinal axis within the opening.
It is a feature of the present invention that a single key provides for all available polarizations.
It is a feature of the present invention that a polarization key is rotated within an opening in a polarized connector to configure the connector.
It is an advantage of the present invention that a polarization key remains with the connector for all polarizations.
It is an advantage of the present invention that the polarization key is easily manipulated with standard instruments.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an perspective view of an FDDI connector having a key according to the teachings of the present invention.
FIG. 2 is an exploded, perspective view of the connector of FIG. 1.
FIG. 3 is an perspective view of the top half of the connector of FIG. 1.
FIG. 4 is an perspective view of the bottom half of the connector of FIG. 1.
FIG. 5 is a plan view of the bottom half of the connector shown in FIG. 4.
FIG. 6 is an perspective, top view of a preferred embodiment of a multimode polarization key according to the teachings of the present invention.
FIG. 7 is an perspective, bottom view of the polarization key of FIG. 6.
FIG. 8 is a plan view of the top surface of a multimode polarization key according to the teachings of the present invention.
FIG. 9 is a cross-sectional, side view of a polarization key according to the teachings of the present invention.
FIG. 10 is a view of the polarization key of FIG. 9 taken along the 10--10 line thereof.
FIG. 11 is an perspective, top view of a preferred embodiment of a singlemode polarization key according to the teachings of the present invention.
FIG. 12 is a plan view of the top surface of a singlemode polarization key according to the teachings of the present invention.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring now to the drawings wherein like reference numerals refer to like elements, polarized FDDI connector is shown in FIG. 1. While the present invention is particularly suited for FDDI style connectors and devices, it will be recognized by those with skill in the art that the polarized connectors and keys described and claimed herein will be useful for any connector which must operate according to multiple polarizations.
Connector 10 comprises a connector body 20 having a channel 190 with an opening 30 therein to receive a polarization key 40. The key 40 mechanically rotates in the opening 30 to an appropriate position to change the polarization of the connector 10. The connector 10 houses a fiber optic cable 50 protected by bend relief element 60 as is conventionally known in the art. Inside the connector 10, the fiber optic cable 50 is distributed and preferably terminates in at least two ferrules 70. The connector 10 mates with a receptacle (not shown) having a polarizing spline member. The connector 10 comprises a top half 80, shown in FIG. 3, and a bottom half 90, shown in FIG. 4, molded from a thermoplastic material such as polyester or nylon. The channel 190 and opening 30 are molded in the top half 80 of the connector 10 to receive the polarization key 40 therein. A bottom half 90 is molded with reciprocal receiving element 100 having a size and position corresponding to the opening 30. To assemble the connector 10, the terminated ferrules 70 and fibers 50 are placed in their respective positions in the bottom half 90 of the connector 10. The top half 80 of the connector 10 is latched to the bottom half 90 to form an FDDI connector as shown substantially in FIG. 1 with opening 30 and reciprocal receiving element in substantial alignment. Polarization key 40 is inserted into opening 30 and reciprocal receiving element 100 where the key may be rotated to complete the assembly.
With reference to FIGS. 3 and 4, the top half 80 of connector 10 has a full width channel 190 to cooperate with the spline in a mating receptacle (not shown). As known by those with skill in the art, the spline member cooperates with a channel in the connector to ensure that the particular receptacle is compatible with the mating connector. The connector 10, therefore, is intrinsically configured for the S polarization without a polarizing element. The FDDI polarizations for multimode fiber are termed A, B, M, and S polarizations and represent the four basic polarization formats for multimode fiber. The FDDI polarizations for singlemode fiber are termed SA, SB, SM, and SS polarizations and represent the four basic polarization formats for singlemode fiber.
With reference to FIGS. 6, 7, 11, and 12, polarization key 40 comprises a polarization member 235 having a profiled top surface 240. The profiled top surface 240 provides three of the four different polarizations in accordance with the ANSI standard for either multimode or singlemode fiber. The polarization member is received by opening 30 and rotates therein to configure the connector from the intrinsic S polarization to one of the A, B, or M polarizations. The top half 80 of the connector 10 has an alignment arrow 191 molded in relief in the channel 190 and pointing toward the opening 30. The polarization member 235 has cooperating alignment markers 192 and polarizations labels 193 for each polarization. For example, for the M polarization configuration, the polarization member 235 is rotated until alignment marker 192 associated with polarization label 193 aligns with alignment arrow 191. The profiled top surface 240 presents a partial width channel central to the full width channel 190. Opposite sides of the polarization member 235, therefore, interfere with the full width of the channel to prevent a receptacle configured in the S polarization to mate with a connector configured in the M polarization. A connector having the polarizing member 235 positioned for the M configuration will mate only with a partial width central spline (corresponding to an M receptacle configuration). Similarly, for the A and B polarizations, the polarization member 235 is rotated until the respective alignment markers 192 align with the alignment arrow 191 in which a partial width left or right of center channel is presented to a cooperating spline in a mating receptacle.
The reciprocal receiving element 100 comprises a landing 200 and a pair of secondary boss members 210. The secondary boss members 210 are separated by a cutout portion 230. Secondary boss members 210 and cutout portion 230 are molded in the reciprocal receiving element 100 at a lower position than the landing 200, and are adapted to interact with surfaces on the polarization key 40 when the FDDI connector is set to the S configuration. The bottom of polarization member 235 is stepped having first bottom surface 260 in a different but parallel plane to a second bottom surface 270. In the S configuration, the bottom surfaces 260,270 interfit with the reciprocal receiving element 100. The first bottom surface 260 engages the landing 200 and a second bottom surface 270 engages the boss members 210. In this position, the polarization member 235 is recessed into the connector 10 and top surface 240 is flush with the floor of channel 190. With the polarization member recessed in this manner, the connector presents the full width channel intrinsic to the connector to a mating receptacle. The polarization key 40, therefore, remains installed in the connector for the S polarization and does not interfere in the channel 190.
With reference to FIG. 5 which is a plan view of the bottom half 90 of the connector, a post 220 is molded in each boss member 210 and extends upwardly therefrom. The polarizing member 235 has a pair of slots 310 oriented 90 degrees from each other. The slots 310 receive the posts 220 in reciprocal receiving element 100 in a friction fit when the polarization member 235 is in the S position. The cooperation between the posts 220 and the slots 310 serves to retain the recessed polarization member 235 in reciprocal receiving element 100 through frictional interference for the S polarization. The top of posts 220 are coplanar with the landing 200. When the polarization member 235 is in the A or B configurations, half of first bottom surface 270 rests on the landing. The other half of first bottom surface 270 rests on one of the posts 220 for reasons of polarization member 235 stabilization. When the polarization member 235 is in the M configuration, the entire surface 270 rests on the landing 200.
The polarization key 40 further comprises a shaft 280 that extends substantially from the bottom surfaces 260,270 of the polarization member 235 downward through the connector 10 and into the reciprocal receiving element 100. The shaft 280 is slotted at 300, extends through the bottom half 90 of the connector 10 and is externally exposed. A flat-edged screwdriver or other instrument may be interfaced with the slotted shaft 280 to rotate the polarization key 40. An outer edge of shaft 280 is preferably bevelled at 340 to permit insertion of the polarization key 40 into opening 30 and reciprocal receiving element 100. The shaft 280 has four detents 320 equally spaced on its outer periphery. The detents 320 resiliently press against the inner wall of the reciprocal receiving element 100 in a frictional interference fit.
A locking projection 290 is positioned on the shaft 280 at an end opposite the polarizing member 235. The locking projection 290 fits within the cutout portion 230 in the reciprocal receiving element 100 when the key 40 is placed in the default or S position. When the key 40 rotates to the A, B, or M polarizations, the locking tab 290 passes below the secondary boss members 210 preventing disassociation of the key 40 from the connector 10. It will be recognized that the polarization key 40 is molded from a similar material as the connector 10, that is, a polyester or equivalent material. In a preferred embodiment, a polyester material is used to mold the polarization key and FDDI connector and is sold under the trademark VALOX, available from the General Electric Company.
There have thus been described certain preferred embodiments of polarized connector and polarization keys provided according to the teachings of the present invention. While preferred embodiments have been described and disclosed, it will be recognized by those with skill in the art that modifications are within the true spirit and scope of the invention. The appended claims are intended to cover all such modifications.
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A polarized connector comprises a connector body having an opening for receiving a polarization key. The key comprises a polarization member and slotted shaft rotatable in the opening about a longitudinal axis. The slotted shaft permits user access to the key to rotate the key within the opening in the connector. The polarized connectors described herein permits simple polarization changes with a single key element that is retained with the connector for all polarization configurations.
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[0001] This application claims the benefit of U.S. provisional application Ser. No. 60/988,952, filed Nov. 19, 2007.
FIELD OF THE INVENTION
[0002] The present invention relates to electrical generating systems for horizontal directional drilling systems.
BACKGROUND OF THE INVENTION
[0003] Horizontal directional drilling (HDD) operations are used in drilling for utilities such as water and telephone lines. In HDD, the boreholes are shallow and typically extend under roads, rivers and other obstacles. To drill the borehole, a drill string is equipped with a drill bit. The drill string is rotated and forced through the ground. Fluid in the form of water or drilling mud is circulated through the drill stem, out the drill bit and back to the surface on the outside of the drill stem.
[0004] Drill stems or strings typically contain a sonde. The sonde is located near the drill bit and transmits a signal. One such sonde is shown and described in U.S. Pat. No. 5,155,442. An operator on the surface above the drill bit has a receiver and can receive the signal. Sonde information is used to guide and steer the drill bit and consequently guide and steer the borehole.
[0005] The sonde requires electrical power to operate. In the prior art, this power is generated by one of seven ways.
[0006] One of the primary ways to supply power downhole is simply through the use of batteries. This system is used in some of the sondes offered by Digital Control Inc. or Charles Machine Works. These batteries have a lifespan that varies, but a typical lifespan is less than 20 hours. The problem with this is that these batteries often fail during the drilling operation. Pulling the drill stem out of the bore and replacing the batteries increases the cost of drilling. Also, batteries need frequent changing requiring operator time to access the sonde. Also once these batteries are “used up” they are thrown away, contributing to a more toxic environment.
[0007] A second way to supply power to the electrical components downhole is to thread a conductive wire through the center of the drill stem. This method is known as a wireline system. This wire supplies electrical power from a power source on the surface. In order to use this system the wire has to be extended through each drill stem as the bore is lengthened. This is done by connecting additional lengths of wire in the I. D. of the stem and then encasing the connection in a protective wrap. U.S. Pat. No. 5,577,560 refers to this type system. This system is very time consuming and cannot be done on some drill rigs.
[0008] A third power supply system uses impellers rotated by the flow of drilling fluid. U.S. Pat. Nos. 7,165,608 and 7,133,325 show this type generating system. A simple generator is sealed off from the drilling fluid while its rotor is turned by the flow of drilling fluid. This system is relatively expensive to produce and is subject to break downs because of the corrosive nature of the drilling fluids.
[0009] A fourth way of generating electrical power is disclosed in U.S. Pat. Nos. 6,857,484 and 5,957,222. These systems have a generator that is lateral to the drill stem and engaged with the drill by gears. As the drill stem rotates, the generator produces power. These systems are relatively expensive.
[0010] A fifth way to generate power downhole is to use a dual drill stem system as does Charles Machine Works as described in U.S. Pat. Nos. 6,857,484 and 7,025,152. This system utilizes a drill string inside of a drill string extended to the surface to activate the elements of a typical generator. Again this system is quite expensive.
[0011] A sixth way is a linear generator which is included in a shock absorber together with the other subsurface components. Details of the linear generator included in a shock absorber can be found in U.S. Pat. No. 3,448,305. This system is expensive and very unwieldy in a drill string.
[0012] A seventh system uses responsive means that uses a piezo-electric disc connected to rectifying and smoothing circuits whereby a D.C. output is obtained. For example, U.S. Pat. No. 3,970,877 discloses a method for generating downhole electric energy using a means responsive to turbulence in the drilling mud flow to convert vibratory motion into an electrical output. This system does not produce an adequate amount of power.
SUMMARY OF THE INVENTION
[0013] The present invention provides an electrical generating system for use in a horizontal directional drilling system. The drilling system has a generally horizontal drill stem that rotates. The electrical generating system comprises a generator and an eccentric mass. The generator has first and second components. The first component is coupled to rotate with the drill stem. The second component is capable of relative rotation with respect to the first component. One of the first and second components comprises an armature and the other of the first and second components comprises a field. The eccentric mass is mounted inside of the drill stem so as to rotate therein. As the drill stem rotates, the eccentric mass can remain stationary. The eccentric mass is coupled to the second component, wherein when the drill stem rotates, relative rotational motion is produced between the first and second components and the generator produces electrical power.
[0014] In accordance with one aspect of the present invention, a transmission is provided. The transmission has an input and an output. The eccentric mass is coupled to the transmission input and the second component is coupled to the transmission output.
[0015] In accordance with another aspect of the present invention, the second component counter-rotates relative to the first component.
[0016] In accordance with still another aspect of the present invention, a sonde is electrically coupled to the generator.
[0017] In accordance with still another aspect of the present invention, the second component comprises a rotor.
[0018] In accordance with still another aspect of the present invention, the eccentric mass further comprises two spaced apart mounting points where the mass is rotatably mounted to the drill stem.
[0019] In accordance with still another aspect of the present invention, flow channels are provided for drilling fluid flowing through the drill stem.
[0020] In accordance with still another aspect of the present invention, the eccentric mass is held relatively stationary by gravity.
[0021] In accordance with still another aspect of the present invention, an electrical regulator is electrically connected to an output of the generator.
[0022] In accordance with still another aspect of the present invention, the electrical regulator is connected to a load, the regulator connecting the load to the generator output when the generator produces a voltage that exceeds a predetermined threshold.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] FIG. 1 is an isometric view of the counterbalance enabled power generator.
[0024] FIG. 2 is an isometric view of the sonde showing a portion cutaway to reveal a battery cavity.
[0025] FIG. 3A is an isometric view of the rechargeable power source showing one end.
[0026] FIG. 3B is an isometric view of the rechargeable power source showing the other end.
[0027] FIG. 4A is an isometric view of the generator.
[0028] FIG. 4B is an end view of the generator.
[0029] FIG. 4C is a cross sectional view taken along the lines M-M of the generator of FIG. 4B .
[0030] FIG. 5A is an isometric view of the speed convertor showing hidden lines.
[0031] FIG. 5B is a side view of the speed convertor showing hidden lines.
[0032] FIG. 6A is an end view of the eccentric mass.
[0033] FIG. 6B is a side view of the eccentric mass.
[0034] FIG. 6C is an isometric view of the eccentric mass
[0035] FIG. 7 is a block diagram of the electrical components of the counterbalance enabled power generator.
[0036] FIG. 8 is a block diagram of the electronic regulating circuitry.
[0037] FIG. 8A is an isometric view of the circuit board.
[0038] FIG. 9A is an isometric view of the case system.
[0039] FIG. 9B is a side view of the case system.
[0040] FIG. 9C is a cross sectional view taken along the lines J-J of the case system of FIG. 9B .
[0041] FIG. 10A is an isometric view of the sonde housing.
[0042] FIG. 10B is an end view of the sonde housing.
[0043] FIG. 10C is a cross-sectional view of the sonde housing taken along the line N-N of FIG. 10B .
[0044] FIG. 11A is an end view of the counterbalance enabled power generator.
[0045] FIG. 11B is a cross-sectional view of the counterbalance enabled power generator taken along the lines P-P of FIG. 11A .
[0046] FIG. 12A is an exploded isometric view of the counterbalance enabled power generator.
[0047] FIG. 12B is an isometric view of the counterbalance enabled power generator.
[0048] FIG. 13A is an exploded isometric view of the counterbalance enabled power generator and the sonde housing.
[0049] FIG. 13B is a side view of the counterbalance enabled power generator and the sonde housing.
[0050] FIG. 13C is a cross sectional view of the counterbalance enabled power generator and the sonde housing taken along the line F-F.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0051] The present invention is used in a drill stem for Horizontal Directional Drilling (HDD). HDD is used to drill horizontal boreholes close to the earth's surface. Such boreholes extend, for example, under roads, buildings, and rivers, and are used to bury utilities, such as telephone and water lines.
[0052] The present invention utilizes generator components to generate electrical power downhole for the purpose of providing continuous power to a sonde in a drill stem. With the present invention a rechargeable power source (RPS) is charged and recharged whenever the drill string is rotated. The sonde draws electrical power from the rechargeable power source. Alternatively, the sonde could draw power, directly from the generator components with or without drawing power from the rechargeable power source, or from a combination of the generator components and a non-rechargeable power source.
[0053] The generator is driven by the rotation of the drill stem. The generator body or stator is connected to the drill stem, so that when the drill stem is rotated the generator stator is rotated. The rotor of the generator is attached to an eccentric mass. The eccentric mass and rotor are stationary, due to the effects of gravity, as the drill stem rotates. This relative rotation between the rotor and the stator produces electrical power.
[0054] The electrical power from the generator is provided to appropriate electrical devices that regulate and modify the current in such a way as to provide a suitable output for charging and recharging a rechargeable power source. These electrical components are generally attached to the generator so that all connections are relatively solid.
[0055] The drill stem is generally horizontal as the borehole is drilled. The borehole begins at the surface, extends down on a slope to some depth, extends at or near that depth may change depths to avoid obstacles and extends back to the surface on a slope. In all of the various positions of the borehole, the drill stem is said to be horizontal. The borehole is relatively shallow as its objective is to traverse a horizontal distance. Contrast this with an oil well borehole; its objective is to achieve access to a formation at some depth.
[0056] FIG. 1 shows a preferred embodiment of the counterbalance enabled power generator unit 1 of the present invention. The generator unit 1 couples to a sonde 2 . The generator unit 1 and sonde 2 are located within a housing 9 (see FIGS. 13A-13C ). The housing 9 is connected in line with a drill stem; the housing 9 forms part of the drill stem. The housing 9 is typically located close to the drill bit. In the preferred embodiment, the housing 9 is connected to the drill bit or a drill bit sub.
[0057] The sonde 2 , which is conventional and commercially available, is shown in FIG. 2 . The sonde 2 transmits a radio signal that is picked up by a receiver on the surface. The sonde 2 has a body 2 A and a cavity 2 B at one end for receiving a power supply. In FIG. 2 , the sonde is shown partially cut away to show the cavity 2 B. The cavity 2 B has threads 2 C on its outer end. The threads 2 C and the body 2 A act as a ground for the flow of electricity. The opposite end of the cavity 2 B has the positive terminal 2 D for the sonde 2 . The sonde 2 is turned on once power is provided. Some sondes may have an on-off switch. If so, the sonde is turned on before it is placed in its housing. Once turned on, the sonde operates continuously. Sondes may have an automatic shut-off. For example, if the sonde stops rotating for a predetermined period of time, such as when drilling has stopped, the sonde will automatically turn off. As another example, some sondes have a park position, where if the sonde is oriented at a particular clock position (with respect to the axis of rotation of the drill stem) for a predetermined period of time, it turns off. If the sonde is automatically turned off, it will turn back on once rotation of the drill stem resumes.
[0058] FIGS. 3A and 3B show the conventional and commercially available rechargeable power source 3 with a positive terminal 3 A and a negative terminal 3 B. As discussed below, the power supply 3 is contained within an end of a case, which is in turn located in the cavity 2 B.
[0059] The generator unit 1 includes a generator 4 , a transmission 5 , an eccentric mass 6 , electronics 7 and a case 8 (see FIG. 11B ).
[0060] FIGS. 4A-4C shows the generator 4 which is conventional and commercially available. I have chosen to use a three phase alternating current generator 4 because of their commercial availability. The generator 4 has a stator 4 A and a rotor 4 B. At least one of the rotor 4 B or the stator 4 A has conductive windings that form an armature, while the other of the rotor 4 B or the stator 4 A has magnets that form a field. The magnets can be permanent magnets or electromagnets, Relative rotation of the stator 4 A to the rotor 4 B produces electrical power. Electrical leads or conductors 4 C extend out of the generator 4 . The rotor 4 B has a shaft that extends therefrom. In addition, using a generator allows electrical power to be produced when the drill stem is rotated in either direction. While traditionally the drill stem is rotated only in a clockwise direction, there are instances when it is rotated counter-clockwise, such as to carve a hole.
[0061] FIGS. 5A and 5B show the transmission or speed convertor 5 . Said transmission 5 is desirable to be used with the particular generator 4 because of the relative low rotation speed of the drill stem. The transmission 5 is of the planetary gear type and obtains relative high rotational speeds between the rotor 4 B and the stator 4 A by counter rotating the rotor 4 B relative to the stator 4 A and the drill stem. For example, if the drill stem rotates clockwise, the rotor 4 B rotates counterclockwise. The transmission 5 is conventional and commercially available and has a transmission body 5 C, rotational input component 5 A and an output component 5 B. In this configuration the output component 5 B rotates at a higher revolution than the input component 5 A. Both the output component 5 B and the input component 5 A rotate relative to the transmission body 5 C. The body 5 C is coupled to the drill stem so as to rotate in unison therewith. The ring gear of the transmission 5 is coupled to the body 5 C. The transmission 5 can be one or more stages. In the preferred embodiment, a single stage has a speed ratio of about 10:1, while a two stage has a speed ratio of about 15:1.
[0062] FIGS. 6A-6C shows the eccentric mass 6 . The eccentric mass 6 acts as the counterbalance in the counterbalance enabled power generator 1 . The eccentric mass 6 is composed of relatively high specific gravity material, such as lead or tungsten, and has a center of gravity 6 A, that when installed into the counterbalance enabled power generator 1 , is not on centerline of the input shaft 5 A of the transmission 5 (or if no transmission is used, is not on the centerline of the generator rotor 4 B). In this embodiment the body of the mass is semi-cylindrical in cross-section and has supports 6 B at each end. The supports 6 B are along the axis of rotation of the transmission input shaft 5 A, while the body center of gravity 6 A is offset from the axis of rotation of the input shaft of the transmission 5 or the generator rotor 4 B. In the preferred embodiment, the supports 6 B are close to being coaxial with the axis of rotation of the drill stem. As a practical matter, the portion of drill stem containing the eccentric mass may rotate about an axis that is different than the centerline of that drill stem portion. Nevertheless, the eccentric mass can still operate properly. The size or magnitude of the mass can vary depending on several factors. The mass should be at least large enough to hold the transmission input shaft 5 A stationary (or rotor 4 B stationary or provide reverse rotation). A larger electrical load may require a larger mass, as the load will have a tendency to exert a stronger rotational force on the rotor. A larger speed ratio in the transmission may also require a larger mass as the mechanical load is greater. Also, the amount or distance of offset of the center of gravity of the mass from the axis of rotation of the input of the transmission is a factor. The larger the offset, the less the mass can be. If need be, the housing surrounding the mass can be enlarged in diameter to accommodate a larger offset. In the preferred embodiment, the mass and offset are sized so that the transmission input shaft 5 A is stationary (or rotor 4 B stationary or providing reverse rotation) under a variety of circumstances. In the preferred embodiment, the product of the size or magnitude of the mass and the distance of its center of gravity from the axis should be at least larger by a factor of 1.5 than the resistant torque on the rotor 4 B.
[0063] FIG. 7 is a block diagram of the electrical components 7 of the counterbalance enabled power generator 1 . The generator 4 is connected to electronic circuitry 7 , which will be described in more detail with reference to FIG. 8 . The electronic circuitry 7 rectifies, and regulates the output of the generator 4 . The electronic circuitry 7 is connected to the rechargeable power source 3 , which in turn is connected to and provides power to the sonde 2 .
[0064] FIG. 8 is a block diagram of the electronic circuitry 7 . The output wires 4 C from the generator 4 are connected to a rectifier 7 A. The rectifier converts the ac output of the generator into dc and smoothes the dc. A filter 7 B also serves to smooth and clean the dc. A regulator 7 C supplies electrical power to the battery 3 . When the drill stem is at rest, and then begins to rotate, there may be a tendency for the eccentric mass to rotate. To minimize this, the regulator connects the load (the power supply 3 or the sonde 2 ) to the generator only after the generator output voltage exceeds a predetermined voltage (for example 4.2V). This allows the generator to start up under a no-load condition. In addition, the regulator properly charges the power supply 3 and does not overcharge the power supply.
[0065] FIGS. 9A-9C shows the thermally conductive and corrosion resistant case system 8 . The case system 8 is designed to house and protect all of the various components 3 - 7 . The case system 8 has four sections. A rechargeable power source section 8 A covers the rechargeable power source 3 . The threaded circuit board section 8 B covers the electronic circuitry 7 , acts as a ground for the flow of power to the sonde 2 , and is a waterproof coupling between the sonde 2 and the counterbalance enabled power generator 1 . The external threads on section 8 B provide the coupling. Case section 8 C covers the generator 4 and the transmission 5 . Mass section 8 D covers and supports the eccentric mass 6 . The sections 8 C and 8 D are designed to maximize their thermal transfer properties. This is done by using high thermally conductive material and maximizing their surface area by fluting 8 E their exteriors. The end 8 F acts as the positive terminal of the counterbalance enabled power generator 1 .
[0066] FIGS. 10A-10C shows a sonde housing 9 is designed to house the counterbalance enabled power generator 1 . The sonde housing 9 is designed to allow a cooling medium such as the drilling fluid used to drill the borehole to flow around and cool the case system 8 and the counterbalance enabled power generator 1 contained therein. The front end 9 A of the sonde housing 9 attaches solidly to a drill bit (not shown). The rear end 9 B of the sonde housing 9 attaches solidly to a drill string (not shown) and thus to a drill rig (not shown). Cavity 9 C is designed to accept the sonde 2 and is somewhat larger in diameter than the sonde 2 . Cavity 9 D is designed to accept the circuit board section 8 B and the generator section 8 C of the case system 8 . The cavity 9 D is somewhat larger in diameter than the circuit board section 8 B and generator section 8 C of case system 8 . Cavity 9 E is designed to accept the mass section 8 D. The cavity 9 E is somewhat larger in diameter than the mass section 8 D. The sonde housing 9 has numerous elongated slots 9 F cut into its outer walls for the transmission of signals from the sonde 2 to the drill rig operator. The elongated slots 9 F are filled with a substance that forms a water tight seal, acts as flexible support for the sonde 2 and also allows signals to exit from the interior of the sonde housing 9 .
[0067] FIGS. 11A and 11B show a completed assembly of the counterbalance enabled power generator 1 . The rechargeable power source 3 , the electronic circuit 7 , the generator 4 , and the transmission 5 are attached to the case system 8 so as to rotate therewith. The eccentric mass 6 is not rotationally attached to the case system 8 and is free to remain stationary, due to the effects of gravity, as the case system 8 rotates with the drill stem.
[0068] Referring to FIGS. 7 , 8 , 11 A and 11 B, the positive terminal 3 A of the rechargeable power source 3 is conductively attached to the positive terminal 8 F of the case system 8 and to the positive output terminal of the electronic circuit 7 . The negative terminal 3 B of the rechargeable power source 3 is conductively attached to the negative terminal 8 B of the case system 8 and to the negative output terminal on the electronic circuit 7 . The electrically conductive leads 4 C of the three phase AC generator 4 are conductively attached to the rectifiers 7 E located in the electronic circuit 7 . The rotor 4 B of generator 4 is rotationally attached to the output component 5 B of the transmission 5 . The body 5 C and the stator 4 A are attached to the section 8 C of the case system 8 . The input component 5 A of the transmission 5 is rotationally attached to the eccentric mass 6 such that the center of gravity 6 A is not on the center line of the input component 5 A of the transmission 5 . The eccentric mass 6 is supported by bearings 10 located in the case system 8 .
[0069] FIGS. 12A and 12B show the counterbalance enabled power generator 1 attached to the sonde 2 (the sonde is shown partially cut-away to reveal the rechargeable power source section 8 A). This configuration allows the counterbalance enabled power generator 1 to power the sonde 2 . The rechargeable power source section 8 A of the case system 8 of the counterbalance enabled power generator 1 is inserted into the cavity 2 B of the sonde 2 , causing the positive terminal 8 F to contact the positive terminal 2 D and the threads 2 C are then mated to the threads 8 B making the negative ground.
[0070] FIGS. 13A-13C shows the counterbalance enabled power generator 1 attached to the sonde 2 solidly installed in the sonde housing 9 .
Operation
[0071] Once the sonde housing 9 is fitted onto the drill string and an appropriate drill bit is fitted onto the opposite end of the sonde housing 9 , drilling can commence. During drilling, the drill string rotates and is thrust into the ground. As the drill string rotates, the sonde housing 9 rotates, as does the sonde 2 and most of the components of the counterbalanced enabled power generator 1 . In particular, the following components rotate: the rechargeable power source 3 , the electronic circuit 7 , the stator 4 A and the body 5 C of the transmission 5 . The case system 8 rotates in conjunction with the sonde housing 9 and the drill stem. A pin (not shown) extends from the sonde housing 9 into a receptacle in the sonde 2 . The pin both orients the sonde 2 and prevents it from rotating. In addition, o-rings are provided around the case system 8 to create friction and prevent rotation as well as providing cushioning. In addition, pins can be provided elsewhere to prevent rotation.
[0072] The transmission input shaft 5 A is held relatively rotationally stationary by the eccentric mass 6 . The eccentric mass 6 is supported on bearings which allow it to not rotate when the case system 8 and the other attached components rotate. The eccentric mass 6 is held relatively rotationally stationary inside of the case system 8 due to gravity. The drill stem and consequently the case system 8 are more horizontal than vertical. Thus, the drill stem rotates about the eccentric mass 6 . As the body 5 C of the transmission 5 rotates and the input shaft 5 A is held rotationally stationary, the output component 5 B rotates in the opposite direction, or counter-rotates, relative to the body 5 C. The rotor 4 B, which is coupled to the output component 5 B likewise counter-rotates with respect to the stator 4 A. Thus, there is relative rotation between the rotor 4 B and the stator 4 A, and electrical power is produced. The electrical power is transferred via the electrically conductive media 4 C to the electrical circuit 7 .
[0073] In the preferred embodiment, the drill string rotates at 85-300 rpm, with about 150 rpm being typical. The generator 4 requires a relative speed ratio between the rotor 4 B and the stator 4 C of about 1000:1 to produce an adequate supply of power. Some generators may work satisfactorily without the rotor counter-rotating relative to the stator. Also some generators may have the rotor held stationary directly via the counterbalance foregoing the transmission. This still produces relative rotation between the rotor and stator.
[0074] Referring to FIG. 7 the electrical power produced by the generator 4 is restricted and regulated by the electric circuit 7 and is used to charge the power supply 3 and power the sonde 2 .
[0075] Thus, the sonde can operate for extended periods of time, without the need to replace the power supply. The drill stem need not be pulled from the hole to replace batteries, as required in the prior art. Furthermore, the sonde can transmit a stronger signal. Such signal transmission requires more electrical power, and in the prior art required either expensive specialized batteries, or frequent battery changes.
[0076] In the preferred embodiment, the generator 4 produces a more power than what the sonde 2 requires. For example, the sonde 2 may draw 300 mA, while the generator 4 produces 600 mA. The drill string does not always rotate; therefore, the generator 4 has the power to operate the sonde 2 and charge the rechargeable power source 3 while the stem is rotating. Alternatively the generator 4 recharges the rechargeable power source 3 faster than it is drained by the sonde 2 .
[0077] During drilling operations, water circulates around the case system 8 . In particular, the water flows in the flutes 8 E, beneath the o-rings. The water serves to cool the counterbalance enabled power generator 1 . The water also flows to the drill bit for assisting in the cutting by carrying away tailings and cooling the drill bit.
[0078] During the commencement of drilling operations, the electronic circuit 7 regulates the load on the generator 4 in order to maintain the eccentric mass 6 in a relatively rotationally stationary position. This is known as a soft start up. As the drill string begins to rotate, there may be a tendency for the eccentric mass 6 to rotate as well, due to friction in the bearings 10 . The friction in the bearings 10 is quickly overcome by continued rotation of the drill string. The load on the generator 4 is non-existent because of the electronic circuit 7 , which does not draw a load until the generator produces more voltage than the rechargeable power source requires. Because the load on the generator is non-existent during the commencement of drilling, there is little “drag” on the rotor 4 A and the eccentric mass 6 , wherein the eccentric mass 6 can remain relatively rotationally stationary.
[0079] The foregoing disclosure and showings made in the drawings are merely illustrative of the principles of this invention and are not to be interpreted in a limiting sense.
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An electrical generating system is used for a horizontal directional drilling system. The drilling system has a generally horizontal drill stem that rotates. A generator has first and second components. The first component rotates with the drill stem, while the second component is able to rotate with respect to the first component. An eccentric mass is rotatably mounted inside of the drill stem and is coupled to the second component, wherein as the drill stem rotates, relative rotational motion is produced between the first and second components and the generator produces electrical power. The eccentric mass is mounted on two spaced apart mounting points inside of the drill stem. The generator provides power to a sonde. The generator is in a housing which has flow channels that allow drilling fluid to flow through the drill stem.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims the priority of German Application Nos. 100 18 798.6 filed Apr. 15, 2000 and 100 57 765.2 filed Nov. 22, 2000, which are incorporated herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to a latch needle, particularly for knitting machines and more particularly for circular knitting machines.
Latch needles are utilized, for example, in circular knitting machines. At one end the latch needles have a hook, adjoined by a latch which is pivotally supported in a sawslot of the latch needle. The latch is arranged in such a manner that in its closed state it lies at or on the end of the hook and closes the trapping space partially bounded by the hook. In its open state the latch is swung back to rest on its back and thus opens the trapping space. Such latch needles which are present in large numbers in knitting machines, are supported in needle beds in which, during operation of the knitting machine, they are rapidly reciprocated in their longitudinal direction. During this occurrence, the latches snap open and closed. For this purpose they have to move easily which, as a rule, requires a certain lateral play between the latch and the needle.
During the knitting operation the hook of the latch needle captures a thread while the needle executes its reverse stroke. A thread which is located behind the latch situated in its reverse state, lies on the upper side of the needle and first closes the latch. Upon further needle motion the thread slides off the hook resulting in the formation of a loop. The thread captured by the hook during this occurrence must be able to slide in the inner hook space and the trapping space must be closed by the latch. Only upon the successive movement of the needle in the opposite direction may the thread slide out of the inner hook space, opening the catch and the trapping space. If the latch is lifted from the hook earlier and thus the trapping space is opened and the thread moves out of the trapping space between the hook tip and the latch, loops will be dropped, resulting in a defective knit of unacceptable quality
Latch needles are also frequently used to produce dual-thread knits. To ensure that such knits have a uniform appearance, it is of the utmost importance that the threads do not switch their sequence in the trapping space of the latch needle. Dual-thread knits, so-called plated knit goods, are manufactured frequently with a combination of unlike threads, for example, a natural fiber yarn and an elastomer thread. In such a product the elastomer thread should, as a rule, be situated on that side of the product which is not visible (that is, on the reverse side of the item). Such a requirement is not fulfilled if the threads switch position. Such an occurrence results in an undesired pattern because, as a rule, the two threads have different shapes and/or color as well as other different properties.
Further, particularly monofilaments, such as elastomer threads are reacting very strongly to damages. Deep surface scratches must be definitely avoided, since even the slightest damage to the thread surface may lead to thread breakage.
Latch needles are known, for example, from German Patent No. 1,069,812. The latch needle has a pivotally supported latch, whose latch spoon (noucat) is provided with a groove for receiving the hook tip. The latch is linear along its inner contour which bounds the trapping space in the closed state of the latch and in the closed state the inner contour of the latch adjoins directly the hook tip.
Right-left circular knitting machines, that is, unifacial circular knitting machines have a sinker ring with hold-down sinkers instead of a dial. Such a ring or sinkers are needed to hold the knit product. For this purpose the sinkers, when the knitting machine needles are in their respective uppermost position, are moved past the loop forming portion of the needle and hold down the last-formed loop. During operation the knitting machine needles are exposed to a high degree of wear, for example, because of the high operating speed of the knitting machine, because of the yarns to be handled, or because of abrasive wear or other effects. The wear in most cases leads to an ever-increasing play in the latch bearing both in the axial and the radial direction resulting in lateral excursions of the latch during operation. The Coriolis force which is generated at the latches by the rotation of the cylinder of the knitting machine may amplify the lateral excursion of the latches of the knitting machine needles. If the lateral excursion of the latches is greater than the play between sinker and latch, the two frictionally engage one another, leading to lateral abrasions of the latch head.
Grooved needle latches as described in the above-noted German Patent No. 1,069,812 are particularly prone to such a wear which causes the originally rounded latch head to be transformed into a latch spoon having a groove with sharp edges. These may damage the threads which may lead to a rupture particularly of threads which break or tear relatively easily, such as elastomer threads.
German Offenlegungsschrift (application published without examination) No. 28 34 558 discloses a needle in which the needle hook is provided with a groove. Thus, the needle has a grooveless latch spoon and the latch head is configured such that it is accommodated by the deep groove in the needle hook when the latch is in its closed state. The inner contour of the closed trapping space, bounded by the hook and the latch, has at its transition from the latch to the hook a projection which prevents a thread motion within the inner space defined by the hook.
Such latch needles too, behave critically when simultaneously a plurality of threads are processed, such as, for example, during the manufacture of dual-thread knits.
British Published Patent Application No. 2,232,689 describes a latch needle for dual-thread knits. The latch needle has a pivotally supported latch which at its inner side is provided with a chamfer or step projecting into the inner space of the hook. The latch shank has a substantially constant height starting at the step and extending approximately to the rounded end of the latch shank. At its free end the latch has a latch spoon provided with a groove for receiving a portion of the hook tip. The step is configured as an oblique surface oriented in the direction of the hook tip and serves as a supporting surface for the threads of the dual-thread knit. The supporting surface is oriented toward the inner space of the hook and contacts the thread particularly when the threads lie on that border of the trapping space which is situated at the latch bearing.
During the knitting operation the threads are to be guided by the reciprocating motion of the needle from that end of the trapping space which is at the latch bearing into the inner space of the hook. Plating defects are intended to be avoided in such a needle structure as well.
SUMMARY OF THE INVENTION
It is an object of the invention to provide an improved latch needle of the above-outlined type which may be used in a diversified manner and which permits the manufacture of knit products having the desired quality.
This object and others to become apparent as the specification progresses, are accomplished by the invention, according to which, briefly stated, the latch needle includes a shank; a hook formed at an end of the shank and having a hook tip; and a latch pivotally supported by the shank and cooperating with the hook. The latch has a closed state and a reverse state. In the closed state the hook and the latch together define a closed trapping space and in the reverse state the hook defines an open trapping space constituted essentially by an inner hook space. The latch includes an inner contour facing the trapping space in the closed state, a free end lying on the hook in the closed state and a stepped portion formed on the inner latch contour and adjoining the free latch end.
The latch needle according to the invention has a latch which, at its inner contour, that is, at that side which is oriented towards the trapping space, is provided with a stepped portion. Such a stepped portion, upon withdrawal of the needle, for example, upon knockover of a loop, guides the thread in the inner hook space in the direction of the needle back and thus away from the hook tip. The step guides the thread which is situated in the trapping space and from which a loop is formed during knockover, into the inner book space and prevents the thread from wedging between the hook tip and the latch spoon which would lead to an escape of the thread between the hook tip and the latch spoon. The stepped portion according to the invention effectively prevents dropped loops from occurring.
The above applies not only to mono-thread knits but in particular to dual-thread knits in which, for example, one thread having a relatively large diameter, such as a natural fiber thread and another thread, such as an elastomer thread having a relatively small diameter, are combined with one another. The invention ensures that the thin elastomer thread too, does not leave the trapping-space and thus does not form dropped loops.
Further, the thread is prevented from running against the hook tip and from being left suspended thereon. This advantageously reduces or avoids damages to the thread. In case of a dual-thread knit, the thread is prevented from remaining suspended on the hook tip and thus from being overtaken by the other thread. Plating defects are thus securely avoided or at least significantly reduced.
Further, the stepped portion on the inner contour of the needle latch according to the invention ensures that the two threads enter the inner hook space in their original sequence. The inner contour of the trapping space is relatively smooth so that neither of the threads remains suspended on an edge or a projection during the knitting process. This is particularly so because the stepped portion provided on the latch is oriented towards the hook tip and complements therewith a substantially smooth inner contour of the trapping spaces. The stepped portion and the adjoining region of the latch thus form an approximately bridge-like structure for guiding the thread into the inner hook space in the closed state of the latch, that is, when the latch spoon lies in the hook groove. In this manner a transition is formed substantially without interruption from the lower latch shaft edge (inner contour) to the lower edge of the hook tip and the adjoining inner edge, and thus neither a slip through (dropped loops) of the yam nor a switching of the yarn sequence way occur.
Such an effect is obtained particularly if the stepped portion is adjoining the hook tip in the closed position of the latch. In such a case the remaining intermediate space between the hook tip and the stepped portion may be particularly small. Preferably, such an intermediate, generally triangular space is open in the direction of the oppositely located inner wall of the trapping space or in the direction of the inner hook space. The stepped portion is preferably configured without an undercut to avoid intolerance between the hook tip and the latch as the latch opens and closes the thread space.
The stepped portion is preferably formed by a protuberance which projects into the trapping space as an imaginary prolongation of the inner arc of the hook. This arrangement prevents either loop drops or changes in the position of threads.
Preferably, the latch needle is of the type where a groove, providing for a nesting engagement between latch and hook, is formed in the hook. Such a groove is located in the vicinity of the hook tip. A latch needle with a grooved hook has, besides the above-discussed advantages, the further advantage that it is exposed to relatively slight wear. Particularly under the rigorous conditions of use in right-left circular knitting machines in which a lateral grinding of the latches may occur as discussed earlier in connection with German Patent No. 1,069,812, the latch needle having a grooved hook has significant advantages. The latch is at its free end laterally slightly flattened and is therefore narrower than the hook and, furthermore, has no groove. If, as the lateral latch play increases, and, as a result, the latch contacts the sinkers, such an event does not lead to a sharpening of the latch head as it is the case with grooved latches. Such an arrangement counteracts a potential damaging of the threads. Such a result is particularly advantageous when delicate threads such as elastomer threads or other monofilaments are used, because the slightest damage to the surface of such threads may lead to rupture. Therefore, this measure too, leads to an improvement of the quality of the knit produced with latch needles according to the invention.
According to an advantageous feature of the invention which contributes to the above-discussed highly satisfactory results, the inner contour of the latch has rounded lateral edges. Such rounded lateral edges are, by virtue of the narrow latch in grooved-hook-type latch needles, protected for a relatively long period from lateral abrasions and thus from developing sharp edges.
In accordance with another additional advantageous feature of the invention, in the grooved-hook-type latch needle the groove is shallow at least at the hook tip but preferably in its entirety to such an extent that at no location is it deeper than one-half of the hook thickness at that location. By virtue of this feature a weakening of the hook tip is avoided. Also, no sharp edges will form at the hook tip. Such a result is achieved despite the fact that by virtue of the stepped portion at the inner contour of the latch a smooth transition from the latch to the hook space is obtained.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a simplified perspective view of a latch needle according to the invention.
FIG. 2 is a perspective view, on a significantly enlarged scale, of an end portion of the latch needle in the closed state of the latch and illustrating two threads in the trapping space.
FIG. 3 is a side elevational view of the hook and latch portion of the latch needle according to the invention, illustrating the latch in a reverse (open) state.
FIG. 4 is a side elevational view of the hook and latch portion of the latch needle in the closed state of the latch, as also shown in to FIG. 2 .
FIG. 5 is a side elevational view of the latch needle illustrated in FIG. 4, illustrated in the closed position and in an even greater enlargement.
FIG. 6 is a side elevational view of the hook and latch portion of a grooved-latch-type needle according to the invention.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
FIG. 1 illustrates a latch needle 1 whose shank 2 is provided with a hook 3 at one end. The hook 3 is bent in a direction away from the needle back 10 and terminates in a hook tip 4 which, as may be particularly well seen in FIG. 5, is slightly spherically bent and is thus rounded. The hook tip 4 may, however, have a shape different from that shown in FIG. 5, for example, it may have a conical shape terminating essentially in a point. FIG. 1 further shows a needle cheek 5 formed between the shank 2 and the hook 3 and having a smooth transition into the upper needle side 20 . A needle latch 7 is pivotally supported in a sawslot 6 provided in the cheek 5 . As seen in FIG. 3, the latch 7 may move back and forth between two positions. The first position is a closed state I (FIG. 2) whereas the second position is a reverse state II (FIG. 3 ). The latch 7 is supported by a non-illustrated rivet defining a pivot axis 8 (FIG. 3 ). In the closed state I a trapping space 9 is bounded by the hook 3 and the latch 7 . If the latch 7 is in the reverse state II, the trapping space 9 is open. One part of the trapping space 9 is bordered by the hook 3 and is designated as the inner hook space 9 a.
The latch needle 1 is of the grooved hook type. This means that the hook 3 , in the vicinity of the hook tip 4 has a groove 11 for accommodating a latch spoon end 12 . The groove 11 is relatively flat as seen in FIG. 5 . The groove 11 has preferably a bottom 14 which at the opposite longitudinal sides is bordered by the remaining walls of the groove. The bottom 14 preferably terminates short of an imaginary center line 15 of the hook cross section. It is to be understood, however, that embodiments are feasible in which the groove 11 , for example, in the region of the hook tip 4 , reaches or even traverses the center line 15 .
As particularly well seen in FIG. 5, the hook 3 has an inner contour which, starting from a bent zone 16 , continues in a region in which the hook 3 has a substantially linear inner edge 17 . The latter terminates at a location 18 where the curved hook tip 4 ends. FIG. 5 shows an imaginary line 19 for distinguishing the hook tip 4 from the remaining parts of the hook 3 . Approximately in the middle of the groove 11 a further line 21 is drawn at which the groove 11 has approximately its greatest depth which is less than one-half, preferably approximately by one third of the thickness.
As particularly well seen in FIGS. 4 and 5, according to the invention the latch 7 of the latch needle 1 is provided with a projection 26 which terminates in a stepped portion 22 . The projection 26 and the stepped portion 22 are formed by the inner contour 23 of the latch 7 as it diverges from an imaginary broken line 24 which is the imaginary extension of the bottom 14 of the groove 11 . As particularly well seen in FIG. 4, the projection-forming contour 23 deviates smoothly from the line 24 to thus provide for a gradual transistion into the projection 26 . In the closed state of the latch 7 an engagement face 25 of the latch 7 lies in contact with the groove bottom 14 . The stepped portion 22 begins preferably immediately at the end 12 of the latch spoon. The latch spoon end 12 projects into the groove 11 when the latch is in its closed state. In this manner the stepped portion 22 covers and thus shields the hook tip 4 so that the thread is deflected and cannot contact the hook tip 4 in the closed state of the latch 7 .
The projection 26 which preferably starts at the groove 11 and allows the inner contour 23 of the latch 7 to merge smoothly into the inner edge 17 of the hook 3 . Thus, the contour 23 may be regarded as having two adjoining length portions: a first length portion which coincides with the imaginary line 24 and a second length portion, constituted by the projection 26 and situated between the free end (latch spoon end 12 ) of the latch and the first length portion. Such a smoothly merging configuration may be particularly well seen in FIG. 5 which shows a connecting line 27 between the location 18 where the inner edge 17 of the hook 3 has its transition to the hook tip 4 and a location 29 at which the stepped portion 22 continues as the inner contour 23 of the latch 7 . It is feasible to shift the location 29 into the trapping clearance 9 , that is, if required, the stepped portion 22 may be significantly larger than shown in FIGS. 4 and 5. Preferably the location 29 is configured such that the connecting line 27 extends generally parallel to the working direction of the latch needle, that is, parallel to the longitudinal direction of the needle shank 2 . In particular cases the location 29 may be configured such that the connecting line 27 forms an acute angle with the longitudinal direction of the shank 2 of the latch needle, wherein the point of the angle is oriented away from the hook 4 .
The inner contour 23 , that is, a portion of the inner surface of the latch 7 forms a sliding surface for the thread or threads to ensure an unimpeded transfer of the thread of threads to the inner hook space 9 i a. The inner contour 23 is, as viewed from the trapping space 9 , preferably concavely bent and thus the components 22 and 23 , as viewed together, have the general shape of a ski jump.
As illustrated in FIG. 3, the stepped portion 22 is free from undercut, that is, it forms with the inner contour 23 and with the engagement face 25 obtuse angles α and β, respectively. Preferably, the angle β is slightly larger than the angle α. In this manner, as viewed from the latch bearing, an inner contour 23 of the latch is obtained which extends away from the line 24 into the trapping space 9 .
As may be observed in FIGS. 4 and 5, in the closed state of the latch 7 the projection 26 and its stepped portion 22 do not overlap the hook tip 4 and thus between the hook tip 4 and the stepped portion 22 a gap 32 is formed which has the shape of an equilateral or isosceles triangle. The gap 32 is preferably so narrow that no thread can penetrate thereinto. This then means that the distance of the location 18 from the location 29 is preferably less than the diameter of the thinnest thread (FIG. 2) that can be expected to be processed by the latch needle 1 . Further, both the inner edge 17 of the hook 3 and the inner contour 23 of the latch 7 are rounded, especially at their lateral edges 33 .
In the description which follows the operation of the above-described latch needle 1 according to the invention will be set forth.
The latch needle 1 may be utilized as a conventional latch needle, particularly as a substitute or replacement for conventional needles. It is adapted, like other latch needles, for processing conventional threads and yarns under the usual operational conditions. The needle according to the invention, however, is particularly adapted for processing delicate threads, monofils like elastomer threads and for making plated wear, that is, two or three-thread knits.
For receiving a thread, the latch needle 1 is moved into its outward position whereby the latch 7 , as shown in FIG. 3, is moved by the thread, situated in the trapping space 9 , into the reverse (open) state II. Thereafter, the thread glides over and beyond the inner contour 23 of the latch 7 until the thread lies against the upper needle side 20 which is opposite the needle back 10 . The hook 3 may now capture, for example, two threads 35 , 36 (FIG. 2) whereupon the latch needle 1 starts its reverse stroke. Upon such an occurrence the latch 7 snaps into its closed state I, thus closing the trapping space 9 . The threads 35 , 36 , which, while in FIG. 2 are shown to have the same diameter, may have different diameters, are now within the trapping space 9 and may move therein. If upon such a movement they glide along the inner contour 23 into the inner hook space 9 a surrounded partially by the hook 3 , they traverse the gap 32 situated between the stepped portion 22 and the hook tip 4 without running onto the hook tip 4 . Rather, the projection 26 forms, similarly to a ski jump or a bridge, a transition from the inner contour 23 of the latch 7 to the inner edge 17 of the hook 3 . The threads 35 , 36 thus run smoothly over the gap 32 without changing their position relative to one another.
Further, there is no risk that one of the threads wedges in the gap 32 and opens the latch or that the thread slips through between the hook tip 4 and the latch spoon end 12 . Thus, with the latch needle according to the invention high quality products may be manufactured without drop loops or thread displacements under stringent operational conditions or quality requirements demanded by the thread quality or the number of threads to be processed. Further, the latch 7 is narrow and has no groove so that even in case of an enlarged lateral latch play which develops over time, there is no danger that the side edges 33 could be sharpened by a grinding effect which would damage the delicate threads.
A further embodiment of the invention is illustrated in FIG. 6 . In this embodiment the latch needle is of the grooved latch type, that is, the latch spoon end 12 forming the free end of the latch 7 is provided with a groove 11 a . The groove 11 a accommodates the hook 3 when the latch 7 , in its closed state, lies against the hook 3 with its latch spoon end 12 . The groove 11 a is surrounded by an edge 14 a whose linear imaginary prolongation is shown as a line 24 in FIG. 6 . The projection 26 , as in the earlier-described embodiment, extends in the direction of the hook space beyond the line 24 . The projection 26 may continue with a stepped portion 22 having a shape merging into the edge 14 a of the groove 11 a . It is, however, feasible to configure the inner contour of the latch 7 such that the edge 14 a of the latch 7 , starting approximately at the location 29 , extends approximately linearly to the latch tip 12 . It is of importance in this construction that the latch 7 , when in the closed state, defines a substantially smooth transition to the hook 3 . Stated differently, the inner edge 17 adjoins substantially smoothly the inner contour 23 . To illustrate such a condition, in FIG. 6 a line 27 is shown which connects the location 18 at which the linear inner edge 17 terminates, with the location 29 at which the substantially straight inner contour 23 terminates. The orientation of the line 27 approximately coincides with the orientation of the needle back 10 .
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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A latch needle includes a shank; a hook formed at an end of the shank and having a hook tip; and a latch pivotally supported by the shank and cooperating with the hook. The latch has a closed state and a reverse state. In the closed state the hook and the latch together define a closed trapping space and in the reverse state the hook defines an open trapping space constituted essentially by an inner hook space. The latch includes an inner contour facing the trapping space in the closed state, a free end lying on the hook in the closed state and a stepped portion formed on the inner latch contour and adjoining the free latch end.
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CROSS REFERENCE TO RELATED APPLICATION
[0001] The present application is based on and claims priority to U.S. Provisional Application Ser. No. 60/621,180, filed Oct. 22, 2004.
BACKGROUND OF THE INVENTION
[0002] IEEE standard 802.15.4 was developed to standardize communication between devices operating within a local area network (LAN). The IEEE standard was targeted at home, building and industrial automation and controls, consumer electronics, PC profiles and medical monitoring. The standards define the interoperability, certification testing and branding of devices that operate within the IEEE standard.
[0003] In a standard 802.15.4 network, the network includes three different device types. The first device type is classified as a network coordinator and maintains overall network knowledge.
[0004] The second type of device type in a 802.15.4 network is referred as a full function device (FFD). Each of the FFDs has full communication functionality with all the features required by the 802.15.4 standard. Further, the FFD includes additional memory and computing power that makes it ideal for acting as a network router. Each of the FFDs is able to communicate with both the network coordinator and lower level devices referred to as reduced function devices (RFDs).
[0005] The third type of device included in the 802.15.4 network is a reduced function device (RFD) that is designed to communicate with a single FFD. Each RFD includes limited functionality as specified by the 802.15.4 standard to limit the cost and complexity of the RFD. As required by the literal interpretation 802.15.4 standard, each RFD communicates solely with an FFD and cannot communicate with other RFDs.
[0006] The 802.15.4 network is contemplated as being particularly desirable in transmitting information within a building automation system. For example, each of the RFDs could be an environmental sensor, smoke detector, motion detector or any other kind of monitoring equipment that is required for monitoring and controlling the operation of a building.
[0007] Although the 802.15.4 networking configuration has worked well, a problem can occur if and when a FFD is rendered inoperative or is out of communications, such as during a power interruption. FFDs are generally designed to be online at all times and therefore are normally line powered. RFDs, by design, are not always online and typically are battery powered. When one of the FFDs is removed from the network, such as during the power loss to the FFD, the RFDs associated with the disabled FFD are unable to communicate information across the network unless they are within communication range of another FFD. If most or all of the FFDs are removed from the network (as might be the case during a power outage), then all of the RFDs will be unable to communicate a detected alarm condition. This drawback can become important when the RFDs are safety devices, such as smoke detectors.
[0008] Therefore, a need exists for an improved communication method operating within the 802.15.4 standard or any extension thereof, that allows for communication during emergency situations or when one or more of the FFDs has been rendered inoperative.
SUMMARY OF THE INVENTION
[0009] The present invention relates to a method of enhancing the communication between reduced functionality devices (RFDs) and full functional devices (FFDs) in a communication network, such as a network operated under the IEEE 802.15.4 standard. The method of the invention enhances communications particularly when one of the FFDs in the network has been rendered inoperative, such as during a power failure.
[0010] A standard network configured using IEEE standard 802.15.4 includes a plurality of RFDs that each include a wireless transceiver. Each of the RFDs is positioned such that the RFD is in communication range with an assigned FFD. In a typical 802.15.4 network, each of the RFDs communicates directly to its assigned FFD and responds only to messages received from the assigned FFD.
[0011] In accordance with the present invention, each of the RFDs is activated during a predetermined activation period. During the activation period, the RFD attempts to establish communication with the FFD to which it is assigned. If the RFD is unsuccessful in establishing communication with the FFD, the RFD enters into an “orphaned” state. The RFD enters into the orphaned state only upon the failure to establish communication with the assigned FFD.
[0012] After the RFD has entered into the orphaned state, the wireless transceiver of the RFD optionally remains active to transmit any alarm message and receive any messages from other RFDs within communication range of the RFD. Although the continued activation of the wireless transceiver of the RFD drains the power of the battery contained within the RFD, the RFD remains active during what may be an emergency situation.
[0013] During the time that the RFD is in an orphaned state and the wireless transceiver remains active or up waking/activation, the RFD can receive messages from either other RFDs or FFDs other than the FFD to which the RFD is assigned. When the RFD is in the orphaned state and receives a message, the RFD is allowed to respond to or relay the message as required. For example, if the RFD is a hazardous condition detector and the message received is a “smoke detected” message from another hazardous condition detector, the RFD is allowed to generate an alarm signal.
[0014] In addition to the orphan state operating conditions above, an RFD while in the orphan state can transmit an orphan state indicator as it attempts to rejoin with its assigned FFD. The orphan state indicator will alert other RFDs and FFDs that might receive the signal that an RFD has been orphaned and is seeking to join the network through an alternative temporary path. As a result, if an RFD wakes up and initiates a communications session with its assigned FFD and in the process receives an orphan state indicator from a near by RFD, the RFD can enter a temporary relay mode state and communicate with both the orphaned RFD and its assigned FFD to complete a temporary communication path over which the orphaned RFD can communicate with an operational FFD.
[0015] In a like fashion, if an orphaned RFD detects other RFDs transmitting an orphan state indicator, the orphaned RFD can respond and intercommunicate with other RFDs in an attempt to form an alternate path back to an operational FFD. Once associated with an alternative FFD or upon being relayed through another RFD, the orphaned RFD will assume an “orphaned but connected state”.
[0016] If an operational FFD can not be located, the orphaned RFDs will optionally remain in communications with one another. This “orphaned and relaying but not connected state”, permits RFDs to relay status and conditional information among themselves until an operational FFD returns to the system.
[0017] When an RFD's primary FFD is lost and subsequently returns to the network, the RFDs assigned to the FFD will drop any temporary alternative communication path that may have been established in the orphan mode with alternative FFDs and rejoin the primary FFD. The RFDs in this case, however, will not automatically drop any relay relationships they may have developed with other RFDs until those RFDs drop their relay relationships with them. This will only occur when the “relay dependent” RFDs primary FFD or an alternative non-primary FFD communications path is established. At this point, the “relay dependent” RFD will no longer need to depend on the RFD that is linked to its FFD for relay services and the relaying RFD can return to its normal mode as a standard operational RFD with an assigned primary FFD relationship.
[0018] In accordance with the present invention, an RFD will always attempt first to communicate with its primary FFD. If the communication is unsuccessful, the RFD will next attempt to join a non-primary FFD as an orphaned RFD until its primary FFD returns. The next level of recovery for an orphaned RFD can be to join with an RFD that has a communications path operational with either a primary or non-primary FFD in an orphaned but connected mode. In this case, the RFD will join with another RFD, which will relay its information to an FFD that is operational but not the primary FFD. Lastly, an orphaned RFD can form a relationship with other orphaned RFDs that have no linkage to an active FFD in the network to permit intercommunications in an “orphaned and relaying but not connected” mode.
[0019] In addition to responding to a received alarm message in an orphaned state, upon receiving the alarm signal, the orphaned RFD will remain active and retransmit the alarm message to other RFDs or non-primary FFDs within wireless communication range. The communication directly between the RFDs allows the RFDs to respond to an emergency condition even if the assigned FFD or any alternates have been rendered inoperative, such as through the interruption of power to the FFD.
[0020] While the RFD is in its orphaned state, the RFD continues to attempt to establish communication with its assigned FFD. Once the RFD establishes communication with its assigned FFD, the RFD exits the orphaned state and is then restricted from directly responding to any messages received from other RFDs, except as noted when other orphaned RFDs are dependent on it in a “relay state”. When the RFD is no longer in the orphan state or the “relay state”, the RFD will return to the “sleep” state and can respond only to messages from the assigned FFD, in accordance with the IEEE 802.15.4 standard.
[0021] During operation of the communication network, an FFD can carry out a test procedure on regularly schedule intervals. During the test procedure, the FFD causes each individual RFD to generate a test signal. After the test signal has been generated by the transmitting RFD, the other RFDs in the communication network act as signal receivers to receive and detect the test signal. Each of the receiving RFDs provide input to the FFD conducting the test on whether the test signal has been received and the quality of the signal. This test procedure is repeated for each RFD individually.
[0022] If during this test process, when an RFD transmits its test signal no other RFD receives the signal, the assigned FFD generates an alarm condition indicating that the transmitting RFD is unable to communicate with at least one other RFD. Such a situation may occur when the battery within the RFD is weak or if something in the communication path is blocking the signal generated by the transmitting RFD making it orphaned with no alternative route when the FFD is not available. The test procedure assures that each RFD is in communication range with at least one other RFD so that should the FFD fail, the RFD can still communicate an emergency message to another RFD. It is important to note that in a FFD failure state, each RFD should not only be capable of communicating with another RFD, but there should be a clear path over which all RFD can be interconnected. This assumes that in a network of more than two RFD's, an RFD that can only communicate with one other RFD must rely on that RFD to relay data to other RFDs. As a result, the relaying RFD in this case should be capable of communicating with at least one other RFD and so on until a complete interconnection of RFDs is accomplished.
BRIEF DESCRIPTION OF THE DRAWINGS
[0023] The drawings illustrate the best mode presently contemplated in carrying out the invention. In the drawings:
[0024] FIG. 1 is a schematic illustration of a standard IEEE 802.15.4 network in which the reduced functionality devices (RFDs) are shown by reference numbers A-L and the full function devices (FFDs) are labeled with reference numerals 1 - 5 ;
[0025] FIG. 2 is a schematic illustration of an 802.15.4 network in which the RFDs are allowed to communicate with each other and at least one alternate FFDs upon a communication failure to the FFD primarily assigned to the RFDs;
[0026] FIG. 3 is a flow chart illustrating the operation of each RFD within the 802.15.4 network;
[0027] FIG. 4 is a schematic illustration of an 802.15.4 network in which each of the FFDs has been rendered inoperative; and
[0028] FIG. 5 is a schematic illustration of a test message generated by one of the RFDs and received by multiple other RFDs and FFDs.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0029] As illustrated in FIG. 1 , the RFDs are shown by reference letters A-L. In the embodiment illustrated, each of the RFDs communicates to a single, full function device (FFD). Each of the FFDs shown in FIG. 1 is labeled with the reference numerals 1 - 5 . In the example configuration of FIG. 1 , the RFDs A, B and C are assigned to FFD 1 and are able to communicate only to the FFD 1 . The FFD 1 is able to communicate to a second FFD 2 .
[0030] In the standard embodiment of an 802.15.4 network, as shown in FIG. 1 , should the RFD A need to transmit information to the RFD B, then RFD A transmits data first to the to FFD 1 and FFD 1 in turn transmits/forwards the message to RFD B. This multi-node communication is required, since both of the RFDs A and B are typically in an off, sleeping mode and are awake to accept messages only on an intermittent basis to conserve battery life. Thus, even if the RFD B was within the RF transmission range of the RFD A, the RFD A is unsure as to when the RFD B will be awake and able to receive a message. However, FFD 1 is active at all times and is aware of the schedule of the associated RFDs A, B and C such that the FFD 1 is able to transmit the received information from the RFD A to the RFD B.
[0031] As can be understood by the above description, the limited communication ability between the RFDs within the 802.15.4 network of FIG. 1 imposes a severe constraint on the network communication and design. Further, the restricted communication results in the requirement that each of the FFDs include some type of battery backup for cases where there may be a power outage. The battery backup ensures that the network continues to operate properly and can communicate messages throughout the network should a power outage occur. For example, if each of the RFDs A, B and C are hazardous condition detectors, such as smoke detectors, carbon monoxide detectors or combination units, if the power is disrupted to the FFD 1 , it may be important for the RFDs A, B and C to be able to communicate with each other should one of the RFDs detect an alarm condition. If the FFD 1 is inactive and unable to communicate the alarm signals between the RFDs A, B and C, an alarm condition in one room of a home may not be relayed to an alarm device in another room.
[0032] In order to address the above identified problem, it is necessary to loosely interpret the 802.15.4 standard to allow each of the RFDs to accept messages from other devices besides their assigned FFDs during a narrowly defined condition. As an example, the RFDs A, B and C will be configured to accept messages from each other and alternate FFDs when the primary FFD is not available. In order to satisfy the 802.15.4 standard, the present invention will allow the RFDs to accept messages from devices other than the assigned FFD only under well constrained circumstances and in specifically defined situations, the details of which follow.
[0033] Referring now to FIG. 2 , in accordance with the present invention, after one of the RFDs (A-L) has failed to communicate with its assigned FFD ( 1 - 5 ), and therefore has transitioned to an “orphaned state” as defined by the 802.15.4 standard, the RFD can remain active and then would be able to accept messages from devices other than the assigned FFD. During this extended emergency receiving time, if the RFD receives a broadcast message, the RFD will accept the message and process the message. As an example, if the RFD A is a hazardous condition detector, such as a smoke detector located within a building, the RFD A will, upon the detection of smoke, transmit an alarm signal to its associated FFD 1 . During normal operation, the FFD 1 would then relay this message to the other RFDs B and C.
[0034] If the communication link between RFD A and FFD 1 is broken, as shown in FIG. 2 , the RFD A enters an “orphaned” state and will continue to transmit the message, which may be received by the RFDs B and C. When the RFDs B and C awaken, the RFDs B and C will first attempt to communicate to the FFD 1 . Once the RFDs B and C determine that FFD 1 is unavailable, the RFDs B and C will be allowed to receive messages from any transmitting RFD, such as RFD A, and process it. For example, if the RFD A is transmitting a “smoke detected” message, RFD B will receive this message directly from the RFD A and relay the message to RFD C, resulting in all three RFDs generating an audible alarm. Thus, the RFDs operating in accordance with the present invention will respond to a detected emergency in a situation that would not have otherwise generated the desired response in accordance with operation under the 802.15.4 standard.
[0035] In addition, upon receipt of the emergency message, both of the RFDs B and C will broadcast the message to any other devices within RF range. As shown in FIG. 2 , FFD 2 will receive and respond to the message from the RFD C, passing the message on to other RFDs in the network. In FIG. 4 where all of the FFDs are disabled, RFD C will communicate directly with RFD E which will relay the message to other orphaned but linked RFDs, propagating the alarm signal. To be clear, the messages are not unicast to each of the other RFDs in the network, but instead are broadcast and therefore “flood” across the network.
[0036] It is anticipated that the alternate transmission mechanism of the present invention will be used only during emergency situations. The RFDs, which would normally be sleeping or only transmitting on a very infrequent basis, will continue to transmit broadcast packets constantly until the emergency situation is resolved or the device is shutdown.
[0037] Although it is understood that the transmission mechanism of the present invention will have a negative impact on the battery life of the RFDs ( FIG. 4 ), battery life is a secondary consideration during an emergency situation. It is much more desirable that the RFD detecting the emergency situation will continue to transmit the message at the expense of battery life as needed to ensure the safety of all premise occupants.
[0038] The result of the alternative communication configuration of the present invention is that even during a power outage affecting the FFDs ( FIG. 4 ), the battery powered RFDs will be able to communicate important/critical/emergency information throughout the network.
[0039] As discussed in detail above, the devices in the 802.15.4 network are allowed to “break” the 802.15.4 standard only under well constrained and limited situations. Specifically, each of the RFDs is allowed to communicate with a device other than its assigned FFD only after it has transitioned to an “orphaned state” and generally only when the RFD receives a broadcast alarm message.
[0040] Referring now to FIG. 3 , when the RFD awakens at its normally scheduled interval, as shown by step 110 , the RFD attempts to communicate with its assigned, local FFD as shown in step 112 . If the RFD is able to communicate with its FFD, the RFD receives messages from the FFD and responds as desired, as shown in step 115 . As an example, if the RFD receives an alarm message from the local FFD, the RFD will generate its local alarm as required. In addition to receiving messages from the FFD, the RFD also transmits information and messages to the FFD in step 117 . As an example, if the RFD is detecting smoke, the RFD will send this message to the FFD so that the FFD can relay the signal to other devices in the network.
[0041] If the communication between the RFD and its local FFD fails in step 114 , the RFD enters into an orphaned state, as shown in step 116 . Although the 802.15.4 standard contemplates each of the RFDs entering into an orphaned state upon the failure to communicate with the local FFD, in accordance with the present invention, when the RFD is in the orphaned state, the RFD listens to determine whether any messages are received from other RFDs or remote FFDs, as illustrated in step 118 . The messages received from the other RFDs or remote FFDs may be alarm conditions or other messages being transmitted by the remote devices.
[0042] As illustrated by step 120 , if the RFD detects any message from another RFD or a remote FFD, the RFD is permitted to process and react to the message as required. For example, if each of the RFDs are smoke detectors, the RFD may receive a smoke alarm signal from one of the other RFDs and can then activate the alarm within the RFD. In addition, the RFD is allowed to retransmit the message, thereby passing the message to other RFDs or FFDs in wireless communication range with the RFD.
[0043] After responding to the message or retransmitting the message, the RFD again attempts to communicate with the local FFD in step 112 . Once the RFD is able to communication with its local, assigned FFD, the RFD will exit the orphaned state and thus be prevented from responding to messages from other devices other than its assigned, local FFD, as required by the 802.15.4 standards.
[0044] It is preferred that under the 802.15.4 standard an FFD maintain Communications Quality of Service (CQOS) statistics for their associated RFD's. This is done to ensure that any RFD is not entering the orphan state as a result of poor signal quality following its initial installation or any time thereafter. When the signal quality between the FFD and an RFD is marginal or the FFD detects a diminished CQOS at any time, an alert is generated by the FFD of a type and in a manner to maintain an acceptable level of integrity of the system. This feature ensures the communications network between devices is maintained at the highest levels and that a battery powered RFD only functions in the orphan mode during true emergencies.
[0045] In addition, to ensure that an RFD is able to intercommunicate with other RFDs during an emergency or when their assigned FFD is unavailable, a test sequence initiate by the FFD is part of the preferred implementation. This optional test procedure is integrated into the FFD on a scheduled and/or on demand basis. The test procedure causes the FFD to cause each of the RFD's to stay online during the test process. During the test procedure, the FFD causes each of the individual RFDs to transmit a test message as is illustrated in FIG. 5 . In this illustration, FFD 4 has instructed all RFDs and other FFDs that it is conducting a test of the network. The FFD 4 then requests that RFD I initiate a test transmission, which is detected in the illustration by RFDs C, E & K as well as FFDs 4 & 2 . After the test signal has been generated by the first, transmitting RFD, the other RFDs in the communication network act as signal receivers to receive and detect the test signal. Each of the receiving RFDs and FFDs notify the FFD conducting the test that they have received the test signal along with any other data that may be needed by the FFD. The FFD optionally records this information into a non-volatile storage location. The test results from each RFD's test message may also be sent to the sending RFD where it may be stored for future reference in emergency situations. This test procedure is repeated for each of the RFDs individually.
[0046] If no other RFD in the group detects the transmission, the FFD can generate an alarm condition indicating that the transmitting RFD is unable to communicate with at least one other RFD. This procedure is essential in installations that are required to maintain a robust and reliable network under all conditions. The failure for one of the RFDs to communicate with at least one other RFD or FFD can occur when the battery of the RFD has been depleted or some obstruction or other factor is corrupting the communication pathway. In any of these cases, the signal generated by the transmitting RFD can no longer be received by one of the other RFDs or FFDs in the network. The test procedure ensures that each RFD is in communication range with at least one other RFD so that should all FFDs fail, the RFDs can still communicate an emergency message to one another. This test procedure insures that under emergency conditions, the integrity of the network will be preserved.
[0047] If no other RFD in the group detects the transmission, the FFD generates an alarm condition indicating that the transmitting RFD is unable to communicate with at least one other RFD. This procedure is essential in all installations to maintain a robust and reliable network under all conditions. The failure for one of the RFDs to communicate with at least one other RFD can occur when the battery within either of the RFDs has been depleted or if some other parameter in the communication pathway has changed such that the signal generated by the transmitting RFD can no longer be received or one of the other RFDs in the network. The test procedure ensures that each RFD is in communication range with at least one other RFD so that should the FFD fail, the RFD can still communicate an emergency message to another RFD. This test procedure insures that under emergency conditions, the integrity of the network will be preserved.
[0048] It is important to note that in a FFD failure state ( FIG. 4 ), each RFD must not only be capable of communicating with another RFD, but there must be a clear path over which all RFDs can be interconnected. This assumes that in a network of more than two RFDs, an RFD that can only communicate with one other RFD must rely on that RFD to relay data to other RFDs. As a result, the relaying RFD in this case must be capable of communicating with at least one other RFD and so on until a complete interconnection of RFD's is accomplished
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In a 802.15.4 network, each reduced functionality device (RFD) is permitted to communicate with only an assigned full function device (FFD). The present invention allows each of the RFDs to communicate with another RFD upon the RFD determining that the local FFD assigned to the RFD is inoperable or unable to communicate. Under emergency conditions, the RFD is able to communicate with a closely located RFDs such that the closely located RFDs can receive and respond to an emergency situation and/or repeat the message. To satisfy the 802.15.4 standards, communication between the RFDs is allowed only during emergency conditions and when the FFD is inoperative. A comprehensive test procedure is included to insure the integrity of the system is preserved at all times.
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BACKGROUND OF THE INVENTION
[0001] 1. Field of the Invention
[0002] The present invention relates generally to high-load centralizer systems and, more specifically, provides a system and method which in one preferred embodiment may be utilized as keel joint subject to substantial mechanical stresses in a marine riser system.
[0003] 2. Description of the Prior Art
[0004] Marine risers have been utilized in the past with non-fixed connections to floating platforms and/or drill ships and/or wellheads that are maintained generally above the wellhead or in the vicinity of a plurality of wellheads. Stress joints may be utilized at the riser connections to the wellhead(s) and to the floating platform because large forces may be applied at these positions due to the relative movement between the wellhead and floating platform. The stress joint utilized at the floating platform is sometimes referred to as a keel joint because it extends through the bottom or the keel of the platform or other marine vessel. As used herein floating and/or offshore platform may refer to any marine structure for use with oil and gas wells. An example of a prior art keel joint is shown in U.S. Pat. No. 5,887,659 issued Mar. 30, 1999, to B. J. Watkins, which discloses an assembly including a protective sleeve spaced about an intermediate pipe of a riser which is adapted to extend through an opening in the bottom of a vertical compartment of a offshore rig for use in drilling or completing a subsea well, with a ball shaped portion on the upper end of the sleeve is closely received by ball shaped surfaces of the upper portion of the riser pipe, while a ball shaped part on the lower portion of the riser pipe is so received within the lower end of the sleeve to permit them to swivel as well as to move vertically with respect to one another.
[0005] A more general type of high stress marine riser interconnection is shown in U.S. Pat. No. 4,185,694, issued Jan. 29, 1980, to E. E. Horton which discloses a marine riser system which extends between a floating offshore platform and one or more well means in a seabed formation and which has riser end portions non-fixedly connected in to the floating platform and to wellhead structure at the well hole. Each end portion of the riser may be adapted to yield axially, laterally, and rotatively during movement of the riser relative to the platform and to the wellhead structure. Each end portion of the riser is provided with fulcrum or pivot contacts, which may preferably comprise centralizers, with hawse pipe carried by the platform and with hawse pipe or casing means provided in the wellhead structure. Bending stresses at the riser end portions or stress joints are reduced at the platform and at the wellhead structure by utilizing the non-fixed connection described therein.
[0006] Other attempts to control, reduce, minimize, and/or distribute forces applied to stress joints and/or keel joints are shown in the following documents:
[0007] U.S. Pat. No. 6,422,791, issued Jul. 23, 2002, to Pallini, Jr. et al., discloses an attachment which extends between an outer sleeve and an inner riser pipe where the pipe penetrates the keel of a platform. In one version, the attachment is a conically-shaped with a small diameter ring that engages the riser pipe and a large diameter ring that engages the outer sleeve. This attachment has elements that are very flexible in bending but relatively stiff and strong in axial load. Other versions include flat rings where lateral load is taken directly into tension and compression in the beams, allowing for relatively high lateral load transfer. Both the conically-shaped attachment and the flat ring have a number of variations that provide low bending stiffness but high axial stiffness of the elements. Depending on whether resistance to axial loads, lateral loads, or resistance to combination of both loads is desired, the attachment and the flat ring may be used alone or in combination. Other variations of the device provide two opposing conical shaped attachments or a conical and flat ring attachment installed together to provide load capability in both axial and lateral directions while still providing angular flexibility.
[0008] U.S. Pat. No. 5,683,205, issued Nov. 4, 1997, to J. E. Halkyard, discloses a stress relieving joint for pipe such as risers, tendons, and the like used in floating vessel systems wherein a vessel is subject to heave, pitch, and roll motion caused by wind, currents, and wave action; the pipe passing through a constraint opening in the vessel and connected to the sea floor and subject to bending or rotation at the constraint opening. The joint comprises a sleeve member of selected length with ends at opposite sides of the constraint opening and centralizing annuli or rings at sleeve member ends for providing spaced contact points or areas to distribute bending stresses imparted to the sleeve member at the constraint opening to the pipe at the sleeve member ends. A method of relieving or distributing stress in a pipe at a constraint location.
[0009] U.S. Pat. No. 5,873,677, issued Feb. 23, 1999, to Bavies et al., discloses a stress relieving joint for use with riser pipe in floating systems wherein a vessel is subject to variable motion caused by wind, currents, and wave action. The riser pipe has one end connectable to the sea floor and an upper portion adapted to pass through a constraining opening at the bottom of the vessel. A ball joint and socket assembly is removably attached to the keel at the constraint opening. A sleeve is attached at substantially its midpoint in the ball joint. Riser pipe received in the sleeve is provided with wear strips that reduces the rate of reduction in wear surface diameter.
[0010] U.S. Pat. No. 4,633,801, issued Jan. 6, 1987, to P. W. Marshall, discloses the apparatus of the present invention comprises a compliant structure for use in reducing bending stress at the ends of an elongated cylindrical tether which may, for example, be used to connect a floating platform supported by a body of water to the floor thereof. The apparatus comprises a plurality of tubular support members concentrically arranged about the elongated cylindrical tether at the tether's end connection. Each tubular support member is connected to each adjacent tubular support member in a manner that allows the entire assembly of tubular members to deflect in unison as the cylindrical tether deflects.
[0011] U.S. Pat. No. 6,467,545, issued Oct. 22, 2002, to Venkataraman et al., discloses a monolithic isolation stress joint is disclosed having a first conduit element, a first insulating joint assembly, and a stress joint connected to the first conduit element through the first insulating joint assembly. The stress joint is formed of a material which has advantageous elastic flexure characteristics but which is electrochemically active with respect to the first conduit element from which it is electrically isolated by the first insulating joint assembly. A second conduit element is connected to the stress joint through a second insulating joint assembly, the second conduit element being formed of a material which is electrochemically active with respect to the stress joint and which is electrically isolated therefrom with the second insulating joint.
[0012] U.S. patent application Publication 2002/0084077 A1, published Jul. 4, 2002, to Finn et al., discloses a spar type floating platform having risers passing vertically through the center well of a spar hull. A gimbaled table supported above the top of the spar hull is provided for supporting the risers. The table flexibly is supported by a plurality of non-linear springs attached to the top of the spar hull. The non-linear springs compliantly constrain the table rotationally so that the table is allowed a limited degree of rotational movement with respect to the spar hull in response to wind and current induced environmental loads. Larger capacity non-linear springs are located near the center of the table for supporting the majority of the riser tension, and smaller capacity non-linear springs are located near the perimeter of the table for controlling the rotational stiffness of the table. The riser support table comprises a grid of interconnected beams having openings therebetween through which the risers pass. The non-linear springs may take the form of elastomeric load pads or hydraulic cylinders, or a combination of both. The upper ends of the risers are supported from the table by riser tensioning hydraulic cylinders that may be individually actuated to adjust the tension in and length of the risers. Elastomeric flex units or ball-in-socket devices are disposed between the riser tensioning hydraulic cylinders and the table to permit rotational movement between the each riser and the table.
[0013] The above cited prior art does not disclose means for highly precise control of stresses and the distribution thereof in a centralized keel joint utilizing substantially solid metallic centralizers. Consequently, there remains a need to provide an improved centralizer system with improved centralizers and centralizer mountings that are not subject to the above problems. Those of skill in the art will appreciate the present invention, which addresses the above problems and other significant problems.
SUMMARY OF THE INVENTION
[0014] Accordingly, it is an objective of the present invention to provide an improved centralizer system especially suitable for non-fixed riser connections which may comprise or utilize stress joints such as a keel joint with a centralizer.
[0015] Another objective of one preferred embodiment of the present invention is to provide an improved system and method for affixing one or more centralizers to a stress joint.
[0016] Yet another objective of the another preferred embodiment of the present invention is to provide a substantially solid centralizer comprising structures therein for reducing forces applied to the stress joint or keel joint.
[0017] These and other objectives, features, and advantages of the present invention will become apparent from the drawings, the descriptions given herein, and the appended claims. However, it will be understood that above-listed objectives and other described advantages and features of the invention are intended only as an aid in understanding aspects of the invention, are not intended to limit the invention in any way, and therefore do not form a comprehensive or restrictive list of objectives, features, and/or advantages. Therefore, any stated objects, features, and advantages are not intended to limit the invention in any manner inconsistent with the claims or other portions of the specification and are not intended to provide limiting language outside of the claim language. It is intended that all alternatives, modifications, and equivalents included within the spirit of the invention and as defined in the appended claims be encompassed as a part of the present invention.
[0018] Accordingly, the present invention provides a centralizer system that may be positioned in a marine riser system connecting between one or more wellbores and a floating platform, the centralizer system being operable for withstanding stresses produced in the marine riser system by relative movement between the one or more wellbores and the floating platform and water motion. The centralizer system may comprise a metallic pipe comprising a pipe outer diameter less than the receptacle inner diameter so as to be insertable into the receptacle and relatively moveable within the receptacle and an upset portion formed on the metallic pipe having an upset outer diameter greater than the pipe outer diameter. A centralizer is preferably heat shrink mounted to the upset portion on the metallic pipe. The centralizer has an outer diameter less than the receptacle inner diameter for insertion into the receptacle.
[0019] The centralizer system may further comprise an upset transition zone on at least one side of the upset portion whereby the upset transition zone outer diameter decreases with distance axially away from upset portion and preferably blends into the pipe outer diameter. In one embodiment, the centralizer is also heat shrink mounted to at least a portion of the upset transition zone. The centralizer is preferably of rigid construction and may preferably utilize rigid solid steel construction. The centralizer may further comprise water flow ports to permit water flow therethrough as the centralizer moves axially with respect to the receptacle.
[0020] In a preferred embodiment, the centralizer defines and at least one preferably annular groove shaped (preferably with an axial component) to limit substantially radially directed forces from being transmitted through the rigid metal centralizer past or through the groove as a result of impact and/or forceful contact between the receptacle and the centralizer. The groove may be selectively positioned within the centralizer to reduce stress at a selected portion of the upset portion. For instance, the groove may be positioned adjacent to a first end of the upset portion to thereby reduce stress in the region of the first end of the upset portion. In another embodiment, two grooves are positioned adjacent opposite ends of the upset portion to thereby reduce stress at the opposite ends of the upset portion.
[0021] An insulative coating may be utilized on an outer surface of the centralizer to reduce corrosion, galvanic reactions, and/or dampen forces. The centralizer outer surface may comprise a curvature or substantially cylindrical surface for contact with the receptacle thereby affecting the stress applied to the upset portion in a desired manner.
[0022] A preferred method of the invention comprises heating the centralizer until the centralizer inner diameter is greater than the upset outer diameter and then positioning the centralizer over the upset outer diameter to thereby heat shrink affix the centralizer to the upset portion.
[0023] Reference to the claims, specification, drawings and any equivalents thereof is hereby made to more completely describe the invention.
BRIEF DESCRIPTION OF DRAWINGS
[0024] For a further understanding of the nature and objects of the present invention, reference should be had to the following detailed description, taken in conjunction with the accompanying drawings, in which like elements may be given the same or analogous reference numbers and wherein:
[0025] FIG. 1 is an elevational view, partially in cross-section, showing a keel joint riser interconnection with a floating platform in accord with one possible embodiment of the present invention;
[0026] FIG. 2 is an elevational view, in cross-section, of a tapered keel joint and shrink fitted centralizer in accord with one possible embodiment of the present invention;
[0027] FIG. 3 is a cross-sectional view along lines 3 - 3 of FIG. 2 in accord with one possible preferred embodiment of the present invention;
[0028] FIG. 4 is an enlarged elevational view, in cross-section, of a tapered keel joint and shrink fit centralizer with upper mounted guide section and stress relief grooves in accord with one possible embodiment of the present invention;
[0029] FIG. 5 is an elevational view, partially in cross-section, of a tapered keel joint and shrink fit centralizer with upper and lower guide sections and axially oriented stress relief grooves in accord with one possible embodiment of the present invention;
[0030] FIG. 6 is an elevational view, partially in cross-section, of a tapered keel joint and shrink fit centralizer with upper and lower guide sections providing an annulus around upper and lower tapered keel joint portions in accord with one possible embodiment of the present invention;
[0031] FIG. 7 is an elevational view, partially in cross-section, of a tapered keel joint and shrink fit centralizer and monolithic lower guide section with stress grooves having radially and axially oriented portions in accord with one possible embodiment of the present invention;
[0032] FIG. 8 is an elevational view of a tapered keel joint in accord with an upset portion one possible embodiment of the present invention;
[0033] FIG. 9 is an enlarged elevational view of a tapered keel joint with a conically tapered upset portion in accord with one possible embodiment of the present invention;
[0034] FIG. 10 is an enlarged elevational view of a tapered keel joint with a gradually variably tapered upset portion in accord with one possible embodiment of the present invention;
[0035] FIG. 11 is an enlarged elevational view of a tapered keel joint with a shortened variably tapered upset portion as compared to the embodiment of FIG. 10 in accord with one possible embodiment of the present invention;
[0036] FIG. 12 is an enlarged elevational view of a tapered keel joint with two different curvatures in a tapered upset portion in accord with one possible embodiment of the present invention; and
[0037] FIG. 13 is an enlarged elevational view of a tapered keel joint with a straight conical and curved tapered upset portion in accord with one possible embodiment of the present invention.
[0038] While the present invention will be described in connection with presently preferred embodiments, it will be understood that it is not intended to limit the invention to those embodiments. On the contrary, it is intended to cover all alternatives, modifications, and equivalents included within the spirit of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0039] Referring now to the drawings and, more specifically, to FIG. 1 , there is shown an example of non-fixed riser connection comprising a tapered keel joint with a preferably shrink fit centralizer assembly 10 for interconnection with floating platform 12 in accord with the present invention.
[0040] Floating platform 12 in FIG. 1 is shown to provide a general conception of the background of operation of tapered keel joint with shrink fit centralizer assembly 10 in accord with the present invention and is not intended to represent the great variety in construction of numerous different types of floating platforms with various different features. Floating platform 12 may comprise various types of vessels which may include without limitation, as examples only, tension leg platforms, spars, barges, ships, and the like (see for Example U.S. Pat. No. 5,887,659) referenced hereinbefore. At some point or location, depending on the particular structure of floating platform 12 , a receptacle or constraining opening such as conductor 20 is provided into which assembly 10 is inserted. One or more risers 28 with one or more shrink fit assemblies 10 may extend between floating platform 12 and one or more wellbores 18 . Relatively greater stresses are produced at upper pipe/riser section 14 especially at the interconnection with conductor 20 and at lower riser section 16 at the interconnection with wellbore 18 . The stresses are the result of loads as applied due to water currents, waves, surges, and various types of relative motion between floating platform 12 and wellhead 18 .
[0041] Assembly 10 is designed to withstand the significant forces and to centralize the portion of the riser 23 above assembly 10 within conductor 20 . One preferred embodiment of assembly 10 comprises shrink fit centralizer assembly 10 A shown in greater detail in FIG. 2 . In one preferred embodiment as shown in assembly 10 A, centralizer 26 is shrink fitted to upset 30 . By shrink fitting, it is meant that centralizer 26 is heated so as to expand and then be positioned around upset 30 . Prior to heating, centralizer 26 may have an internal diameter slightly less than the outer diameter of upset 30 . For instance, centralizer 26 may have an internal diameter of 12.240 inches prior to heating and upset 30 may have an outer diameter of 12.250 inches. To position the heated centralizer 26 at an exact position with respect to upset 30 , removeable stops (not shown) may be mounted or clamped to pipe 38 which provide stop surfaces to thereby place centralizer 26 at the exact desired position around upset 30 . Centralizer 26 may then be evenly and slowly heated, such as in an oven or the like to a relatively high temperature without damaging desired metal characteristics, e.g., in the range of 475-500 degrees Fahrenheit. The centralizer 26 may then be slipped over the pin end of pipe 38 until engaging the removable stop surface to thereby align centralizer 26 at the desired position around upset 30 . Sufficient cooling to fasten centralizer 26 to upset 30 may take approximately five minutes or so at room temperature whereby centralizer 26 is then securely fastened to upset 30 .
[0042] Utilizing heat shrink construction has many advantages. It is much less expensive than machining, and just as strong. Machining the centralizer and keel joint out of a single piece of material would be quite expensive. It is much simpler and more cost effective to machine the keel joint with upset and the centralizer separately and then heat shrink fit the centralizer onto the upset position of the centralizer. Also, for stress design purposes, it is much easier to predict exactly where the stresses will be applied because the relative location of centralizer 26 and upset 30 is more exactly defined than is the case where the centralizer is simply bolted on because there is essentially no movement whatsoever. Slight movement may occur to bolted on centralizer structures especially due to the anticipated high stresses applied thereto during operation, which movement can vary over time due to changes in the bolted connection. However the present invention does not preclude the possibility of bolting centralizer 26 on or otherwise mounting such as by welding, or heat shrinking and then welding and/or bolting. In any case, due to the shrink fit construction, there is virtually no axial movement. Even very slight movements as may occur by other mounting methods such as bolting are reduced or eliminated thereby permitting a much more exact stress analysis and resulting improved, more efficient, more reliable, and less expensive design construction.
[0043] In operation, tapered keel joint with shrink fit centralizer assembly 10 A is inserted into conductor 20 and may move axially with respect to conductor 20 . Referring to FIG. 2 and FIG. 3 , water flow passageways 22 may be utilized to reduce or limit any hydraulic forces that resist axial movement of tapered keel joint with shrink fit centralizer assembly 10 with respect to conductor 20 . Resistance to axial movement might otherwise occur especially if centralizer maximum outer diameter 24 of centralizer 26 for assembly 10 A is of relatively close tolerance to the inner diameter or smallest restrictions of conductor 20 . Due to tensioners and/or air cans and/or telescoping joints utilized by floating platform 12 , which control the tension in riser 28 (see FIG. 1 ), it may therefore be desirable to avoid or limit the creation of additional axial forces acting on riser 28 , by utilizing water flow passageways 22 , to relieve any hydraulic forces created thereby.
[0044] As noted hereinbefore, tapered keel joint with shrink fit centralizer assembly 10 A is a type of stress joint which is designed to handle the significantly greater forces created on the riser at the points of contact of riser with floating platform 12 and wellhead 18 . Stress joints may be comprised of various materials, e.g. steel or titanium. Although in assembly 10 A, a preferred embodiment is comprised of steel, the present invention is not limited to steel. In the embodiment of assembly 10 A, the keel joint comprises a reinforced thickened exterior wall or upset 30 with a selected tapered portion 36 . Due to the various types of floating platforms involved and the various constructions thereof, the types of forces involved with non-fixed riser interconnections may vary considerably. Accordingly, to handle the various types of anticipated stresses that may be experienced by assembly 10 A, the general configuration of assembly 10 A and the components thereof such as centralizer 26 and preferably upset 30 may be varied as desired.
[0045] It is desirable that assembly 10 absorb the maximum stress applied to riser 28 . By utilizing the components of assembly 10 A, it is possible to control, direct, and/or spread the stress forces to thereby place maximum stresses at the strongest regions of assembly 10 A and reduce or minimize forces applied to other components thereby providing a lower cost, more efficient, and longer lasting assembly 10 .
[0046] In one preferred embodiment of the invention, it may be desirable to control forces applied to upset 30 by limiting and/or directing some forces within centralizer 26 itself. One possible presently preferred embodiment of the invention utilizes shaped grooves within centralizer 26 to control stress by preferably significantly reducing maximum stresses that are applied to the upper and lower ends of upset 30 as compared to not utilizing the grooves. In the embodiment of FIG. 2 , relief grooves 32 and 34 may formed in the upper and lower surfaces of centralizer 26 to thereby limit the force transmitted through upper surface 40 and lower surface 42 of centralizer 26 with respect to the corresponding upper and lower portions of upset 30 . In this case, stress relief grooves 32 and 34 preferably comprise an axial shape component in that a significant portion of grooves 32 and 34 is oriented laterally aligned and preferably substantially parallel to the central axis of assembly 10 thereby limiting the maximum substantially laterally forces transmitted along the upper and lower surfaces and applied to upset 30 as a result of impact or hard pressure contact with receptacle 20 . The axial orientation of grooves 32 and 34 is therefore significant for limiting lateral forces and highly useful for controlling stresses applied to upset 30 as the result of generally laterally directed forces which include rolling lateral forces due to water motion impact and forceful contact pressures between centralizer and conductor 20 . As well the positioning of grooves 32 and 34 closer to upset 30 assists in this function especially due to bending loads applied to centralizer 26 which may vary depending on whether centralizer 26 has a more tapered or a more cylindrical profile when viewed in elevation. Various additional groove constructions for centralizer 26 are also discussed hereinafter.
[0047] In embodiment 10 A shown in FIG. 2 , centralizer outer diameter 24 is curved or arced or circular, as indicated at 25 which may be desirable for several types of operating environments. A curved surface 24 is useful for guiding assembly 10 A into conductor 20 and/or for guiding assembly 10 A by any restrictions that may be found within conductor 20 . Curved outer surface 25 may also be utilized to limit friction with conductor 20 . The width of centralizer 30 may be utilized to spread the stresses over upset 30 , and the length of upset 30 may be varied as well. The point contact of curved surface 24 may be more useful in anticipating and modeling forces than a cylindrical surface. A purely lateral or slight rolling lateral contact at or near the maximum OD 24 of rounded outer diameter centralizer 26 , which will occur near the axial center of centralizer 26 , may also tend to direct a substantial portion of the force of contact towards the central portion of upset 30 , i.e., the strongest portion of upset 30 , while reducing the stresses applied to the upper and lower portions of upset 30 . In this way, the stresses at the ends of upset 30 are then reduced and tend to further decrease in transition zones 36 where the minimized forces are applied to the remainder of the keel joint through blended upset transition zones.
[0048] Thus, for assembly 10 A, the combination of a tapered centralizer mounted to upset 30 , may provide a more even distribution of forces than if centralizer 26 were provided with a purely cylindrical profile which might tend to produce significantly higher maximum forces adjacent the upper and lower surfaces of centralizer 26 especially due to angled contact with conductor as may be produced by rolling waves and the like, whereby these maximum forces are applied to the upper and lower portions of upset 30 resulting in higher stress distributions and significant changes during operation to those distributions for the remainder of the keel joint thereby increasing the possibility of fatigue and/or operating life.
[0049] As explained in examples given hereinbefore and hereinafter, it will be appreciated by those of skill in the art that the present invention provides a variety of functional features that may be utilized as tools as discussed for selectively controlling, directing, and/or spreading stresses depending on the expected operating conditions. Various types of specially developed stress analysis computer simulation programs such as finite element analysis codes may be utilized to simulate and/or special testing facilities may be utilized to simulate the physical responses expected from a particular floating platform/marine riser system construction. Therefore, depending on the environment of operation, the design of upset 30 and centralizer 26 may vary considerably. Accordingly, once the anticipated stresses to applied are known, then the various specific design features as taught herein may be utilized to provide a better operating, longer lasting, more fatigue resistant, less expensive, and more reliable keel joint.
[0050] As mentioned briefly above, another presently preferred feature of one possible preferred embodiment of shrink fit centralizer assembly 10 , is that upset 30 may preferably utilize a tapered or blended region 36 between the thickest portion of upset 30 and remaining relatively narrower or nominal size tubular wall 38 of assembly 10 to thereby minimize the forces applied to the narrower tubular wall 38 . Depending on the types of forces, various types of tapers 36 or blended upset portions may be utilized as illustrated in FIG. 8-13 discussed hereinafter. Upset 30 may be cylindrical as in convenient for heat shrink mounting but could also be comprised of different shapes, if desired.
[0051] While the above discussed features of oriented centralizer grooves, tapered or blended upset regions, and shrink fit centralizer to stress joint 38 , and subsequently discussed features, may be utilized in combination for synergistic effects as illustrated in some presently preferred embodiments discussed herein, it will be understood that each of these features are important in themselves and may be utilized effectively separately, in various combinations, and/or in combination with other constructions to effect desirable results.
[0052] Assemblies 10 B, 10 C, 10 D, and 10 E, shown respectively in FIG. 4 , FIG. 5 , FIG. 6 , and FIG. 7 illustrate other embodiments, variations, and features of the present invention.
[0053] Assembly 10 B provides centralizer 40 which has a straight outer profile or cylindrical outer surface 42 . Outer surface 42 may comprise an insulative coating 44 electrically insulative and/or water tight sealing insulative coating 44 such as an elastomeric coating to avoid potential problems with corrosion and/or galvanic action of two dissimilar metals. Coating 44 may be comprised of various types materials such as elastomerics or other suitable insulative materials some of which maybe at least somewhat flexible, compressible, resilient, and/or at least more pliable than steel. Coating 44 may be relatively thick as desired to provide shock insulation. Coating 44 may also comprise composite materials that are electrically nonconductive and provide high load-bearing, fatigue-resistant interface between centralizer 40 and receptacle 20 in which centralizer 40 may operate (see FIG. 1 ). If a composite is used, the composite could be comprised of reinforcing filler supported in a polymeric matrix selected from a group consisting of thermoplastic resins, thermosetting resins, and mixtures thereof. Non-limiting examples of reinforcements thereof may comprise fibers such as glass fibers, aramid fibers, boron fibers, continuous fibers. Fiber reinforced coatings may be laminated and/or molded.
[0054] Even though outer surface 42 of centralizer 40 is cylindrical, the earlier mentioned problems of stress produced at the tops and bottoms of the centralizer and at the corresponding upper portion 46 and lower portion 48 of upset 50 are reduced by means of stress relief grooves 52 and 54 as well as upper annular guide 56 and lower annular guide 58 , which is integral with shrink fit centralizer 40 . Stress relief grooves 52 and 54 limit lateral forces applied through centralizer 40 to corresponding upper and lower portions 46 and 48 of upset 50 as explained before. Upper guide 56 and lower guide 58 also spread the forces over a wider area including the entire upset including upper transition zone 60 and lower transition zone 62 . Thus, large stresses at upper and lower portions 46 and 48 of upset 50 are reduced and the stress along upset 50 is more uniform. Guide 56 and lower guide 58 also provide additional axial movement guidance of assembly 10 B as may be useful for axial movement into and within receptacle 20 . Stress relief grooves 52 and 54 utilize both an axially oriented portion 64 and a radially oriented portion 66 which reduces stress at upper and lower portions 46 and 48 of upset 50 for purely lateral forces as well as for bending forces whereby the forces tend to be directed more towards the central portion of upset 50 as is desirable.
[0055] Assemblies 10 C and 10 D, in FIG. 5 and FIG. 6 , utilize similar shrink fit rounded edge centralizer portions 70 and 90 as centralizer 24 of assembly 10 A. However, upper guides 72 , 92 and lower guides 74 , 94 are utilized. The widths of centralizers 70 and 90 are larger with respect to the length of the corresponding upsets 76 and 96 as compared to upset 30 , thereby providing additional stress spreading. Axially oriented grooves 75 and 77 limit stress applied to upper and lower portions of upset 76 . Axially oriented groves may be formed at other positions that the top and bottom of the centralizer, if desired, as previously shown in FIG. 10B , for desired stress control, directing, spreading. Annular opening 78 around lower upset transition region 82 permits greater flexibility for anticipated flexing needs of lower tubular 80 .
[0056] In FIG. 6 , annular openings 98 and 100 at both upper and lower upset transition zones plus radially oriented grooves 102 and 104 permit additional flexibility of upper and lower pipe sections 106 and 108 for system 10 D. Upper and lower contact surfaces 97 and 99 spread some already significantly reduced stresses due contact with surface 110 to pipe sections 106 and 108 thereby enhancing stress reducing operation of upset transition zones 101 and 103 . Insulation layer 110 reduces corrosion, galvanic reactions, and/or shocks.
[0057] Assembly 10 E provides yet another embodiment of a shrink fit centralizer 120 whereby forces tend to be more greatly minimized over the lower portions due to lower guide 122 , lower positioned slot 124 , and round outer surface 126 . This embodiment might be preferred under operating conditions where contact with cylinder 20 or obstructions therein is more likely to occur adjacent the lower portion of centralizer 120 .
[0058] Thus, the above assemblies 10 A- 10 E provide various advantages depending on predicted operating conditions.
[0059] As alluded to hereinbefore, additional means for controlling, directing, and/or spreading stresses is provided utilizing different upset transition zones as illustrated in FIG. 8 , FIG. 9 , FIG. 10 , FIG. 11 , FIG. 12 , and FIG. 13 whereby the outer diameter varies from the outmost diameter 130 to of upset 132 to the nominal outer diameter 134 of the pipe. Computer analysis of the expected operating forces may be utilized to select the most desirable transition zone along with cost/benefit considerations. Blended or gradual changes over larger areas are more likely to absorb/spread bending stresses. Sharper edges may be utilized where less bending is anticipated because stress concentrations tend to be increased at sharper edges. However, cost may be a factor since there may be no cost justification to machine a more gradual change in the upset. On the other hand, in some circumstances it may be desirable to avoid any sharper points at all as indicated FIG. 12 which actually comprises a convex and concave upset transition zone which results in more gradual or uniform stresses. Further more complicated shapes may also be utilized.
[0060] Sharper edges such as shown at 140 , 142 , 144 , ( FIG. 9 , FIG. 10 , and FIG. 11 ) may be utilized when forces are well within desired tolerances and wherein it is desired that stresses drop off or blend into the nominal wall thickness at various rates of change as provided by conical transition zone 146 ( FIG. 9 ), gradual concave transition zone 148 , ( FIG. 10 ), and sharper concave transition zone ( FIG. 11 ). FIG. 13 , provides a two stage upset transition zone 152 and 154 as may be most appropriate in anticipation certain operating conditions. Additional stages may be utilized, if desired.
[0061] The above features including grooves such as axially oriented grooves, shrink fit centralizers, tapered transition zones may be adjusted and utilized in various ways to meet anticipated operating conditions to provide durable long-lasting keel joints. The above embodiments are given only as examples. Grooves may be varied in size and location, for instance axially oriented grooves may be positioned adjacent upset portions at which it is desired to reduce stresses or make them more uniform. Bending stresses at anticipated bending portions of the keel joint may be reduced by more gradual or tapered upset transition zones. The design of the centralizer, the outer surfaces thereof, the position and type of stress grooves, the width of the centralizer, the length of the upset and length and type of transition zone are all tools that may be flexibly utilized as discussed hereinbefore to provide an improved keel joint. The larger portions of the upsets shown above are generally cylindrical but could take other shapes as desired as may need coordination with shrink fitting of the centralizer and costs thereof.
[0062] Accordingly, the present invention provides shrink fit centralizer assemblies of various types which may are especially useful as stress joints for absorbing the high stresses associated with keel joints and other riser interconnections. The invention relates to stress joints such as a keel joint having an upset with a centralizer that is shrink-fitted to the upset portion of the keel joint. The keel joint has an upset, generally cylindrical, which has tapered sections on the upper and lower ends thereof, which in some embodiments gradually blend into the OD of the pipe sections above and below the upset.
[0063] The foregoing disclosure and description of the invention is therefore illustrative and explanatory of a presently preferred embodiment of the invention and variations thereof, and it will be appreciated by those skilled in the art that various changes in the design, organization, order of operation, means of operation, equipment structures and location, methodology, and use of mechanical/insulative/cathodic equivalents, as well as in the details of the illustrated construction or combinations of features of the various elements, may be made without departing from the spirit of the invention. As well, the drawings are intended to describe the concepts of the invention so that the presently preferred embodiments of the invention will be plainly disclosed to one of skill in the art but are not intended to be manufacturing level drawings or renditions of final products and may include simplified conceptual views as desired for easier and quicker understanding or explanation of the invention. As well, the relative size and arrangement of the components may be greatly different from that shown and still operate within the spirit of the invention as described hereinbefore and in the appended claims. It will be seen that various changes and alternatives may be used that are contained within the spirit of the invention.
[0064] Accordingly, because many varying and different embodiments may be made within the scope of the inventive concept(s) herein taught, and because many modifications may be made in the embodiment herein detailed in accordance with the descriptive requirements of the law, it is to be understood that the details herein are to be interpreted as illustrative of a presently preferred embodiment and not in a limiting sense.
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A centralizer system is provided for use in a marine riser system to provide a stress joint or keel joint with a upset portion. The centralizer is preferably heat-shrink fitted to the upset portion of the keel joint. The upset portion has tapered sections on the upper and lower ends which may be of various shapes and lengths that gradually blend into the outer diameter of the pipe used as the keel joint. The centralizer may also be heat-shrink fitted to one of the tapered sections. The centralizer may or may not utilize guide sections mounted on either end thereof. In a preferred embodiment, the centralizer comprises axially extending annular grooves in surrounding relationship to the upset portion, the grooves serving to permit forces acting on the centralizer to be redirected or dissipated to thereby prevent excessive buildup on a selected region of the upset portion adjacent the radial grooves. In one embodiment, the grooves are formed annularly around the ends of the upset portion to thereby limit stresses that otherwise tend to build up on the ends of the upset portion.
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CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. patent application Ser. No. 11/312,006, filed Dec. 20, 2005, which claims the benefit of U.S. Provisional Patent Application Ser. No. 60/667,449 filed on Apr. 1, 2005, which are incorporated by reference as if fully set forth.
FIELD OF INVENTION
[0002] The present invention generally relates to wireless communication systems, and more particularly, to a method and apparatus for validating radio resource control messages.
BACKGROUND
[0003] The 3GPP standard 25.331 specifies the radio resource control (RRC) protocol for the radio interface between a wireless transmit/receive unit (WTRU) and a UMTS terrestrial radio access network (UTRAN). Section 8.6 of standard 25.331 describes the rules that the WTRU must follow for validating downlink peer messages received from the UTRAN. Included in this section are rules regarding transport channel information elements (IEs).
[0004] Specifically, the standard states in Section 8.6.5.2 that if the IE “Transport format combination set” is not included and either (1) if no transport format combination set is stored in the WTRU; or (2) if transport channels are added or removed in the message; or (3) if any transport channel is reconfigured in the message such that the size of the transport format set is changed, then the WTRU shall set the variable INVALID CONFIGURATION to TRUE.
[0005] This means that if the any of the above conditions are met, the WTRU should reject the peer message. The rule does not take additional information into account, such as the type of transport channel being modified, the configured RRC state of the WTRU, etc.
[0006] The two basic operational modes of a WTRU are “Idle” and “Connected” modes. The Connected mode is further divided into several RRC states (i.e., a CELL_DCH state, a CELL_FACH state, a CELL_PCH state, and a URA_PCH state), which define the kind of channels that the WTRU is using. In the CELL_DCH state, dedicated channels are allocated to the WTRU. In the CELL_FACH state, no dedicated channel is allocated for the WTRU but the WTRU uses common channels which are shared by all WTRUs. While in the CELL_FACH state, the WTRU may receive (and must retain) certain information regarding dedicated channels. This information may then be used by the WTRU if the WTRU is directed by UTRAN to transition into the CELL_DCH state.
[0007] During an interoperability test session, a WTRU under test failed several connection attempts. Analysis showed that the WTRU was rejecting the network's RRC connection setup message because it broke the validation rule. Specifically, the message was directing the WTRU to the CELL_FACH state and was adding a dedicated transport channel, but was not including a transport format combination set (TFCS). The problem was that the validation rule was indeed broken as written. Based on this test result, the implementation of the validation rule could benefit from being more flexible.
[0008] Network operators may be tempted to read this rule liberally, thinking that the rule should only apply to transport channel elements that the WTRU will use in its immediately configured RRC state. The temptation (and perhaps confusion) is reinforced by the current ASN.1 message syntax which requires networks to add dedicated transport channels to all WTRUs upon RRC connection setup, even those being configured for the CELL_FACH state. However, simply delaying an application of the rule until such time as the channels will be used (i.e., when the WTRU is configured for CELL_DCH) will not suffice since the rule is transaction-based. By applying the rule as it is written, the WTRU may reject an operable configuration (such as in the case described above). But by delaying the application of the rule, as the following example shows, the WTRU may accept an inoperable configuration, which is arguably worse.
[0009] For example, consider a WTRU that is operating in a CELL_DCH state. A UTRAN sends a message to the WTRU directing it to a CELL_FACH state and removing a transport channel, but not including a new TFCS. The WTRU accepts this message because the transport channels will not be used in the CELL_FACH state. A UTRAN sends a message to the WTRU directing it to a CELL_DCH state, including neither new transport channel information nor a new TFCS. The WTRU accepts this message because it does not break the validation rule. However, the WTRU will not be able to operate in the CELL_DCH state because it lacks the appropriate transport channel information or TFCS.
SUMMARY
[0010] A method for validating radio resource control (RRC) messages includes determining whether an RRC message received by a wireless transmit-receive unit (WTRU) is valid based on: an RRC state for which the WTRU is configured, whether or not the WTRU needs a new transport format combination set, and whether or not the RRC message will configure the WTRU for a CELL_DCH state.
[0011] A WTRU includes a rule application device configured to implement the method.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] A more detailed understanding of the invention may be had from the following description of a preferred embodiment, given by way of example, and to be understood in conjunction with the accompanying drawings, wherein:
[0013] FIG. 1 is a flowchart of a method for applying a validation rule to an incoming RRC message; and
[0014] FIG. 2 is a block diagram of a device configured to apply a validation rule to an incoming RRC message.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0015] Hereafter, the term “wireless transmit/receive unit” (WTRU) includes, but is not limited to, a user equipment, a mobile station, a fixed or mobile subscriber unit, a pager, or any other type of device capable of operating in a wireless environment. When referred to hereafter, the term “base station” includes, but is not limited to, a Node B, a site controller, an access point, or any other type of interfacing device in a wireless environment.
[0016] If a WTRU wants to allow for a liberal interpretation of the validation rule as defined in the standard (and therefore operate in the most networks possible) and still protect itself against invalid configurations, the WTRU must perform transport channel validation in a manner not described in the standard.
[0017] FIG. 1 is a flowchart of a method 100 for applying the standard validation rule to an incoming message. The method 100 begins by receiving a peer message at a WTRU (step 102 ). The WTRU applies the validation rule to the received message (step 104 ). A determination is made whether the WTRU needs a new TFCS based on the received peer message (step 106 ). If the WTRU needs a new TFCS, then a TFCS indicator (e.g., a TFCS_NEEDED flag) is set to true (step 108 ). The TFCS indicator is maintained in the WTRU. If the WTRU does not need a new TFCS, then the TFCS indicator is left unchanged.
[0018] Next, a determination is made whether the WTRU received a new TFCS in the received peer message (step 110 ). If the WTRU received a new TFCS, then the TFCS indicator (e.g., the TFCS_NEEDED flag) is set to false (step 112 ). If the WTRU did not receive a new TFCS, then the TFCS indicator is left unchanged.
[0019] A determination is then made whether the WTRU is configuring itself for the CELL_DCH state based on the received peer message (step 114 ). If the WTRU is not configuring itself for the CELL_DCH state, then the message is accepted (step 116 ) and the method terminates (step 118 ). If the WTRU is configuring itself for the CELL_DCH state (step 114 ), then the TFCS indicator is evaluated to determine if it is set to true or false (step 120 ). If the TFCS indicator is set to true, then the WTRU rejects the message (step 122 ) and the method terminates (step 118 ). Since the WTRU needs a new TFCS and the network has not supplied the new TFCS during configuration for the CELL_DCH state, the message is properly rejected. If the TFCS indicator is set to false, then the message is accepted (step 116 ) and the method terminates (step 118 ). Since the network has supplied the WTRU with a new TFCS prior to or during configuration into the CELL_DCH state, the WTRU correctly accepts the message. In all cases, the WTRU continues operating error-free in the data plane.
[0020] The present invention allows the WTRU to operate on networks that interpret the validation rule liberally. The present invention also allows the WTRU to still protect itself against invalid configurations and, therefore, continue operating without self-induced errors in the data plane (leading to less retry and/or fallback handling, and ultimately fewer dropped calls).
[0021] Alternatively, the WTRU may not apply the TFCS validation rule, but the WTRU risks accepting invalid configurations or dropping calls. Another alternative is that the WTRU may delay applying the cited TFCS validation rule until the WTRU is configured for the CELL_DCH state. In this case, the WTRU also risks accepting invalid configurations or dropping calls.
[0022] FIG. 2 is a block diagram of a device 200 configured to apply a validation rule to an incoming RRC message. In a preferred embodiment, the device 200 is a WTRU. The device 200 includes a receiver 202 , a rule application device 204 in communication with the receiver 202 , a message accepting device 206 in communication with the rule application device 204 , and a message rejecting device 208 in communication with the rule application device 204 . In operation, the receiver 202 receives an incoming RRC message for the device 200 . The rule application device 204 applies a message validation rule to the received message and checks the configured state of the WTRU. If the message passes the validation rule or is not configured for the CELL_DCH state, then the message accepting device 206 takes the message and processes it accordingly. If the message fails the validation rule and is configured for the CELL_DCH state, then the message is passed to the message rejecting device 208 and is discarded.
[0023] Although the features and elements of the present invention are described in the preferred embodiments in particular combinations, each feature or element can be used alone without the other features and elements of the preferred embodiments or in various combinations with or without other features and elements of the present invention.
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A method for validating radio resource control (RRC) messages includes determining whether an RRC message received by a wireless transmit-receive unit (WTRU) is valid based on: an RRC state for which the WTRU is configured, whether or not the WTRU needs a new transport format combination set, and whether or not the RRC message will configure the WTRU for a CELL_DCH state. A WTRU includes a rule application device configured to implement the method.
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FIELD OF THE INVENTION
This invention relates to an amusement device, more particularly to a toy that simulates the various postures effected by a pair of wrestlers. Although it may be conceivably used as an interactive toy, the preferred embodiment conceives of single operator usage that is meant to amuse use rather than instill a combative or competitive spirit in the participants.
BACKGROUND AND SUMMARY OF THE INVENTION
Many games, both interactive and sole participant, have been developed through the years and which have the primary purpose of amusement only, that is, it was the intent of the inventors to delight the player or participant rather than instill in two or more players a competitive or combative spirit. An almost negligible portion of these games, if of the purely amusement type, were composed of two or more characters, dolls or game devices. It seemed to the inventor that if one were to amuse oneself by observing a game that related to a combative sport (boxing, wrestling, karate, etc.), he would have to view television, cinema or attend such a function, in person.
I devised the present invention so that a child of tender years could be amused by a two-character game, specifically wrestling or any game which included body grips and unusual physical contortions or postures, without being compelled to face violent situations or a rival in order to enjoy the game. Also after watching younger children enjoy cartoons and television shows dealing with today's superheros, I felt there was a compelling need to provide such an amusement device that would allow the child to simply enjoy the game as an observer, without being inundated by the superfluous media that today attends such events.
One of the first attempts to provide amusement of the aforementioned type, was that disclosed by Watkins in his AMUSEMENT DEVICE, U.S. Pat. No. 1,167,958. The Watkins invention embodied a pair of jointed puppets that employed interactive manipulative means to effect a boxing activity. The doll employed in the Watkins device used pivoting at the hip joints and at the shoulder joints.
Unfortunately, this pivotable jointing allowed only a single degree of freedom (rotational) for the members so joined. The interactive play of the rival players comprised a jiggling or up-and-down motion which was imparted to the dolls by a string-pulley arrangement. A single connection between the dolls of this invention, at the boxers' abdomens, served to maintain the dolls at the same proximity. Although this mechanism served Watkins well, it would not suffice in my invention since the posture of wrestlers is one of almost constant interconnectivity which could not be served by either the singular hip and arm rotational motions, the held-apart relationship of the dolls or the jiggling action.
In 1938, Mangold disclosed, in U.S. Pat. No. 2,114,657 an ADVERTISING AND AMUSEMENT DEVICE that required only single participant (or drive means) activity and effected a pair of boxers engaged in the sport while suspended over, but not touching, a horizontal surface. Intermittent or momentary fixed contact was made between the fighters by the placement of small spikes on their hands. When contact was made by the fist of one fighter with the body of the other, the spikes would momentarily penetrate the body of the struck fighter. Thus, as with the Watkins invention, Mangold's could at best effect only an intermittent coupling or clinching, which is not satisfactory for a wrestling-type amusement device. Further, even though Mangold employed connections to the heads of his figures, the motion imparted to them was a jiggling motion rather than a twisting and turning motion which is more common in wrestling and in the prolonged body contacting sports.
One invention having only a single figure was disclosed by Gardel, in U.S. Pat. No. 3,700,384, in 1972. The singular doll figure was attached to a motive mechanism, at its head. It was the purpose of the motive mechanism to impart a regular torquing motion to the figure which possessed interconnected moveable arms and thighs. Because this doll was to effect the motions of a ballerina, the arm and leg motions were of necessity synchronized. This very clever amusement device well suited the objectives of the inventor; but those objectives led to the creation of a device which was inappropriate for effecting the motions of two figures, notably wrestlers. In order to provide a suitable wrestling simulation amusement device, it was necessary to overcome the limitations of the prior art by providing a motor means which torqued rather than jiggled the characters, dolls or figures. Further, it was found necessary to provide connections essentially at the head of one of the figures so that a twisting motion rather than a jiggling motion could be imparted to it. Finally, a means was devised for imparting an irregular twisting motion as well as a stylized interconnectivity or coupling between the figures to assure a form of continued gripping and clinching contact.
In carrying out the invention I have employed a pair of human-like figures of the same shape and dimension, fashioned out of a relatively light-weight material such as balsa wood or polystyrene. The heads of the figures are attached by slender flexible shafts, preferably wire, to the clavicle portion of the body. The arms of both figures are formed circularly, the fore and upper arms being rigid and fixedly joined together. The hands of each figure are joined and actually comprise either a singular loop of wire or an interlinked pair of clevises; thus, each figure's forearms are joined by a "hand". The upper arms pivot at the shoulder and thus, in their rigid circular posture, can move with only a single degree of freedom (rotational). In my preferred embodiment, the hand loop of the second figure is pivotally fixed about the neck shaft of the first figure. This is done in order that the motion or torque which will be applied, to the first figure only, will serve to carry the second figure along with the first. Continuing with the construction of the figures, rigid thighs are fixedly joined, at predetermined angles, to rigid lower legs. The thighs are joined to the hip positions of the figures by links that allow essentially two degrees of freedom movement. The remaining portion of the body comprises fixedly joined foot portions that may be joined to the lower ends of the lower legs in varying angular relationship.
The figures are suspended above a frictional surface that will have the effect of retarding or restricting the sliding or moving motion of the figures as they sweep over it. A single wire is connected to a clevis located on the top of the head of the first figure and it is through this wire that an intermittent torque is applied to the assembled apparatus. The means which I have employed for applying intermittent torque to my invention is a very thin, flexible wire which has the ability to store a rotational force (torque) as spring tension. Those familiar with the art will recognize that several means of imparting intermittent torque are possible, including an intermittently operated motor, a flexible spring such as employed by the inventor, a rotating shaft which has been linked to the head of the first figure by a coiled spring, rubber bands, or other suitable tension-storing device or the application of the torque through a slip-clutch transmission.
To operate the invention and effect the various wrestling postures, it is only necessary to impart a torquing moment to the top of the head of the first figure. The frictional surface has a tendency to constrain the first figure (and the second figure which is connected to the first) in its rest position. The torquing force builds and is aggregated by the tension storing mechanism until enough force is accumulated to overcome the frictional constraint on the figures, as well as rest inertia, and the first figure abruptly breaks free of the restraining surface. The second figure, teathered to the first by its hand-neck connection, is literally dragged and twisted along with the first figure. The momentum of the twisting figures rapidly releases the tension in the tension storage means and imparts, by inertia, a countertorque back along to the motive means. At this point, the figures come to rest in an entirely different posture. The continual or intermittent application of the torquing force, combined with the near-instantaneous break away of the figures from the constraining medium, allows the observer to witness myriad postural relationships between the figures that very closely emulate a wrestling pair.
Other objects of the invention and other amusement applications as may be hereinafter devised should become apparent from practice with the novel elements of the preferred embodiment. Such objects and varying applications are meant to be limited therefore only by the appended claims.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an isometric illustration of the two figures of the invention;
FIG. 2 is an isometric illustration of the two figures suspended over a frictional surface; and
FIG. 3 is a top view schematic of the motive means and torque storage means.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Reference now being had to the drawings, specifically FIG. 1, there is depicted a first FIG. 10 and a second FIG. 12. This isometric illustration portrays the two human-like figures of the preferred embodiment with the limbs of the bodies poised so as to reflect a singular possible posture of the two figures. Each figure comprises a head 13 attached to a torso 14 by a single straight wire 15 that further comprises the neck shaft of each figure. The upper arms 16 and the thighs 20 are pivotally affixed to the torso and comprise he only moving parts of the discrete figures; specifically, motion or movement is effected at shoulder-upper arm joint 30 and hip-thigh joint 19. Forearms 18 are connected to upper arms 16 by a bendable wire 26. With the exception of joints 30, 19, all other joints between the various limbs, torso and head are comprised of such bendable wire 26. At the ends of the forearms are the figures' hands comprised of interlinked clevises or loops 21, in the case of the first FIG. 10, and a single loop 34, in the case of the second FIG. 12. The observer should note that this form of linkage gives rise to a circular arm formation for both figures that, because of pivotal pin 32, will allow the arms to move only upward and downward, in relation to the torso; that is, the plane comprising the arm circle can pivot upward and downward with a single degree of freedom.
The thighs are joined to the torso hips at joint 19 in a slightly different fashion than the arms. Interlinked cleavises 28, or wire loops, are used to lend a two-degree of freedom movement to the leg members. As with the arms, the remaining portion of the legs (the lower 22) and foot parts 24 are joined in the same fashion, by attaching the feet to the lower legs, and they to the thighs 20 by means of bendable wires 26. The use of bendable wires 26 allows the bending of the lower leg portions into different angular relationships with respect to the thighs 20.
Two distinct differences ar noticed in this illustration that avoid congruence between the figures. First, the "hands" of the first FIG. 10 comprise interlinked wire loops or clevises 21. These loops are herein depicted having angular geometries, more precisely they are squares. If, instead, a clevis is inserted at the end of each forearm 18, interlinked with its counter part to form the hand 21 herein depicted, they should be shaped to embody right angles. Although a circular loop or interlinked loops have been used with some degree of success, as well as a bendable wire 26, the inventor has observed the best operation of his invention when all elements are constructed as herein portrayed.
The second difference is the placement of the single loop 34 which comprises the hands of second FIG. 12, about the neck shaft 15 of the first FIG. 10. When an irregular torquing moment is applied about the head 13 of the first FIG. 10, only it (the first figure) has a tendency to rotate. With the first spasm however, the arms of the first figure rise and engage the outstretched arms of the second figure in a somewhat lifting motion. As the first figure breaks away from its original (inert) position, the second figure is dragged by the connection 34/15 and urged upward because of the rising twisting motion of the first figure's arms 16/18. It must be remembered that only the first figure is actually a motivated figure; in that, the torquing moment is being applied at the first figure's head clevis 36. It is the sudden spasmodic movement of the first figure which thrusts the second figure, constrained at point 34/15 into a slightly upward and tangential direction. Simultaneously, the torso 14 of the second figure, taking the momentum delivered through its arms 16/18, attempts to rise off its legs, allowing them to rotate on joints 28 with essentially two degrees of freedom. Thus, when the figures come to rest again, the original posture has been radically perturbed and a new one has been assumed.
FIG. 2 is an isometric illustration of the assembled amusement device of the instant invention. The figures are suspended by flexible wire 40 connected by wire loop 38 to the first figure's head clevis 36. Brace 42 ensures that wire 40 suspends the figures at a point where they just make contact between foot members 24 and frictional surface 46. Frictional surface 46 is in actuality the top of box 49 and also serves as a receiver for support mounting 44. Tube 48 represents the conduit for the output shaft of a rotary motive device. The coupling of output shaft 50 through flexible wire 40 to the head 13 of the first FIG. 10 insures direct coupling of the torquing moment to the first figure.
As in the aforementioned operating description, when a torquing moment is applied to head 13, the twisting motion of the first FIG. 10 (which is very abrupt, as the figures' feet 24 break away from frictional surface 46), causes both figures to take on a sudden momentum that serves to reposition the limbs and to effect a totally different combative posture. Even though the "hands" of the second figure never leave the neck of the first figure, nor do the arms of the first figure ever grasp or take hold of the body of the second figure, the myriad physical contortions that the figures appear to emulate, leave the viewer with a distinct impression that the figures are engaged in wrestling.
Box 49 contains the motive mechanism for the apparatus and is depicted in the schematic of FIG. 3. The torquing moment output shaft 50 is observed in the upper left hand corner and penetrates through the corner of the box by a tube 48, terminating in hook 52. The linkage between hook 52 and coupling mechanism 64, which is attached to the output shaft of transmission 67, is an embodiment selected by the inventor which would allow him to transmit the torque of electric motors 66 through transmission 67 to output connecting shaft 50 in a cost-effective manner while still acquiring a torque storage mechanism to effect the intermittent application of torque to the first figure. Rubber bands 54/62 are used singularly or pluralistically in generally parallel array, to convey the torquing moment applied to coupling 64 to hook 52. Push-pull tab 58 is used to intercept the end of hook 56 so as to abruptly stop all rotary motion that is applied to shaft 50. Inertial cylinder 60 is employed by the inventor so as to maintain the system's rotational inertia, much in the manner of an automotive fly wheel, after it has been set in motion. The entire apparatus presented between coupling 64 and shaft 50 is extremely useful for imparting the intermittent torquing moment; but, it is not considered an essential part of the invention. Likewise, the use of electric motor 66 gives rise to a need for battery or power source 68 means and switch 70 means in order to effect its operation. However, those of ordinary skill will recognize that shaft 50 may be readily driven by a rotary hand crank and a single rubber band 62 with or without an interial mass 60. In actual operation, the preferred embodiment operates as follows: the interrupt shaft 58 is inserted until it engages hook 56, assuring that no motion will commence until it is withdrawn. Switch 70 is thrown energizing motor 66 by battery 68 and motive power is applied through transmission 67 to coupling 64. The rotational moment representing output from the transmission 67 is stored in the rubber bands 62. When desired, the operator of the device withdraws interrupter 58 from hook 56 and rotary moment is immediately applied to interial mass 60, which in turn drives shaft 50, rapidly twisting flexible wire 40. The acute onset of rotary moment savagely twists the head of the first figure snapping the figure free of the frictional restraint 46, in what appears an attempt to "throw" the second figure. Inertial mass 60 will over shoot the nominal unwound position of bands 62 and, if the player desires interrupter 58 may be at that time inserted and the figures abruptly stopped. Whether interrupter 58 is used is irrelevant as the figures will always assume a new and uniquely contorted posture.
Other combative sport types of games may be readily devised admitting to the principles herein disclosed for this wrestling amusement device. While the instant invention derives its unique reposturing characteristics through the use of an irregularly applied force and an asymmetrical coupling between its figures, it is recognized tat several other variations of this particular theme may very well be attempted. Uses and application of the invention are therefore meant to be practiced within the scope of the appended claims.
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An amusement device of two moveably jointed, cojoined, articulated figures. The head of the first figure is caused to twist irregularly about its vertical axis and simultaneously impart a spasmodic momentum to the second figure. The figures are animated by the cooperation of the irregular twisting action operating through the first body and into the second through their joining. Motivation is suggested, as well as disclosed herein, for imparting an irregular torquing moment to the first of the figures.
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FIELD OF INVENTION
This invention relates to a method and device for cleaning a continuously advancing web-form textile material, wherein the material is soaked in a washing-active liquid that contains one or more surfactants and a compound that has a high adsorptivity for the contaminants being washed out and no affinity for the fibers of the textile material, and is subjected to a steam treatment immediately thereafter.
BACKGROUND OF THE INVENTION
DE 32 13 840 Al teaches the application of a foam to the pile side to wash or rinse a textile web of material and then to subject the textile material immediately thereafter to a steam treatment, in order then to rinse it with water to wash out the dissolved contaminants. It is also intended to perform the foam application in two stages, with the first applied foam initially being vacuumed off with the dissolved contaminants or squeezed out of the textile material and only then is the textile material precleaned in this fashion, fed into the steamer with a second applied foam. It is important for both stages that the foam prepared from one or more surfactants that have no affinity for the fibers of the textile material but exhibit a high adsorptivity for the contaminants being washed out, be prepared before the application to the textile material and be merely applied. This method does not ensure any intensive contact between the foam and the fibers of a thick pile, especially not over its complete length down to the roots. Complete cleaning is therefore not possible with this method.
Another treatment method is disclosed in DE 30 26 349 Al which teaches a cleaning method in which a foam is likewise poured onto the textile material, and is worked into the textile material before steaming. This treatment method, which has a pronounced influence on the pile, destroys the pile at least partially and produces a great deal of fluff, so that such working of foam is not suitable for textile materials with a pile.
Of course, the same applies when, as in foam dyeing as known from DE 30 45 644 Al, a liquid is applied to the textile material but the foam must then be produced by fulling or the like on the textile material.
SUMMARY OF THE INVENTION
The goal of the invention is to provide a method and a device with which the above-mentioned problems can be overcome. The textile material, especially with a pile, must be deep-cleaned without using large amounts of water or washing agent in a simple and brief continuous processing method without fluff being produced by forced mechanical working of the nap.
Taking its departure from the method of the type heretofore disclosed, the invention proposes the following for achieving the stated goal: the textile material is saturated with a liquid containing chemicals such as foaming agents to generate foam in a steam atmosphere, the textile material is transported to a steamer wherein the washing-active foam is generated; there the textile material is steamed under saturated steam conditions; and after passing through the steamer, the textile material is vacuumed from the visible or exposed side.
The advantage of this method is that the added liquid can be immediately conveyed without any difficulty down to the base of the pile into the textile material. When the foam is created under the influence of temperature in the steamer, it rises from the roots of the fibers to the tips thus transporting the contaminants to the surface of the textile material. There the contaminants can easily be vacuumed off in an environmentally friendly manner without additional washing water.
Of course, the process can be repeated or the textile material can be fed once again into the steamer without adding further liquid in order to align the nap laid down during vacuuming without disturbing the pile side.
BRIEF DESCRIPTION OF THE DRAWINGS
The device for working this method consists of an assembly of elements which are known of themselves. Advantageously, the elements are associated with one another in a special arrangement for this method and are further described with reference to the accompanying drawings wherein:
FIG. 1 is a vertical section through a shaft steamer in the transport direction of the web of textile material; and
FIG. 2 is a shaft steamer similar to the one shown in FIG. 1 but with a different arrangement for guiding the textile material.
DETAILED DESCRIPTION OF THE INVENTION
The apparatus shown in FIGS. 1 and 2 is a cleaning or washing device for a textile web wherein a steamer, here shaft steamer 1 is used. For cleaning and especially prewashing a continuously advancing web of textile material 2, which can have a pile 3, initially a liquid is applied to the pile through the application device 4 located below steamer 1 and then the web 2 is transported into the steam atmosphere for foaming the washing-active liquid. This foam, which transports the contaminants to the surface of the textile material, is then vacuumed away outside steamer 1 at vacuum device 5, whereupon cleaning is complete.
The cleaning device according to FIG. 1 consists individually of a stand or support frame 6, which supports application device 4, steamer 1, and vacuum device 5. Web 2, which travels with pile 3 upward, is deflected around deflecting rollers 7, 8, so that the pile is facing downward and then travels through a liquid outlet slot 9. Slot 9 extends only over the working width and ensures a uniform application of liquid over the length of the slot. For this purpose, the device consists of a beam 10 to which the liquid is supplied by one or more connections not shown. By suitable distribution of the liquid in beam 10 similar to the device according to DE 40 26 198.0 Al it is uniformly distributed and passes over the length of slot 9 into the pile of web 2. Above web 2, at its back, a pressure roller 11 travels in order to influence the penetration of the liquid into pile 3. It is possible then to feed web 2 directly into steamer 1 or to deflect it again in the direction of trough 12, formed by an immersion roller 13 and a gutter 13'. Trough or channel 13' extends with a runoff sheet 14 below beam 10 to catch excess liquid. On roller 13, pile 3 of web 2 can be dipped or the web can be sprayed only from above with liquid. For this purpose, a spray tube 15 is directed into the gap between the downward traveling web 2 and the dip roller 13, so that the liquid is forced by roller 13 from the back into textile material or web 2.
The liquid which is guided at the application device into the web, especially into the pile thereof, is a special mixture of washing-active chemicals and foaming agents that foam under thermal energy. The adsorptivity of the washing-active substances for the contaminants contained in the textile material and the simultaneous lack of affinity for the fibers causes the contaminants to be loosened from the fibers. Then each particle of dirt is carried by the resultant foam upward to the tips of the fluff fibers in order to be vacuumed easily therefrom.
For steaming in a saturated steam atmosphere, web 2 then travels upward into shaft steamer 1 which is open at the bottom, for which purpose the steamer deflecting roller 16 which is located at the top and is preferably driven is provided in the steamer housing. Web 2 travels over spreading guide rollers 17 back to stand 6 in which, ahead of the next deflecting roller 18, vacuum device 5 is positioned relative to the pile or the visible side of the webs of goods. The web then goes to the next treatment assembly over a speed-controllable roller 19 as shown in FIG. 1 or over a dancer roller control 19' as shown in FIG. 2.
Shaft steamer 1 consists of a simple housing open at the bottom, likewise mounted on stand 6. The endwise inlet wall 20 ends further down than wall 21 on the outlet side, so that only excess steam can escape from steamer 1. This steam is then captured and vented by means of hood 22 located outside wall 21. The required steam is supplied at the top through pipes 23 and then passes through perforated walls 24 into the processing chamber. Any condensate that is present flows down the sloping or vertical inside walls of the steamer into the gutters or troughs 25 that may be heated.
The steamer according to FIG. 2 resembles the steamer shown in FIG. 1 but the web guidance is provided for only a double input of the web. For this purpose, vacuum device 5 is directed upward in order to vacuum the horizontally aligned web from below. In the gore or space between downwardly traveling web 2 and deflecting roller 18 a spray tube 28 can also be provided to force other washing fluid at roller 18 through the textile material and vacuum it away at the same time. After passing around driven roller 27, the web then travels with the pile outward back into steamer 1, upward to steamer deflecting roller 26 and back down again to dancer roller control 19' as indicated. By means of the second steaming process, the nap or pile of the textile material can be evened out under the effects of heat in simple fashion.
The liquid for foaming under a steam atmopshere is sold for example by the Bayer company under the trademark "Levalin VKU-N." It consists basically of an alkylamide with an alkyl polyglycol sulfate. It is acid-resistant and is used essentially for polyamide tufting carpets. The same liquid is sold by the Ciba-Geigy company under the trade name "Irgapadol PN" and is prepared on the basis of a fatty acid amide and an alkyl polyglycol sulfate. The liquid is anionic and has a pH of 6.5-7.5.
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Textile webs that are to be dyed, printed, or otherwise finished must be fed to such a treatment process in a clean condition. For continuous cleaning without large apparatus and without environmental impact, the pile of the textile web is saturated with a liquid containing washing-active substances and compounds which are caused to foam under the effects of heat especially under steam. After steaming, the foam that is produced in the steam for cleaning is vacuumed away with the contaminants it contains.
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FIELD OF THE INVENTION
The present invention relates to a process for recycling polyester/cotton blends to the components of lower dialkyl ester of terephthalic acid and cellulose acetate.
Millions of pounds of waste textiles consisting of various blends of polyester fibers and cellulose fibers such as cotton and the like are produced annually in the manufacture of cloth, clothing, and other textile products. Such textiles are generally treated with resinous and other materials of various types to impart special properties to the fabric such as crease resistance, flame retardency, and the like. Small quantities of this waste are collected by waste dealers for use in paper, inner linings, and a few other low value products. The remaining waste is either burned or buried in landfills. Disposal of such a large volume of solid waste is an increasing problem for the apparel industry. Implementation of the Resource Conservation and Recovery Act is expected to intensify the problem of such waste materials.
Waste polyester scrap can be recycled for reuse by various processes. Generally, such processes involved initially degrading the polyester with a lower alkyl alcohol, such as glycol, and subsequently recovering the dicarboxylic diester by crystallization and the alcohol from the resulting reaction mixture by distillation.
A process has been disclosed in U.S. Pat. No. 3,801,273 providing a method of recovering waste cellulose fibers from mixtures of waste cellulosic fibers, waste polyester and/or acrylic fibers and synthetic, cross-linked resinous material. The methods therein disclose heating a mixture of the waste cellulosic fibers, waste polyester and/or acrylic fibers and synthetic, cross-linked resin materials within the range of from 212° to 275° F. for a period of from 3/4 to 5 hours in an aqueous treating solution containing an alkali metal hydroxide and one or more added, normally liquid chemical agents such as ketones, alcohols, lactones and sulfides which initiates the decomposition or solubilization of the waste polyester and/or acrylic fibers and synthetic, cross-linked resin materials; adding a neutral or alkaline oxidizing agent to the mixture of waste fibers and synthetic, cross-linked resin materials; heating the mixture of waste fibers in synthetic, cross-linked resin materials in the presence of the neutral or alkaline oxidizing agent to complete the decomposition or solublization of the waste polyester; and the recovery of the waste cellulosic fibers. A similar process is disclosed in U.S. Pat. No. 3,843,321. In the foregoing references, the cellulose fibers are washed and dried. Degradation of the cellulosic fibers is of such a low order that their usefulness in textile processes for the production of nonwoven fabrics is not impaired.
Various methods have been described in the prior art for the recovery of polyester from cellulose fibers. U.S. Pat. No. 3,937,671 discloses a process in which textile waste composed of blended polyester and cellulose fibers are subjected to the action of glacial acetic acid and acetic anhydride in the presence of a catalyst under conditions which serve to convert the cellulose component of the waste to cellulose acetate which is separated from the unreacted polyester component in the form of a solution adapted to be used in the manufacture of cellulose derivatives where the polyester is removed in a form which may be garnetted to obtain a staple fiber for reuse.
A similar process has been disclosed in U.S. Pat. No. 3,937,675. In the disclosed process, textile waste formed of blended cellulose and polyester fibers are treated with a mineral acid agent such as sulfuric acid, under conditions which serve to hydrolyze the cellulose and convert it to a form which is readily removed from the polyester fibers while leaving the polyester fibers substantially unaffected. The cellulose material is recovered in the form of fibrets adapted for use as such or for treatment in producing other cellulosic compounds whereas the polyester fiber recovered may be garnetted for reuse in either spun yarn manufacture or in nonwoven processes.
In such processes, the cotton is recovered in a highly crystalline form of hydrocellulose with a degree of polymerization determined by viscosity measurements of approximately 100. Dimensionally, the fibrets range in length from several microns to several millimeters and they have the typical diameters of cotton fibers. On the other hand, the polyester material separated from the cotton was washed with water and was dried and was then garnetted with the result that essentially undamaged polyester fibers adapted for reuse in spun yarn manufacture or in nonwoven processes were recovered.
These methods are very expensive and have not met with commercial success. Large quantities of reactants per weight of waste material are needed in the process of the U.S. Pat. No. 3,937,671 and the recovery materials must be dried. High reaction temperatures and large quantities of acid are necessary in the process of U.S. Pat. No. 3,937,675 and again the recovered materials must be dried.
Accordingly, there is a need for an economical process for recovering polyester fibers and cellulosic materials in useful forms from polyester/cotton textile waste.
It is another object of this invention to recover polyester fibers and cellulosic materials in useful forms from such textile waste. It is still another object of this invention to provide a process for recycling polyester/cotton blends which does not include a preliminary aqueous acid treatment. These and other objects of the invention will be apparent to one skilled in the art as the description thereof proceeds.
SUMMARY OF THE INVENTION
The present invention provides a process which is effective and economical in recycling polyester/cotton blend by reducing the polyester to a lower dialkyl ester of terephthalic acid and reducing the cotton to cellulose acetate. In particular, the present invention discloses a process for converting polyester and cotton blends to a lower dialkyl ester of terephthalic acid and cellulose acetate, including the steps of: (a) providing a blend of polyester and cotton fibers; (b) subjecting the blend to a first alcoholysis in a bath containing an alcohol and an effective catalyst and having a suitable temperature until the polyester is depolymerized; (c) removing the remaining cotton portion from the alcoholic solution of oligomers generated during the first alcoholysis; (d) performing a second alcoholysis of the depolymerized polyester in a bath containing a lower alkyl alcohol in the presence of an effective catalyst to produce the lower dialkyl ester of terephthalic acid; and (e) processing the recovered cotton fibers through pulping and acetylyzing processes until the cellulose acetate is recovered.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
In accordance with the present invention, sources for polyester/cotton blends may be obtained from various sources including, but not limited to, cut and sew waste from manufacturers, spinning waste from manufacturers and post consumer garments. It is noted that foreign materials should be removed from such sources, including other polymers such as nylon, and metallic objects such as zippers and buttons. It is also preferred that the polyester contained in the scrap materials be 100 percent PET, although up to 10 percent copolymer such as isophthalic acid may be still used, but will affect the yield of the diester of terephthalic acid produced. It is also noted that the cotton material used in the scrap should not be mercerized. This is a common process used in the cotton industry to improve the luster of the cotton material.
Once the scrap material has been accumulated, it is preferred that the scrap material be cut and chopped into small pieces for ease of handling and subsequent transfer into a reaction vessel. One example would be one inch squares of fabric. The material is then treated by a first alcoholysis in a normal reaction vessel. In such vessels, the scrap polyester/cotton blend is deposited, along with a lower alkyl alcohol and a suitable catalyst. Such alcohols used may include ethylene glycol, butane diol, propane diol, and methanol. Preferably, ethylene glycol is used. Suitable mono or di alcohols are suitable for use in the present invention. It is noted at this time that if methanol is used, then the DMT may be prepared directly.
Suitable catalysts which may be used would include basic alkali metal salts, such as sodium carbonate, lithium carbonate, sodium hydroxide or lithium hydroxide. Quantities of the alcohol and the catalyst used would be based on the amount of the polyester/cotton blend used in the reaction vessel. Preferably, the weight of alcohol used should be about three to four times the weight of the polyester/cotton blend sample. For example, if 100 grams of polyester/cotton blend is put into the polymerization vessel, then 300 to 400 grams of an alcohol, such as ethylene glycol is used. The amount of the catalyst used should be about 0.25 percent of the polyester/cotton blend weight.
The first alcoholysis is preferably run at atmospheric pressure with a constant nitrogen purge. It is noted that when methanol is used, the reaction is run at between 150 and 250 psig. As the reaction is started, the temperature will increase as the reaction proceeds, but should run between 180° C. to 210° C. for four to six hours. This reaction time can be shortened by using a monomer heel in the reaction vessel. The first alcoholysis is run until a degree of polymerization of less than 15 is obtained and preferably a degree of polymerization of less than 3. The reaction product is cooled to 150° C. to 170° C. The resultant slurry is then filtered to separate the cotton from the polyester slurry.
The means for removing the cotton from the reaction products includes filtering, centrifuging or belt presses. Preferably, in the present embodiment, filtering is used. The filtering may be either gravity or a vacuum type filter or a pressure filter. Typical filter media include glass frits for laboratory purposes, and stainless packing for production purposes. Subsequent to the filtering, the cotton can be air dried or nitrogen dried and washed with methanol to remove any residual oligomers and contaminants from the cotton.
Subsequent to the filtering, two processes will be done on the polyester oligomers and cotton. The polyester oligomers will process through a second alcoholysis from which a lower dialkyl ester of terephthalic acid will be produced. Generally, the alcohol used is an alcohol having an alkyl of less than 6 carbons and typically 1 or 2 carbons, and preferably methanol is used. A catalyst such as sodium carbonate is added and pressure in the range of 0 to 50 psi is applied to the alcoholysis at a temperature from 65° C. to 100° C. depending on the degree of polymerization of the oligomer. The process is continued until the diester of terephthalic acid is produced.
The cotton produced from the washing may be processed to cellulose acetate. The process for this includes both pulping the cotton and acetylation of the product. For laboratory pulping, the caustic digestion of the cotton is processed at 130° C., 4 percent on cellulose, 10 percent consistency for 1 hour subsequent to the caustic digestion, the product is hypochlorite bleached at 60° C., 3 percent solution, 10 percent consistency for 1.3 hours. Subsequently, the product is treated with cold caustic extraction at 40° C., 9.5 percent solution, 6 percent consistency for 30 minutes. The product is then washed. The cotton product is then acetylated to produce the triacetate cellulose.
EXAMPLES
To the bottom of a 1 L 2-piece reaction vessel with 3-24/40 ground glass joints was added 160 g of 50/50 polyester/cotton blend fabric (or any form of blend), 32 g of BHET made from glycolysis of PET bottle flake, 600 g of fresh EG, and 0.5 g of Na 2 CO 3 as catalyst. The top of the vessel was then put in place and equipped with a reflux column and condenser with nitrogen inlet, and two glass stoppers. The vessel and contents were purged with nitrogen for 45 min prior to the application of heat. The reaction was then heated at reflux (approximately 195°-200° C.) for 5 hours. The resulting mixture was allowed to cool to about 160° C. and was suction filtered through a pre-heated 2 L fritted filter. 514 g of EG solution was recovered with the remainder of the solution being soaked up by the residual cotton. The cotton was washed on the filter with 500 g of fresh EG. The recovered EG solution was saved and combined with the previous EG solution for concentration on the rotary evaporator. The cotton was further washed on the filter with 2×420 g of fresh methanol. These washings were combined and used as the solvent/reactant in the methanolysis step below. The cotton was then suction dried on the filter with application of a rubber dam over the top of the funnel allowing for more effective vacuum buildup and allowed to air dry for 24 hours at which time the still slightly wet cotton weight was 100 g.
The EG solutions (approx. 725 ml total) were concentrated by rotary evaporator to 1/3 of its original volume giving a solution with approximate concentration of BHET of 2 mol/L. This was used in the methanolysis reaction below.
To a 2 L 3-neck round bottom flask equipped with an air condenser and water condenser in sequence, and glass stoppers was added the combined methanol washes from above, and 0.5 g Na 2 CO 3 as catalyst. The solution was heated to approximately 40° C. at which time the concentrated (and still hot) EG/BHET solution was added. The reaction was allowed to reflux for about 30 minutes and allowed to cool. The resulting DMT was suction filtered, washed with a small amount of cold methanol and air dried. The resulting yield of DMT was 90 g (85% of theoretical). Analysis of the DMT showed it to be pure by thin layer chromatography (>98% purity).
Thus, it is apparent that there has been provided in accordance with the invention a method of recycling polyester/cotton blends to recover lower dialkyl esters of terephthalic acid and cellulose acetate. While the invention has been described in conjunction with the specific embodiments thereof, it is evident that many alternatives, modifications and variations will be apparent to those skilled in the art in light of the foregoing description. Accordingly, it is intended to embrace all such alternatives, modifications that fall within this sphere and scope of the invention.
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A process for recycling polyester/cotton blends by reducing the polyester to a lower dialkyl ester of terephthalic acid and reducing the cotton to cellulose acetate. The novel process to recycle the polyester/cotton blends includes the steps of (a) providing a blend of polyester and cotton fibers; (b) subjecting the polyester/cotton blend to a first alcoholysis in a bath containing an alcohol and an effective catalyst at a suitable temperature until the polyester is depolymerized to a lower molecular weight polyester oligomer; (c) remove the cotton fibers from the alcoholic solution of oligomers and process the recovered cotton fibers by pulping and acetylyzing processes to recover the cellulose acetate; and (d) alcoholyze the low molecular weight polyester oligomers to produce the lower dialkyl ester of terephthalic acid.
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This application is a continuation of application Ser. No. 236,732, filed Aug. 26, 1988, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a protective material capable of protecting a reforming catalyst and component materials from an electrolyte, in a molten carbonate fuel cell for generating electric energy by consuming hydrogen, which is formed from a raw fuel such as hydrocarbons.
2. Description of the Prior Art
FIG. 1 shows a perspective view of a major part of a conventional internal reforming type molten carbonate fuel cell disclosed in, for instance, Japanese Patent Application Laid-Open (KOKAI) No. 60-32255 (1985). In the figure, 1 denotes an electrolyte matrix composed of a porous ceramic with spaces therein filled with a carbonate used as an electrolyte, 2 denotes a fuel electrode (anode) composed of porous nickel or the like, and 3 denotes an oxidizing agent electrode (cathode) composed of a porous material such as nickel oxide. The fuel electrode 2 and the oxidizing agent electrode 3 are disposed opposite to each other, with the electrolyte matrix 1 therebetween, and these constitute a single unit of a cell. In the figure, 4 denotes an oxidizing agent passage provided for the oxidizing agent electrode 3, 5 denotes a perforated fuel-side spacer disposed in contact with the fuel electrode 2, and 6 denotes a rib provided perpendicularly to the fuel-side spacer 5, with the spacer 5 and the ribs 6 defining fuel gas passages 7. By 8 is denoted a fuel reforming catalyst packed in the fuel gas passages 7.
FIG. 2 shows a system diagram illustrating the construction of a fuel cell power generation system employing an external reforming type molten carbonate fuel cell body disclosed in Japanese Patent Application Laid-Open (KOKAI) No. 60-230365. In the diagram, a fuel treating device 9 and an air supply device 10 are connected to a molten carbonate fuel cell body 11. A combustor 12 is provided for oxidizing a fuel gas not reacted in the fuel cell body 11, a heat exchanger 13 is provided for removing surplus heat generated in the fuel cell body 11 to the exterior of the system, and a circulating blower 14 is provided for circulating an oxidized gas, which serves as a coolant.
Operations of the fuel cells will now be explained. In the internal reforming type fuel cell, the fuel reforming catalyst 8 provided in the fuel gas passages 7 adjacent to the fuel electrode 2 is used to induce a reforming reaction of a hydrocarbon or alcohol contained in the fuel gas, thereby forming hydrogen. Hydrogen thus formed through the reforming reaction in the fuel gas passages 7 is oxidized to water by an electrochemical reaction at the fuel electrode 2 adjacent to the passages 7. Part of the energy generated on the oxidation is converted to electric energy. For a long, stable operation of the internal reforming type fuel cell, therefore, it is essential to maintain a stable activity of the reforming catalyst 8 for a long time. However, in the conventional internal reforming type fuel cell, the reforming catalyst 8 is held adjacent to the fuel electrode 2 and, therefore, adhesion of the electrolyte to the reforming catalyst 8 is inevitable. On the other hand, the external reforming type fuel cell power generation system operates as follows. In a conventional fuel cell power generation system as shown in FIG. 2, the electrolyte or a substance formed therefrom which is contained in the fuel gas or oxidized gas discharged from the molten carbonate fuel cell body 11 is fed, as it is, downstream through the power generation system. This causes corrosion of component members of piping or apparatus, or lowering in the activity of the reforming catalyst. At a low-temperature part, in particular, problems such as solidification of the electrolyte and clogging of passages are generated. Thus, the conventional fuel cell power generation system has generally had the problem of reduction of the characteristics of the component apparatuses and the problem of a short service life.
Namely, in the conventional molten carbonate fuel cell power generation system as mentioned above, whether the molten carbonate fuel cell body is of the internal reforming type or of the external reforming type, the electrolyte evaporated or spattered into the reaction gas in the fuel cell body or the substance formed from the electrolyte will adhere to the materials constituting the fuel cell power generation system inclusive of the fuel cell body itself, to impair the characteristics of the constituent materials, thereby making it difficult to operate the system for a long time.
More particularly, for instance, the internal reforming type fuel cell body has the following problem. The reforming catalyst 8 is reduced in performance when contacted by the electrolyte held in the electrolyte matrix 1 or by decomposition products of the electrolyte. This arises from the migration of the electrolyte, through evaporation or the like, from the matrix 1 to the place where the reforming catalyst 8 is disposed. The degradation of the performance of the reforming catalyst 8, for instance, a nickel catalyst takes place as follows. When nickel particles (about 200 Å in diameter) makes contact with the electrolyte, nickel dissolves in the electrolyte as NiO, and growth of particles occurs. The particles grow to a particle size of about 500 to 3000 Å, with a reduction in surface area. Alternatively, the adhered electrolyte lowers the catalytic activity of the catalytically active substance (nickel particles). Thus, the performance of the catalyst is degraded. The dissolution of NiO in the electrolyte is discussed in literature [C. E. Baumgartner, "Solubility and Transport of NiO Cathodes in Molten Carbonate Fuel Cells", J. of American Ceramic Society, Vol. 69 (1986), pp. 162-168].
On the other hand, the use of the external reforming type fuel cell body has the following problems. First, the vapor of the electrolyte reacts with a main constituent material of piping or apparatus, for example, stainless steel parts at high-temperature, to form a corroded layer, thereby enbrittling or weakening the constituent material. In addition, adhesion or solidification of the electrolyte occurs at low-temperature parts to cause clogging, especially at narrow parts. Besides, as a total effect of the above, the electrolyte causes reduction in the characteristics and service life of the circulating blower 14, the heat exchanger 13, etc. For example, in a single-cell test on molten carbonate fuel cells, adhesion or solidification of the electrolyte was observed at narrow parts, particularly at an outlet pipe on the fuel gas side. For a steady operation, it was necessary to clean the piping, for instance, at a time interval of 1000 to 3000 hours.
SUMMARY OF THE INVENTION
The object of the present invention, attained for solving the above-mentioned problems, is to provide a protective material which is capable of preventing the degradation of a reforming catalyst in a molten carbonate fuel cell power generation system, protecting the component materials of a fuel cell body from an electrolyte and thereby preventing degradation of performance and ensuring a longer service life.
The protective material for a reforming catalyst used in a fuel cell according to the present invention comprises a ceramic comprising an oxide material capable of reacting with the electrolyte or a substance formed from the electrolyte.
Therefore, when the protective material for a reforming catalyst in a molten carbonate fuel cell according to the present invention, which includes a ceramic comprising an oxide material capable of reacting with the electrolyte or the substance formed from the electrolyte, is interposed between an electrolyte matrix and the reforming catalyst in the molten carbonate fuel cell, the protective material reacts with the electrolyte leaking from the electrolyte matrix or reaction products of the electrolyte, thereby preventing the electrolyte or the reaction products thereof from reaching the reforming catalyst.
The protective material for an electrolyte used in a molten carbonate fuel cell according to the present invention includes a ceramic comprising an oxide material capable of chemically reacting with the electrolyte in the fuel cell, and protects the component materials of a molten carbonate fuel cell power generation system from the electrolyte or the substances formed from the electrolyte.
Therefore, when the protective material is held in an appropriate place in a fuel gas system or an oxidized gas system in the fuel cell power generation system, the protective material reacts with the electrolyte leaking from the electrolyte matrix or reaction products of the electrolyte, thereby preventing the electrolyte or the reaction products from reaching the component materials of the power generation system.
Furthermore, when the protective material for the electrolyte contains an oxide material having a melting point lower than the temperature at which the fuel cell is used, the oxide material is melted to a liquid during use, thereby enabling rapid reaction thereof with the electrolyte or the reaction products of the electrolyte.
The above and other objects, features and advantages of the present invention will become apparent from the following description and appended claims, taken in conjunction with the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 shows a perspective view of a major part of a conventional internal reforming type molten carbonate fuel cell body;
FIG. 2 shows a system diagram illustrating the construction of a conventional external reforming type molten carbonate fuel cell power generating system;
FIG. 3 shows a perspective view of a major part of an internal reforming type molten carbonate fuel cell body employing the protective material for an electrolyte according to one embodiment of the present invention; and
FIGS. 4 and 5 each show a system diagram illustrating the construction of an external reforming type molten carbonate fuel cell power generation system employing the protective material for an electrolyte according to one embodiment of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
Of the materials usable as the oxide material for the protective material according to the present invention, those which are particularly preferable include, for example, TiO 2 , SiO 2 , MoO 3 , WO 3 , ZrO 2 , GeO 2 and B 2 O 3 .
Where a mixture of Li 2 CO 3 and K 2 CO 3 is used as the electrolyte, for example, TiO 2 , MoO 3 , WO 3 and ZrO 2 powders can be selected as a material to be reacted with K 2 CO 3 , while SiO 2 and GeO 2 powders can be selected as a material to be reacted with Li 2 CO 3 , and B 2 O 3 can be selected as a material to be reacted with both of the carbonates. Of these oxide materials, B 2 O 3 has the lowest melting point, 450° C., and is capable of functioning as a binder for TiO 2 or SiO 2 powder.
Now, TiO 2 and SiO 2 will be taken as examples. After addition of B 2 O 3 to TiO 2 or SiO 2 powder in an amount of 2 to 50% by weight, preferably 5 to 20% by weight, the admixture is molded in the shape of rods, pellets or disks, and the molded product is heated to a temperature of at least 450° C. for 10 min., whereby B 2 O 3 can be melted, and a firm ceramic can be obtained upon cooling. When a mixture of both of the ceramics is used, it is possible to capture Li 2 CO 3 and K 2 CO 3 .
Alternatively, B 2 O 3 may be added to a mixed powder obtained by mixing TiO 2 and SiO 2 powders in a predetermined ratio, in an amount of 2 to 50% by weight, followed by molding the admixture. The ceramic thus obtained, when used singly, is capable of capturing both Li 2 CO 3 and K 2 CO 3 .
The TiO 2 powder undergoes a chemical reaction upon contact with K 2 CO 3 , forming K 2 Ti 2 O 5 or the like. For example, the following reactions may take place.
SiO.sub.2 +K.sub.2 CO.sub.3 →K.sub.2 SiO.sub.3 +CO.sub.2 ↑
2TiO.sub.2 +K.sub.2 CO.sub.3 →K.sub.2 Ti.sub.2 O.sub.5 +CO.sub.2 ↑
Upon contact with Li 2 CO 3 , the SiO 2 powder forms Li 2 SiO 3 or the like through a reaction, for example:
SiO.sub.2 +Li.sub.2 CO.sub.3 →Li.sub.2 SiO.sub.3 +CO.sub.2 ↑
Upon contact with K 2 CO 3 or Li 2 CO 3 , B 2 O 3 forms KBO 2 or LiBO 2 or the like through reactions, for example:
B.sub.2 O.sub.3 +K.sub.2 CO.sub.3 →2KBO.sub.2 +CO.sub.2 ↑
B.sub.2 O.sub.3 +Li.sub.2 CO.sub.3 →2LiBO.sub.2 +CO.sub.2 ↑
The reaction of K 2 CO 3 with TiO 2 or the reaction of Li 2 CO 3 with SiO 2 proceeds at a very low rate if the electrolyte is not molten. On the other hand, when the electrolyte is molten (for example, a mixture of Li 2 CO 3 and K 2 CO 3 has a lowered melting point and is completely melted under the operating condition of the fuel cell), both of the reactions proceeds at a high rate. Since B 2 O 3 melts at 450° C., the reaction thereof with the electrolyte takes place at a high rate even when the electrolyte is in a solid state.
This characteristic feature is particularly important to the application of the present invention where it is necessary to remove efficiently the vapor of the electrolyte contained in the reaction gas in an extremely low concentration, for instance, 0.001 mol % or below, under the actual use conditions of the fuel cell.
TABLE 1 shows the results of investigation of the reactivities of the oxide materials, which can be used in the present invention, with electrolyte, carried out by use of a differential scanning calorimeter (DSC).
TABLE 1______________________________________Investigation results of reactivityof oxide materials with electrolyte Li.sub.2 CO.sub.3 K.sub.2 CO.sub.3 Li.sub.2 CO.sub.3 (62)-K.sub.2 CO.sub.3 (38) (solid) (solid) (liquid)______________________________________TiO.sub.2 (solid) slow slow fastSiO.sub.2 (solid) slow slow fastB.sub.2 O.sub.3 (liquid) fast somewhat fast slowMoO.sub.3 (solid) slow slow fastWO.sub.3 (solid) slow slow fastZrO.sub.2 (solid) slow slow fastGeO.sub.3 (solid) slow slow fast______________________________________
The above description pertains to TiO 2 and SiO 2 taken as examples of the protective material and referring to the addition of B 2 O 3 , but it should be noted that the protective material according to the present invention is not limited to TiO 2 and SiO 2 .
MoO 3 , WO 3 , ZrO 2 and GeO 2 can also be used as a material for capturing the electrolyte, in the same manner as TiO 2 and SiO 2 , because these oxides react with K 2 CO 3 or Li 2 CO 3 to form potassium molybdate, potassium tungstate, potassium zirconate and lithium germanate or the like, respectively.
The present invention will now be described more in detail while referring to the following examples.
EXAMPLE 1
To a TiO 2 powder having a particle diameter of 10 μm, 5% by weight of polyvinyl alcohol and 20% by weight of water were added, and after sufficient mixing, the mixture was molded by a pellet molder to prepare spherical pellets of 5 mm diameter. The pellets were packed into a fuel cell at the time of assembling the fuel cell, and were heated at the beginning of the fuel cell operation to evaporate off the residual binder and water.
EXAMPLE 2
Spherical pellets of 10 mm diameter were prepared in the same manner as in Example 1 except for using an SiO 2 powder of 30 μm particle diameter in place of the TiO 2 powder.
EXAMPLE 3
Spherical pellets of 5 mm diameter were prepared in the same manner as in Example 1 except for using an MoO 3 powder of 5 μm particle diameter in place of the TiO 2 powder.
EXAMPLE 4
Spherical pellets of 5 mm diameter were prepared in the same manner as in Example 1 except for using a WO 3 powder of 20 μm particle size in place of the TiO 2 powder.
EXAMPLE 5
To a ZrO 2 powder having a particle diameter of 3 μm, 10% by weight of B 2 O 3 of 10 μm particle diameter was added, and after sufficient dry mixing, a suitable amount of an alcohol was added to the mixture, followed by molding by a pellet molder to prepare spherical pellets of 3 mm diameter.
EXAMPLE 6
To an SiO 2 powder having a particle diameter of 50 μm, 20% by weight of B 2 O 3 of 30 μm particle diameter and 20% by weight of acetone were added, and after sufficient mixing, the mixture was molded by a pellet molder to prepare disk-shaped pellets of 10 mm diameter and 3 mm thickness.
EXAMPLE 7
A mixture of TiO 2 of 30 μm particle diameter with an SiO 2 powder of 30 μm particle diameter in a molar ratio of 1:2 was prepared. To the mixture, 5% by weight (based on the amount of the mixture) of a B 2 O 3 powder of 10 μm particle diameter was added, and after sufficient mixing, the resultant mixture was molded by a pellet molder into a rod shape of 5 mm diameter and 200 mm length. The rod-shaped pellets were heated to 500° C. for 10 min, and taken out, thereby enhancing the strength of the pellets.
EXAMPLE 8
A mixture of a GeO 2 powder of 20 μm particle diameter with a B 2 O 3 powder of 20 μm particle diameter in a molar ratio of 1:3 was prepared. By using the mixture, rod-shaped pellets of a ceramic were prepared in the same manner as in Example 7.
Each of the eight kinds of specimens prepared as above was interposed between a fuel electrode and a reforming catalyst (a nickel catalyst was used) of a fuel cell. The fuel cells thus obtained were subjected to a power generating operation. After about 5,000 hours of operation, none of the specimens showed abnormality in the reforming catalyst.
On the other hand, fuel cells assembled without using the protective material of the present invention showed a lowering in the activity of the catalyst after about 1,000 hours of operation.
When the ability of the protective material to capture the electrolyte is lowered, the protective material is replaced with a new one, whereby degradation of the performance of the reforming catalyst can be effectively prevented over a long time.
FIG. 3 shows one embodiment of the present invention, in which an internal reforming type molten carbonate fuel cell body was assembled by using the protective material for an electrolyte according to one embodiment of the present invention. In the figure, 1 denotes an electrolyte matrix, 2 a fuel electrode, 3 an oxidizing agent electrode, 4 oxidizing agent passages, 5 a fuel-side spacer, 6 a rib, 7 a fuel gas passage, and 8 denotes a reforming catalyst, which are the same as those in the prior art example. By reference numeral 15 is denoted the protective material for the electrolyte. In this embodiment, the protective material 15 for the electrolyte is interposed between the fuel electrode 2 and the reforming catalyst 8, thereby preventing the electrolyte contained in the electrolyte matrix 1 from adhering to the reforming catalyst 8 via the fuel electrode 2.
Each of the eight kinds of specimens prepared as above-mentioned was interposed between the fuel electrode and the reforming catalyst (a nickel catalyst was used), as shown in FIG. 3. The fuels cells thus obtained were subjected to a power generating operation. After about 5,000 hours of operation, none of the specimens showed abnormality in the reforming catalyst. Besides, an increased pressure loss due to clogging of an outlet pipe was not observed.
On the other hand, fuel cells assembled without using the protective material of the present invention showed a lowering in the activity of the catalyst after about 1,000 hours of operation.
FIG. 4 shows another application of the present invention, in which a power generation system is assembled by using an external reforming type fuel cell body provided with an electrolyte removing bed by employing the protective material for an electrolyte according to one embodiment of the present invention. In the figure, 16 denotes the electrolyte removing bed, namely, the bed of the protective material for the electrolyte, in which the protective material 15 for the electrolyte is held.
In such a fuel cell power generation system, the reaction gas discharged from the molten carbonate fuel cell body 11 is led first to the electrolyte removing bed 16 together with a fuel gas system and an oxidized gas system. By the function of the protective material 15 for the electrolyte, which is held in the electrolyte removing bed 16, the electrolyte contained in the reaction gas or substances formed from the electrolyte are removed from the reaction gas. Therefore, the cleaned reaction gas not containing the electrolyte is supplied to the downstream side of the electrolyte removing bed 16. As a result, in the fuel cell power generation system by the application of the present invention, it is possible to minimize the lowering in the characteristics of the component apparatuses or constituent materials due to the adhesion thereto of the electrolyte, and it is possible to carry out a stable operation for a long time. The electrolyte removing bed 16 can be easily obtained, for example, by packing a reaction pipe with particles of the protective material 15 for the electrolyte. In addition, when the protective material 15 for the electrolyte is held in an outlet-side gas manifold of the molten carbonate fuel cell body 11 or in a piping connected to the manifold, it is possible to realize a compact power generation system and to minimize the corrosion of the piping at a connection pipe portion.
FIG. 5 shows a system diagram illustrating the construction of a fuel cell power generation system obtained by a further application of the present invention. In this fuel cell power generation system, a plurality of fuel treating devices 9 (for instance, two such devices 9a and 9b in FIG. 5) and a plurality of molten carbonate fuel cell bodies 11a and 11b are connected by a fuel gas system. The heat of reaction which is required in the fuel treating devices 9 is supplied by transferring the surplus heat generated in the fuel cell bodies 11 via a heat exchanger 13 (broken lines in FIG. 5 indicate the flow of heat).
The characteristic features of this power generation system are the following two points:
(a) the steam produced through an electrochemical reaction in the molten carbonate fuel cell body 11ais effectively utilized for the reforming reaction in the fuel treating device 9b, and
(b) the surplus heat generated in the molten carbonate fuel cell bodies 11a and 11b is effectively utilized in the fuel treating devices 9a and 9b. Thus, by the effective utilization of the reaction product and the heat derived from the reactions, a high power generation efficiency is obtainable. In this application of the invention, particularly, it is possible to prevent the deterioration of the reforming catalyst held in the fuel treating device 9b, by the function of the electrolyte removing bed 16.
Though in the application of the invention shown in FIG. 5 the surplus heat generated in the molten carbonate fuel cell bodies 11a and 11b is supplied through the heat exchanger 13 to the fuel treating devices 9a and 9b as the heat of reaction, it is possible to supply the surplus heat directly to the fuel treating device, for example, by disposing the fuel treating device thermally adjacent to the fuel cell body.
Also, by holding the protective material for the electrolyte in the fuel treating devices 9a and 9b or in the molten carbonate fuel cell bodies 11a and 11b, it is possible to assemble the electrolyte removing bed 16 into the fuel treating devices 9a and 9b or into the fuel cell bodies 11a and 11b.
Besides, for effective utilization of the steam produced in the fuel cell body for the reforming reaction in the fuel treating device, a system has been studied in which a portion of the steam-rich fuel gas discharged from the fuel cell body is recycled to the fuel treating device located on the upstream side of the fuel cell body. In the system, also, the protective material 15 for the electrolyte according to the present invention can be used to prevent the lowering in the activity of the reforming catalyst due to the adhesion thereto of the electrolyte.
As has been described above, it is apparent that the protective material for an electrolyte used in a molten carbonate fuel cell power generation system according to the present invention is extremely useful.
When the ability of the protective material to capture the electrolyte is reduced, the protective material is replaced with a new one, whereby degradation of the performance of the component materials of the fuel cell power generation system can be prevented, over a long time.
As has been described above, according to the present invention, a protective material for a reforming catalyst includes a ceramic comprising an oxide material which is capable of chemically reacting with an electrolyte used in a molten carbonate fuel cell or a substance formed from the electrolyte, namely, capable of chemically reacting with the electrolyte diffused from the electrolyte matrix under the operating conditions of the fuel cell. Therefore, the present invention effectively prevents the degradation of the performance of the reforming catalyst.
Also, according to the present invention, it is possible to protect the component materials of the molten carbonate fuel cell power generation system from the electrolyte or the substance formed from the electrolyte. It is therefore possible to effectively prevent a reduction in the performance of the component materials and to ensure a longer service life.
Furthermore, when at least one of the oxide material has a melting point lower than the service temperature of the fuel cell, the at least one oxide material is melted to a liquid during use, thereby ensuring rapid reaction thereof with the electrolyte or the reaction products of the electrolyte. Thus, a protective material for the electrolyte having a higher activity is obtainable.
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A protective material for a molten carbonate fuel cell, which comprises a ceramic comprising an oxide material capable of chemically reacting with an electrolyte used in the molten carbonate fuel cell for generating electric energy by consuming hydrogen formed from a raw fuel such as hydrocarbons, or with a substance formed from the electrolyte. The protective material protects a reforming catalyst or component materials of the fuel cell power generation system from the electrolyte or the substance formed from the electrolyte.
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[0001] This application claims priority to U.S. Provisional Patent Application No. 60/732,511 filed Nov. 2, 2005 and incorporated herein by reference.
BACKGROUND
[0002] The field of the invention is treatment of in ground contamination. For much of the twentieth century, chromite ore was processed at various locations in the United States, to manufacture chromium and related materials. Processing the chromite ore created large amounts of chromite ore processing residue (COPR). Millions of tons of COPR were then placed into the ground, often at or near the processing locations. These sites, which are now contaminated with COPR, are in or near densely populated urban and waterfront areas in United States. There are similarly contaminated sites in Europe, Japan, and other countries.
[0003] COPR is similar in texture to coarse gravel. It is formed as solid nodules or pellets generally ¼ to ½ inch in diameter, as a waste product from ore processing. These pellets were often used like gravel, as grading and fill material, and also in construction of residential, commercial and industrial buildings. COPR was also used in roadbeds and pipeline trenches. Consequently, some COPR deposits may extend for thousands of feet under dense urban development. In addition, in many of these locations, the COPR is below the ground water table.
[0004] COPR is a strong alkaline or caustic material. It typically has a pH of about 11-12. COPR typically also contains %1-%30 of hexavalent chromium, having the chemical symbol Cr(VI). Cr(VI) is toxic to humans. It can be absorbed into the body via the skin, mouth or via inhalation. It is known to cause cancer and genetic mutations. Consequently, COPR presents serious environmental and public health hazards.
[0005] At COPR contaminated sites, the chromium is present in the solid particles as well as in the ground water in the pores or spaces between the COPR particles or pellets. Since Cr(VI) is soluble in water, if the pore water is removed, the hexavalent chromium is replaced by a slow diffusion or leaching of additional hexavalent chromium from within the particles. As a result, pump and treat or soil washing is ineffective or at least impractical for treatment of COPR sites.
[0006] Cr(VI) in pore water can be converted to trivalent chromium, which has the chemical symbol Cr(III), using remediating chemical compounds. These compounds include soluble ferrous iron salts, such as ferrous sulfate or ferrous chloride, or other similar remediating compounds. Cr(III) is insoluble and relatively non-toxic. Accordingly, if the Cr(VI) could be substantially completely converted to Cr(III), the COPR at many sites could then be safely left in the ground. However, with these chemical remediation methods, the soluble remediating compounds tend to be washed away by ground water movement relatively quickly. Consequently, the conversion process expectedly does not last long enough to clean up the site.
[0007] Other in-situ clean up processes use biological reduction of the Cr(VI), with or without use of other remediating materials. In biological clean up techniques, organic materials containing bacteria and nutrients are mixed into the COPR contaminated soil. However, in general, these types of biological reduction techniques require a pH conducive for growth of bacteria, typically about 6.5 to 9.5. Consequently, biological techniques have required adding large amounts of acid into the contaminated site, to lower the pH to a level acceptable for growth of bacteria. The acid causes destruction of the COPR particle structure. This can make future handling of the COPR more difficult. The acid also generates large volumes of carbon dioxide gas. In addition, placing large amounts of acid into the ground can damage structures on or in the ground. The disadvantages of the need for this use of acids has largely prevented effective use of biological remediation techniques on COPR.
[0008] In view of these problems, plans for permanent clean up of COPR sites have largely contemplated excavation and removal of the COPR material. This can require demolition, in-fill, and reconstruction of buildings on the contaminated sites. Moreover, the excavated material must still be remediated off site to convert the Cr(IV) to Cr(III), before it can be placed in landfill or other final disposal site. The costs, disruption, and delays associated with excavation and removal of the contaminated material can of course be enormous. Accordingly, improved methods for cleaning up COPR contaminated sites are needed.
[0009] Chlorinated solvents are more common contaminants found in groundwater throughout the United States. Chlorinated solvent contaminants include perchloroethylene (PCE), tricholoroethylene (TCE) and dichloroethylene (DCE), as well as various other halogenated aliphatic compounds and solvents. These contaminants typically have resulted from spills or leaks. Typical sites contaminated with chlorinated solvents will have the solvent dissolved in the ground water, or the solvent in an in ground bulk non-aqueous liquid phase, or both. Even relatively small amounts of solvent can pose serious risks to the environment and to water supplies.
[0010] Various technologies have been developed for the treatment of chlorinated solvents. However, most of these are difficult or costly to implement. Technologies that rely on abiotic reduction using various iron reducing compounds have been used extensively for the treatment of chlorinated solvents. For example, metallic zero valent iron has been used. However, zero valent iron is a solid material, typically granular or a powder, and is generally difficult to distribute into the subsurface. As a result, zero valent iron is usually applied by excavation and emplacement, or by mixing with the soil. Ferrous sulfide has been identified as an alternative reducing compound that will abiotically reduce chlorinated solvents (as well as hexavalent chromium). However, achieving practical methods for the large scale production and delivery of ferrous sulfide needed for ground water clean up, has been technically challenging.
[0011] Accordingly, improved systems and methods for treatment of in ground contamination are needed.
SUMMARY OF THE INVENTION
[0012] In a first aspect, in a method for treatment of dissolved chromium or COPR, a reducing compound is provided as a substantially insoluble material in the pores of the COPR. The reducing compound accordingly substantially remains in place and is not washed out by water movement or diffusion. Accordingly, the reducing agent is available when hexavalent chromium diffuses from the COPR. The reducing compound may advantageously initially be a liquid or solution, which can be injected into the COPR formation, and then change to a more solid form. In liquid form, the reducing compound is easier to apply into the ground. The distribution throughout the pores may also better in comparison to applying a reducing compound in a solid form.
[0013] In a second aspect of the invention, in a method for treatment of chlorinated solvents, dissolved hexavalent chromium, and similar contaminants, a reducing compound is provided as a substantially insoluble material in soil pores. The reducing compound may be ferrous sulfide. The reducing compound substantially remains in place and is not washed out by water movement or diffusion. Accordingly, the reducing agent is available when chlorinated solvents diffuse out from the dense non-aqueous phase liquids or from up-gradient solvent sources. The reducing compound may initially be a liquid or solution, which can be injected into the formation, and then change to a more solid form.
[0014] Other objects, features and advantages will become apparent from the following description. The invention resides as well in sub-combinations of the steps and elements described. The steps and elements essential to the invention are described in the claims, other steps and elements being not necessarily essential.
DETAILED DESCRIPTION
[0015] In general, for treatment of COPR, the reducing compound should be effective at reducing hexavalent chromium at a pH of about 8-13, and typically about 10, 11, 12, or 13, so that the alkalinity of the COPR does not need to be neutralized. This avoids the need to add large amounts of acid to lower the pH. The reducing compound advantageously generally does not excessively promote the formation of minerals that can result in the swelling of the COPR. The reducing compound is also preferably capable of remaining in the pores for at least 6, 9 or 12 months, or longer, without loss of effectiveness, even with movement of ground water. At some sites, it may be necessary or advantages to have the reducing compound remain in place for several years.
[0016] In one embodiment, a ferrous salt solution and a sulfide salt solution (such as ferrous sulfate and sodium sulfide) are dispersed into the COPR or chlorinated solvent contaminated zone. The ferrous ions combine with the sulfide ions to form a colloidal precipitate of ferrous sulfide. Since the ferrous sulfide particles form in the injection system piping or in the soil, they are small (colloidal) and hence easy to mix completely with COPR and surrounding soil pores. In the treatment of chlorinated solvents, the ferrous sulfide particles are similarly small and easy to distribute in the subsurface. Particles with a size of less than about 5, 4, 3, 2 and more often 1 micron (mean diameter) are generally more effectively injected in an aqueous liquid, in comparison to larger size particles. The FeS particles are consequently formed with an intended particle size of 1 micron or less.
[0017] The ferrous sulfide reacts with hexavalent chromium in solution converting the chromium to the trivalent form, which precipitates as a hydroxide. The ferrous iron is oxidized and forms ferric hydroxide precipitate. The sulfide is oxidized to elemental sulfur. For the treatment of treatment of solvents such as TCE or PCE, the ferrous sulfide reduces the chlorinated solvents abiotically with acetylene as the major reaction product. The low solubility of ferrous sulfide helps to prevent it from being washed out of the system by groundwater movements. Ferrous sulfate may be used with or instead of ferrous chloride.
[0018] The result of these reactions is the in situ lowering of the hexavalent chromium in the water surrounding the COPR. Additional hexavalent chromium will dissolve and diffuse from inside the COPR particles to the particle surfaces, where it will react with the solid ferrous sulfide particles. In addition, the ferrous sulfide solids will partially dissolve releasing molecules of ferrous sulfide which penetrate the COPR particles and react with dissolved Cr(VI) in the COPR. Due to the low solubility of ferrous sulfide only a small portion of the ferrous sulfide is dissolved as needed for the Cr(VI) reaction. Hence the solid will remain for a long time, unless needed for reduction of the Cr(VI). By injection of adequate ferrous and sulfide salts, sufficient ferrous sulfide particles are generated in-situ, to treat the hexavalent chromium and/or chlorinated solvent(s) over a period of months or years to a desired remediation standard.
[0019] The ferrous sulfide may be generated in situ by the mixing of a ferrous salt solution with a solution of sodium sulfide by the following reaction:
FeCl 2 +Na 2 S→FeS(s)+2Na + +2Cl − .
[0020] The resulting precipitate of ferrous sulfide tends to form rapidly. It generally will first form a neutral molecule of ferrous sulfide, followed by growth to colloidal and larger particles of ferrous sulfide. This makes it easier to inject and distribute throughout the COPR when compared to a solid that has to be injected as a slurry.
[0021] The FeS is advantageously formed as a solid either in the pores of the COPR or in the pore space between individual COPR particles, or in the equipment used to mix and inject the chemicals into the COPR formation. If formed on the outside of the pores, it is preferably pushed uniformly throughout the pores of the COPR or the subsurface. Excess ferrous sulfide is advantageously added to account for oxidation by air, insufficient mixing, or other losses.
[0022] Ferrous sulfide reacts with hexavalent chromium (represented as chromate) by the following reaction:
CrO 4 −2 +FeS+2H 2 O+2H + →Fe(OH) 3 +S+Cr(OH) 3
[0023] Iron and chromium are converted to their trivalent form and precipitate as hydroxides. Sulfide is oxidized to elemental sulfur (not sulfate). This helps to avoid swelling, which appears to be associated with mixing sulfate salts with COPR.
[0024] For stoichiometric reaction, for each gram of hexavalent chromium (as Cr) need to add 1.08 grams of ferrous chloride (as Fe) plus 1.5 grams of sodium sulfide (as Na 2 S). Therefore add 3 times stoichiometric of 3.24 g of ferrous chloride or ferrous sulfate (as Fe) plus 4.5 g of Na 2 S for each gram of hexavalent chromium. An FeS concentration greater than 3 times this stoichiometric dose may be needed to provide good results. Commercial solutions of ferrous sulfate and ferrous chloride may be used, as these contain acid in addition to the salt. These materials are the byproduct of acid pickling of steel. Accordingly, they are economically available in large quantities. To minimize corrosion to chemical delivery equipment, the excess acid may be neutralized with an alkaline compound such as sodium hydroxide before injection.
[0025] Although the concentrations of the reducing compounds may of course be varied for specific applications, the following guidelines may be used.
Ferrous Chloride: 9 to 14% solution (as Fe) liquid technical grade Ferrous Sulfate: 5 to 7% solution (as Fe) liquid technical grade Sodium Sulfide: 10 to 30% solution (make from dry chemical)
[0029] The measurement of acceptable remediation of Cr(IV) may vary depending on the characteristics, location, and regulation of each specific contaminated site. A reduction of Cr(IV) to concentrations of 240 to 20 mg/kg, or less, may be required, representing reduction of 95% to 99.5% or more of the initial concentration of Cr(VI) in the contaminated soil or COPR.
[0030] The ferrous sulfide may be injected or placed by pumping solutions of the two chemical separately with precipitation occurring in the ground. When injected as a liquid, the reducing compound may be placed into the ground with a hydro-punch or pipe, or with injection wells, or using direct push methods. In a typical application, a 1-4 inch diameter pipe is driven into position and then the liquid is pumped in or injected. Injection times at each punch or placement may vary, with 5-90 minutes being typical. The pipe is then moved over to the next designated position. This procedure can repeated, in a grid, spiral, or other pattern, until the entire site has been injected. Slant injection may also be used to place the liquid or slurry reducing compound under in or on ground structures, or to reach positions not easily directly accessible from vertically above. Hydraulic or pneumatic fracturing methods may also be used, optionally in combined fracturing/injection methods to deliver a slurry containing ferrous sulfide particles to the in ground formation. Fracturing has the potential for improving delivery of the FeS into low permeability formations. Permeability of fractured formations may be dramatically increased, depending on the site conditions.
[0031] With injection methods for treatment of COPR, the FeS particles may be formed by mixing of the FeCl 2 and the Na 2 S solutions into the injection equipment. Separate metering pumps may be used for each component, with the solutions passing through an in line mixer before injection. Since the reaction between the Fe 2+ and the S 2− is very rapid, small particles may be created. Deflocculating and/or sequestering agents, such as polyphosphate, non-ionic detergent, or silicone-based dispersing agents may be added to help keep the FeS particles dispersed as they are delivered into the underground matrix. Since the FeS is practically insoluble in water, emulsified vegetable oil may be used as a transport medium to disperse the FeS through the COPR.
[0032] While it may not be necessary in most applications, the reducing compound may also be placed in permanent, or semi-permanent wells or well pipes. While most COPR deposits are below the water table, the present methods may also be used in COPR deposits above the water table. Similarly, these methods may be used to clean up Cr(VI) contamination other than from COPR sites, or chlorinated solvents, above or below the water table. In the case of COPR, since the reducing compound will generally be mixed with a solution containing water before or as it is placed into the COPR deposits, the pores between the pellets will become filled with the ferrous sulfide containing liquid even above the water table.
[0033] In augering applications, conventional or hollow stem augers may be used. With augering, the reducing compound may be a solid, a liquid or a slurry. Alternatively, components can be mixed in-line before injection or mixed and injected using an auger soil mixer.
[0034] Testing was conducted on chromite ore processing residue (COPR). Several columns were prepared to evaluate COPR chromium reduction with various concentrations of sulfide along with either ferrous chloride or ferrous sulfate. The columns were prepared in the following manner:
[0035] 1. Column material consists of 6-inch clear PVC pipe with white PVC end caps.
[0036] 2. The bottom end cap included a ½ inch plastic valve for sampling the liquid phase of the column, and was sealed using PVC glue.
[0037] 3. The top end cap included two ¼ inch barbed fittings for filling and venting during set up and sampling, and was sealed with an inert silicone based vacuum grease, allowing the top to be removed for solids sampling.
[0038] 4. Approximately 1-inch of geotextile material and approximately 4-inches of 0.2-mm quartz sand were added to the base of the column to support the COPR material, and allow water to drain freely.
[0039] 5. Deionized water was added to the columns to determine the pore volume contained in the geotextile material and sand. This volume was determined to be 900-ml. Two of these pore volumes will be removed from the column before liquid samples are taken, which will represent the liquid portion surrounding the COPR.
[0040] 6. The COPR material was screened using a 0.5-inch sieve.
[0041] 7. The stoichiometric amount of sodium sulfide was determined from the Cr-VI concentration in the COPR. The sodium sulfide solid material was weighed on an analytical balance and dissolved in 1-liter of deionized water.
[0042] 8. The amount of iron product was determined based on the sulfide and Cr-VI concentrations. Analytical grade ferrous chloride (powder hydrated with deionized water) was used for column 1 (C1), and technical grade ferrous chloride and ferrous sulfate liquid material was used for the other columns.
[0043] 9. The appropriate amount of screened COPR was placed in a 2-gallon disposable plastic bucket and placed in a laboratory fume hood.
[0044] 10. 1-liter of site groundwater was added to the COPR first, to create a slurry.
[0045] 11. ⅓ of the sulfide was added, mixed well, and then followed with ⅓ of the ferrous iron and additional mixing. This process was continued until all the treatment chemicals were added.
[0046] 12. The COPR with treatment chemicals was then added to the test 20 columns.
[0047] 13. The top end cap was sealed with vacuum grease and placed on the column. Groundwater was added to fill the column and eliminate headspace.
[0048] 14. Table 1 summarizes the conditions used for each of the column tests.
[0049] 15. Sampling was started by allowing 1,800-ml to flow from the column first. This represents two times the void volume contained in the geotextile material and sand at the base of the column. After this portion is removed, samples that represent the liquid contained in the COPR material is collected for testing.
[0050] 16. After the water samples are collected the top caps are removed for solids sampling. A core device is used to collect a top-to-bottom column of COPR material for testing.
[0051] 17. After sampling the top cap was replaced, and the initial pore water was returned to the column, along with additional groundwater to eliminate headspace.
[0052] 18. Analytical data for samples taken during the first 72 days following chemical addition are presented in tables 2 and 3. Table 2 shows the pore water hexavalent chromium concentrations. Table 3 shows the hexavalent chromium in the solid COPR.
[0053] 19. All doses of ferrous iron and sulfide reduced the pore water concentration of hexavalent chromium in the pore water and in the COPR solids within a 2 month period.
TABLE 1 Column Dose Calculations Dose for Each Column Parameter Units C1 C2 C3 C4 C5 COPR amount Kg 5.0 5.0 4.0 4.0 4.0 COPR Cr—VI g/Kg 3.41 3.41 3.41 3.41 3.41 COPR Cr—VI g 17.05 17.05 13.64 13.64 13.64 COPR Cr—VI moles 0.33 0.33 0.26 0.26 0.26 Na 2 S*9H 2 O (˜100%) g 472 Sulfide, as S g 63 Sulfide, as S moles 1.97 Na 2 S (60%) g 182 146 152 101 Sulfide, as S g 44.8 35.9 37.4 24.9 Sulfide, as S moles 1.4 1.12 1.16 0.77 FeCl 2 *4H 2 O (reagent) g 389 Fe 2+ g 109 Fe 2+ moles 1.96 Ferrous Chloride (Kemiron) 10.46% Fe 2+ g 2,107 530 350 Fe 2+ g 220 55 37 Fe 2+ moles 3.95 0.99 0.66 Ferrous Sulfate (Kemiron) 5.20% Fe 2+ g 3,379 Fe 2+ g 176 Fe 2+ moles 3.15 Sulfide:Cr—VI ratio as S:Cr mole/mole 6.0 4.2 4.3 4.5 3.0 Iron:Cr—VI ratio as Fe 2+ :Cr mole/mole 6.0 12.0 12.0 3.8 2.5
[0054]
TABLE 2
COPR FeS Column Test Results - Water
Reaction Time
Cr—VI (ug/L)
(days)
C1
C2
C3
C4
C5
0
2,650
2,650
2,650
2,650
2,650
5
—
<1
<1
—
—
14
<1
—
—
8.44
9.02
42
—
—
—
—
—
46
—
—
—
ND
ND
68
—
ND
˜7
—
—
77
˜7
—
—
—
—
[0055]
TABLE 3
COPR FeS Column Test Results - Solids
Reaction
Cr—VI (mg/Kg)
Time (days)
C1
C2
C3
C4
C5
0
3,410
3,410
3,410
3,410
3,410
12
—
<0.010
<0.019
—
—
14
—
—
—
0.30
<0.11
21
0.13
—
—
—
—
42
—
—
—
—
—
46
—
—
—
0.11
0.42
68
—
<0.053
<0.065
—
—
77
0.42
—
—
—
—
[0056] As used here, the singular includes the plural and vice versa, unless specifically excluded by the context. The word “or” as used here means either one, or any one, both, or all of the listed items, and does not mean an alternative qualitatively different element, or a non-equivalent element. The systems and methods described may be used for clean up of dissolved hexavalent chromium, from virtually any source, including non-COPR sources, as well as for various other types of organic contaminants, including chlorinated and other solvents.
[0057] Thus, novel methods and systems have been described. Various changes and modifications may of course be made without departing from the spirit and scope of the invention. The invention, therefore, should not be limited, except to the following claims and their equivalents.
|
In systems and methods for treatment of underground contamination, a reducing compound is provided as a substantially insoluble material in an underground formation. The reducing compound accordingly remains substantially in place, even over long periods of time, and is not washed out by underground water movement or diffusion. Accordingly, the reducing compound acts continuously to chemically reduce and remove contamination. When used for treatment of chromium ore processing residue contamination, the reducing compound may be formed and remain in the pores of the residue. As hexavalent chromium diffuses from the residue, it is reduced by the reducing compound. The reducing compound may be injected as a liquid into the underground formation, and then change to a more solid form. Chlorinated solvent contamination may also be treated.
| 2
|
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This is a divisional application of U.S. patent application Ser. No. 13/432,683, filed Mar. 28, 2012, which claims the benefit of U.S. provisional patent application Ser. No. 61/471,477, filed Apr. 4, 2011 and U.S. provisional patent application Ser. No. 61/583,536, filed Jan. 5, 2012, the disclosures of which are incorporated herein by reference in their entireties.
BACKGROUND
[0002] Referring to FIGS. 1-2B , electrical connectors can be constructed to be mounted to a substrate, for instance a printed circuit board (PCB), that is configured with an industry standard MicroTCA® Press Fit (MicroTCA® PF) footprint (as illustrated in FIGS. 2A and 2B ). For example, the electrical connector 100 and the PCB can be constructed in accordance with industry standard document MicroTCA.0, Rev. 1.0, 6 Jul. 2006, the disclosure of which is incorporated herein by reference in its entirety. The electrical connector 100 can be constructed as a card edge connector configured to receive Advanced Mezzanine Cards (AdvancedMCs), for instance as an AdvancedMC Backplane Connector in accordance with the MicroTCA® standard (see FIGS. 12A-12B ). Further in accordance with the MicroTCA® standard, a MicroTCA® Carrier Hub (MCH) can comprise at least two, for instance four, electrical connectors 100 supported by a respective substrate (see FIGS. 13A-13B ). However when the industry standard MicroTCA® PF footprint is utilized with existing electrical connectors that are constructed to mount to the industry standard MicroTCA® PF footprint, peak bandwidth or data transmission rates are typically restricted to about 8 Gigabits/sec or less.
SUMMARY
[0003] In accordance with one embodiment, a card edge electrical connector includes a connector housing. The card edge electrical connector further includes a plurality of electrical signal contacts supported by the connector housing. Each electrical signal contact includes a contact body that defines a mating end and a mounting end, wherein respective pairs of the plurality of electrical signal contacts define differential signal pairs. The card edge electrical connector further includes a plurality of ground plates supported by the connector housing. Each of the plurality of ground plates includes a first ground mating end that defines a first ground flow return path and a second ground mating end that defines a second ground flow return path. At least one ground plate of the plurality of ground plates defining respective first and second ground flow return paths that are substantially symmetrical with respect to one another. The mating ends of the plurality of electrical signal contacts and the first and second ground mating ends of the plurality of ground plates collectively define one hundred seventy mating ends that are spaced along two rows that extend along a row direction. The one hundred seventy mating ends defining a 0.75 mm column pitch, and the connector housing supports each of the plurality of electrical signal contacts and the plurality of ground plates such that respective pairs of differential signal pairs are disposed between successive ground plates.
[0004] In accordance with another embodiment, an electrical connector includes a connector housing. The electrical connector further includes a first vertical electrical signal contact configured to be supported by the connector housing. The first vertical electrical signal contact includes a first contact body that defines a first mounting end and a first mating end that is opposite the first mounting end. The first mounting end carries a first mounting element configured to be placed in electrical connection with a printed circuit board, and the first vertical electrical signal contact defines first and second broadsides and first and second edges that extend between the first and second broadsides. The electrical connector further includes a second vertical electrical signal contact configured to be supported by the connector housing. The second vertical electrical signal contact includes a second contact body that defines a second mounting end and a second mating end that is opposite the second mounting end. The second mounting end carries a second mounting element configured to be placed in electrical connection with the printed circuit board, and the second vertical electrical signal contact defining first and second broadsides and first and second edges that extend between the first and second broadsides, wherein the first mating end and the second mating end are spaced from each other along a first direction that is substantially perpendicular to the first and second broadsides of the first and second vertical electrical signal contacts. Each of the first and second contact bodies is twisted such that the broadsides at the first mounting end is angularly offset with respect to the broadsides at the first mating end, the broadsides at the second mounting end is angularly offset with respect to the broadsides at the second mating end, and the first mounting element is aligned with the second mounting element along a second direction that is substantially perpendicular to the first direction.
[0005] In accordance with another embodiment, a printed circuit board includes a substrate body that defines opposed upper and lower surfaces. The substrate body supports a plurality of vias that define a footprint configured to receive mounting tails of only a single connector. The footprint includes a first pair of signal vias that extend into the upper surface of the substrate body. Each of the first pair of signal vias are arranged inline with respect to each other along a first column that extends substantially along a column direction. The footprint further includes a second pair of signal vias that extend into the upper surface of the substrate body. Each of the second pair of signal vias are arranged inline with respect to each other along a second column that extends substantially along the column direction. The footprint further includes at least a first ground via that extends into the upper surface of the substrate body. The first ground via is disposed in a third column that extends substantially along the column direction, wherein the third column includes no more than a pair of first ground vias. The footprint further includes at least a second ground via that extends into the upper surface of the substrate body. The second ground via is disposed in a fourth column that extends substantially along the column direction, wherein the fourth column includes no more than a pair of second ground vias. The first and second columns are disposed between the third and fourth columns.
[0006] In accordance with another embodiment, a method of fabricating an electrical connector includes the step of supporting a plurality electrical signal contacts in a connector housing. The signal contacts define signal mounting tails and mating ends, wherein respective pairs of the plurality of electrical signal contacts define differential signal pairs. The method further includes the step of supporting first and second ground plates in the connector housing. Each of the plurality of first and second ground plates includes ground mounting tails and ground mating ends. The two supporting steps include defining one hundred seventy matting ends that are spaced along two columns that each extend along a row direction collectively from the mating ends of the plurality of electrical signal contacts ground mating ends. The one hundred seventy mating ends define a 0.75 mm column pitch. The method further includes the step of positioning the plurality of electrical signal contacts and the ground plates in the connector housing such that the signal and ground mounting tails define a footprint that differs from a footprint defined by vias of a printed circuit board that are arranged in accordance with MicroTCA specification Rev. 1.0, such that the electrical signal contacts are configured to transfer data between the mounting tails and the mating ends at a minimum of approximately 12.5 Gigabits/second at an acceptable level of near-end crosstalk.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] The foregoing summary, as well as the following detailed description of example embodiments of the application, will be better understood when read in conjunction with the appended drawings, in which there is shown in the drawings example embodiments for the purposes of illustration. It should be understood, however, that the application is not limited to the precise arrangements and instrumentalities shown. In the drawings:
[0008] FIG. 1 is a perspective view of an electrical assembly including a printed circuit board and an electrical connector mounted to the printed circuit board so as to place respective pluralities of electrical signal contacts and ground plates supported by the electrical connector in electrical communication with the printed circuit board;
[0009] FIG. 2A is a top elevation view of the printed circuit board illustrated in FIG. 1 , the printed circuit board including a plurality of vias that extend into the printed circuit board;
[0010] FIG. 2B is a top elevation view of a portion of the plurality of vias illustrated in FIG. 2A , the portion of the plurality of vias arranged in accordance with an industry standard MicroTCA® press fit footprint;
[0011] FIG. 3A is a perspective view of two pairs of electrical signal contacts and a pair of ground plates constructed in accordance with an embodiment, the electrical signal contacts and the ground plates configured to be supported by the electrical connector illustrated in FIG. 1 ;
[0012] FIG. 3B is a side elevation view of the electrical signal contacts and ground plates illustrated in FIG. 3A ;
[0013] FIG. 3C is a bottom elevation view of the electrical signal contacts and ground plates illustrated in FIGS. 3A-3B ;
[0014] FIG. 3D is a front elevation view illustrating an example asymmetric ground return flow path of the ground plates illustrated in FIGS. 3A-3C ;
[0015] FIG. 4A is a perspective view of a pair of leadframe assemblies, each leadframe assembly comprising a pair of the electrical signal contacts illustrated in FIGS. 3A-3C , the pair of leadframe assemblies configured to be inserted into the electrical connector illustrated in FIG. 1 ;
[0016] FIG. 4B is a perspective view of the electrical connector illustrated in FIG. 1 , a plurality of respective pairs of the leadframe assemblies illustrated in FIG. 4A , and a plurality of the ground plates illustrated in FIGS. 3A-3D , the respective pluralities of pairs of leadframe assemblies and ground plates arranged adjacent one another so as to be inserted into the electrical connector;
[0017] FIG. 4C is a perspective view of the electrical connector, leadframe assemblies, and ground plates illustrated in FIG. 4A , with the leadframe assemblies and the ground plates inserted into the electrical connector;
[0018] FIG. 4D is a zoomed perspective view of a portion of the electrical connector illustrated in FIG. 4C ;
[0019] FIG. 5A is a perspective view of the electrical signal contacts illustrated in FIG. 3A and a pair of ground plates constructed in accordance with an alternative embodiment, the electrical signal contacts and the ground plates configured to be supported by the electrical connector illustrated in FIG. 1 ;
[0020] FIG. 5B is a side elevation view of the electrical signal contacts and ground plates illustrated in FIG. 5A ;
[0021] FIG. 5C is a bottom elevation view of the electrical signal contacts and ground plates illustrated in FIGS. 5A-5B ;
[0022] FIG. 5D is a front elevation view illustrating an example symmetric ground return flow path of the ground plates illustrated in FIGS. 5A-5C ;
[0023] FIG. 6A is a perspective view of an electrical connector supporting a plurality of respective pairs of the leadframe assemblies illustrated in FIG. 3E and a plurality of the ground plates illustrated in FIGS. 5A-5D ;
[0024] FIG. 6B is a zoomed perspective view of a portion of the electrical connector illustrated in FIG. 6A ;
[0025] FIG. 7A is a perspective view of the electrical signal contacts illustrated in FIG. 3A and a pair of ground plates constructed in accordance with another alternative embodiment, the electrical signal contacts and the ground plates configured to be supported by the electrical connector illustrated in FIG. 1 ;
[0026] FIG. 7B is a side elevation view of the electrical signal contacts and ground plates illustrated in FIG. 7A ;
[0027] FIG. 7C is a bottom elevation view of the electrical signal contacts and ground plates illustrated in FIGS. 7A-7B ;
[0028] FIG. 7D is a top elevation view of a plurality of printed circuit board vias arranged in accordance with an alternative embodiment of a press fit footprint, the plurality of vias arranged such that the electrical signal contacts and ground plates illustrated in FIGS. 7A-7C can be inserted into the vias;
[0029] FIG. 8A is a perspective view of the electrical signal contacts illustrated in FIG. 3A and a pair of ground plates constructed in accordance with still another alternative embodiment, the electrical signal contacts and the ground plates configured to be supported by the electrical connector illustrated in FIG. 1 ;
[0030] FIG. 8B is a side elevation view of the electrical signal contacts and ground plates illustrated in FIG. 8A ;
[0031] FIG. 8C is a bottom elevation view of the electrical signal contacts and ground plates illustrated in FIGS. 8A-8C ;
[0032] FIG. 8D is a top elevation view of a plurality of printed circuit board vias arranged in accordance with another alternative embodiment of a press fit footprint, the plurality of vias arranged such that the electrical signal contacts and ground plates illustrated in FIGS. 8A-8C can be inserted into the vias;
[0033] FIG. 9A is a perspective view of the electrical signal contacts illustrated in FIG. 3A and a pair of ground plates constructed in accordance with still another alternative embodiment, the electrical signal contacts and the ground plates configured to be supported by the electrical connector illustrated in FIG. 1 ;
[0034] FIG. 9B is a side elevation view of the electrical signal contacts and ground plates illustrated in FIG. 9A ;
[0035] FIG. 9C is a bottom elevation view of the electrical signal contacts and ground plates illustrated in FIGS. 9A-9B ;
[0036] FIG. 9D is a top elevation view of a plurality of printed circuit board vias arranged in accordance with still another alternative embodiment of a press fit footprint, the plurality of vias arranged such that the electrical signal contacts and ground plates illustrated in FIGS. 9A-9C can be inserted into the vias;
[0037] FIG. 10A is a perspective view of two pairs of electrical signal contacts constructed in accordance with an alternative embodiment and a pair of the ground plates illustrated in FIGS. 9A-9C ;
[0038] FIG. 10B is a side elevation view of the electrical signal contacts and ground plates illustrated in FIG. 10A ;
[0039] FIG. 10C is a bottom elevation view of the electrical signal contacts and ground plates illustrated in FIGS. 10A-10B ;
[0040] FIG. 10D is a perspective view of respective portions of the electrical signal contacts and ground plates illustrated in FIGS. 10A-10C ;
[0041] FIG. 10E is a perspective view of a pair of leadframe assemblies, each leadframe assembly comprising a pair of the electrical signal contacts illustrated in FIGS. 10A-10D ;
[0042] FIG. 10F is a bottom elevation view of the leadframe assemblies illustrated in FIG. 10E and the ground plates illustrated in FIGS. 10A-10D supported by the electrical connector illustrated in FIG. 1 ;
[0043] FIG. 10G is a top elevation view of a plurality of printed circuit board vias arranged in accordance with still another alternative embodiment of a press fit footprint, the plurality of vias arranged such that the electrical signal contacts and ground plates illustrated in FIGS. 10A-10F can be inserted into the vias;
[0044] FIG. 11 is a perspective view of respective portions of the electrical signal contacts and ground plates illustrated in FIGS. 10A-10C , with the mounting ends of the electrical signal contacts and ground plates supporting solder balls;
[0045] FIG. 12A is a top elevation view of an electrical assembly including the electrical connector illustrated in FIGS. 6A-6B , mounted to a printed circuit board, illustrating a crosstalk victim differential signal pair and five aggressor differential signal pairs;
[0046] FIG. 12B is a side elevation view of the electrical assembly illustrated in FIG. 12A .
[0047] FIG. 13A is a top elevation view of a pair of electrical connectors constructed in accordance with the electrical connector illustrated in FIGS. 6A-6B , illustrating a crosstalk victim differential signal pair and eight aggressor differential signal pairs; and
[0048] FIG. 13B is a side elevation view of the electrical assembly illustrated in FIG. 13A .
DETAILED DESCRIPTION
[0049] The present disclosure describes electrical connectors, such as card edge connectors and card edge connector footprints, including MicroTCA® (μTCA) compatible connectors and footprints that can be utilized in accordance with industry standards specifications such as the Peripheral Component Interconnect (PCI) Industrial Computer Manufacturers Group (PICMG®) Open Modular Computing Specifications, for example MicroTCA.0, Rev. 1.0, 6 Jul. 2006, which is incorporated herein by reference in its entirety.
[0050] Referring initially to FIGS. 1 to 4D , an example electrical assembly 10 constructed in accordance with existing MicroTCA® standards includes an electrical connector 100 and a substrate 200 , such as a printed circuit board 202 , that is configured to be placed in electrical communication with the electrical connector 100 . The electrical connector 100 can include dielectric or electrically insulative connector housing 102 and a plurality of electrical contacts 105 that are supported by the connector housing 102 . The connector housing 102 includes a housing body 103 that defines opposed first and second sides 103 c and 103 d that are spaced from each other along a first or lateral direction A, a first end 103 a that can define a front end, a second end 103 b that can define a rear end and that is spaced from the first end 103 a along a second or longitudinal direction L that extends substantially perpendicular to the lateral direction A, and opposed upper and lower ends 103 e and 103 f that are spaced from each other along a third or transverse direction T that extends substantially perpendicular to both the lateral direction A and the longitudinal direction L.
[0051] The connector housing 102 can define a centerline CR 3 that extends along the longitudinal direction L and separates the housing body 103 into first and second portions that are spaced along the lateral direction A. For instance, the centerline CR 3 can bifurcate the housing body 103 , such that the first and second portions are substantially symmetric about the centerline CR 3 . The connector housing 102 can be constructed of any suitable dielectric or insulative material as desired, for instance plastic. It should be appreciated for the purposes of illustration that the electrical connector 100 is oriented such that the longitudinal direction L and the lateral direction A are oriented horizontally, and the transverse direction T is oriented vertically, though it should be appreciated that the orientation of the electrical connector 100 can vary during use.
[0052] The connector housing 102 can define a mating interface 116 proximate to, such as substantially at, the upper end 103 e that is configured to mate with a complementary electrical component, such as an edge card. In accordance with the illustrated embodiment, the housing body 103 defines a slot 101 that is elongate along the longitudinal direction L and that extends into the upper end 103 e along the transverse direction T, the slot 101 configured to at least partially receive a complementary electrical component, such as an edge card, that is mated to the electrical connector 100 . Thus, the connector housing 102 can be constructed as an edge card connector housing and thus the electrical connector 100 as a card edge electrical connector. The mating interface 116 can be defined in the slot 101 . The connector housing 102 can further define a mounting interface 118 proximate to, such as substantially at, the lower end 103 f that is configured to mount onto a complementary electrical component, such as the printed circuit board 202 , thereby placing the printed circuit board 202 and the complementary electrical component in electrical communication during operation. In accordance with the illustrated embodiment, the mating interface 116 is oriented substantially parallel to the mounting interface 118 . Thus, the electrical connector 100 can be configured as a vertical electrical connector. However it should be appreciated that the electrical connector 100 can alternatively be configured as a right-angle electrical connector, whereby the mating interface 116 is oriented substantially perpendicular to the mounting interface 118 .
[0053] The connector housing 102 can have at least one such as a plurality of retention members 138 defined by the housing body 103 and configured to retain the plurality of electrical contacts 105 in inserted positions in the connector housing 102 . For example, in accordance with the illustrated embodiment, the housing body 103 defines respective pluralities of retention slots 139 that are spaced along the longitudinal direction and extend into such as through the first and second sides 103 c and 103 d of the housing body 103 , respectively. The housing body 103 can further define a void 141 configured to receive the plurality of electrical contacts 105 . In accordance with the illustrated embodiment, the first and second ends 103 a and 103 b , and the first and second sides 103 c and 103 d , define an outer circumference of the void 141 , such that the void 141 extends upward into the lower end 103 f of the housing body 103 along the transverse direction T.
[0054] The connector housing 102 can further include at least one guidance member 144 such as a pair of guidance members 144 . Each guidance member 144 can be configured to interface with a complementary guidance member supported by the substrate 200 , for instance the printed circuit board 202 , so as to ensure proper alignment of the plurality of electrical contacts 105 with respect to the printed circuit board 202 during mounting of the electrical connector 100 to the printed circuit board 202 . At least one such as both of the guidance members 144 can further be configured as retention members that act to retain the electrical connector 100 in a mounted position relative to the printed circuit board 202 . In accordance with the illustrated embodiment, the housing body 103 includes a pair of substantially cylindrically shaped posts 146 that extend downward with respect to the connector housing 102 along the transverse direction T. The posts 146 are disposed on opposite ends of the housing body 103 , proximate the first and second ends 103 a and 103 b , respectively. In accordance with the illustrated embodiment the posts 146 can be integral, such as monolithic, with the housing body 103 , and thus extend out from the housing body 103 . Alternatively, the posts 146 can be separate and can be attached to the housing body 103 . It should be appreciated that the electrical connector 100 is not limited to the illustrated guidance members 144 , and that the connector housing 102 can be alternatively constructed with any other suitable guidance members as desired.
[0055] Referring now to FIGS. 1 and 2 A- 2 B, the substrate 200 , such as the printed circuit board 202 , can include a substrate body 204 that defines a first end 204 a that can define a front end, a second end 204 b that can define a rear end that is spaced from the first end 204 a along the longitudinal direction L. The substrate body 204 can further define a first side 204 c and a second side 204 d that is spaced from the first side 204 c along the lateral direction A. The substrate body 204 can further define an upper surface 204 e and a lower surface 204 f that is spaced from the upper surface 204 e along the transverse direction T. The printed circuit board 202 can further include at least one such as a plurality of electrically conductive elements 205 that can be supported by the printed circuit board 202 , for instance by the substrate body 204 .
[0056] The electrically conductive elements 205 can be electrically connected to electrically conductive traces that are routed through the substrate body 204 or along one or more surfaces of the substrate body 204 , such as along one or both of the upper and lower surfaces 204 e and 204 f thereof, in any combination as desired.
[0057] In accordance with illustrated embodiment, the printed circuit board 202 includes a plurality of electrically conductive elements 205 in the form of a plurality of vias 206 that can be configured as plated through holes that extend into such as through the substrate body 204 along the transverse direction T, for instance into the upper surface 204 e . Each of the plurality of vias 206 can be configured to receive a complementary portion of a respective one of the plurality of electrical contacts 105 , thereby placing the plurality of electrical contacts 105 in electrical communication with the printed circuit board 202 . The plurality of vias 206 can include at least one or both of electrical (for instance electrically conductive) signal vias 208 or electrical (for instance electrically conductive) ground vias 210 , in any combination as desired.
[0058] The plurality of vias 206 can be disposed along the substrate body 204 in accordance with any suitable arrangement, such that the plurality of vias 206 define a footprint configured to receive a corresponding arrangement of the plurality of electrical contacts 105 of the electrical connector 100 . For example, in accordance with the illustrated embodiment, the plurality of vias 206 can include respective pluralities of electrical signal vias 208 and electrical ground vias 210 arranged in accordance with the industry standard MicroTCA® press fit footprint.
[0059] In accordance with the industry standard MicroTCA® press fit footprint, the vias 206 are arranged along the substrate body 204 in rows of vias 206 that extend along a row direction R that can be, for instance, the longitudinal direction L and in columns of vias 206 that extend along a column direction C that can be, for instance, the lateral direction A. Thus, it should be appreciated that each of the columns are spaced from each other along the row direction R at the mating and mounting interfaces 216 and 218 . It should be further appreciated that the electrical connector 100 can define a column pitch measured as a distance between adjacent columns along the row direction R, for instance from the center of the respective mating or mounting ends of the electrical contacts 105 of a first column to a center of the respective mating or mounting ends of the electrical contacts 105 of a second column that is adjacent the first column along the row direction R. Each column can include a single electrical ground via 210 and four electrical signal vias 208 . The electrical ground via 210 and each of the electrical signal vias 208 can be substantially equally spaced from each other along the column direction. The electrical signal vias 208 in each column can be grouped into pairs 212 of electrical signal vias 208 , including a first pair 212 a and a second pair 212 b . The first pair 212 a of electrical signal vias 208 can include an upper or first electrical signal via 208 a and a lower or second electrical signal via 208 b . Similarly, the second pair 212 b of electrical signal vias 208 can include an upper or first electrical signal via 208 c and a lower or second electrical signal via 208 d . The electrical ground via 210 can be disposed between the first and second pairs 212 a and 212 b of electrical signal vias 208 , that is between the second electrical signal via 208 b of the first pair 212 a and the first electrical signal via 208 c of the second pair 212 b.
[0060] The first electrical signal via 208 a of the first pair 212 a , the electrical ground via 210 , and the first electrical signal via 208 c of the second pair 212 b are disposed along a first centerline CR 1 that extends substantially parallel to the lateral direction A. The second electrical signal via 208 b of the first pair 212 a and the second electrical signal via 208 d of the second pair 212 b are disposed along a second centerline CR 2 that extends substantially parallel to the first centerline CR 1 and is offset from the first centerline CR 1 along the lateral direction A. This column arrangement can be repeated along the substrate body 204 , with the columns C spaced apart from one another along the row direction. For example, in accordance with the illustrated embodiment, the substrate body 204 can have twenty seven columns C of vias 206 arranged in accordance with the industry standard MicroTCA® press fit footprint. It should be appreciated that the printed circuit board 202 is not limited to the illustrated electrically conductive elements 205 , and that the printed circuit board 202 can be alternatively constructed with any other suitable electrically conductive elements as desired. For instance, in accordance with an alternative embodiment of the printed circuit board 202 , at least one such as a plurality of electrical contact pads can be substituted for respective ones such as each of the vias 206 .
[0061] The printed circuit board 202 can further include at least one guidance member 214 such as a pair of guidance members 214 . Each guidance member 214 can be configured to interface with a complementary guidance member 144 supported by the connector housing 102 , so as to ensure proper alignment of the plurality of electrical contacts 105 and corresponding ones of plurality of vias 206 during mounting of the electrical connector 100 to the printed circuit board 202 . At least one such as both of the guidance members 214 can further be configured as retention members that act to retain the electrical connector 100 in a mounted position relative to the printed circuit board 202 . In accordance with the illustrated embodiment, the printed circuit board 202 includes a pair of guidance members 214 in the form of a pair of apertures 216 that extend into, such as through, the substrate body 204 along the transverse direction T, the apertures configured to receive respective ones of the posts 146 supported by the connector housing 102 . The apertures 216 can be configured to receive the posts 146 in press-fit engagement, such that the posts 146 and apertures 216 act as retention members to retain the electrical connector in a mounted position with respect to the printed circuit board 202 . The apertures 216 can be offset along the lateral direction A relative to each other, so as to ensure that the electrical connector 100 must be properly oriented relative to the printed circuit board 202 before the electrical connector can be mounted to the printed circuit board 202 .
[0062] Referring now to FIGS. 3A-3D , the plurality of electrical contacts 105 can include at least one or both of at least one electrical signal contact 104 or at least one electrical ground contact that can be defined by an electrically conductive ground plate 106 . In accordance with the illustrated embodiment, the electrical connector 100 includes respective pluralities of electrical signal contacts 104 and ground plates 106 , the respective pluralities of electrical signal contacts 104 and ground plates 106 configured to be supported by the connector housing 102 . The connector housing 102 can be configured to support the respective pluralities of electrical signal contacts 104 and ground plates 106 . The electrical signal contacts 104 and the ground plates 106 of the respective pluralities can be constructed of any suitable electrically conductive material as desired, for instance metal. Each electrical signal contact 104 includes a contact body 107 that defines a mounting end 108 that can define a first region of the contact body 107 , a mating end 112 that can define a second region of the contact body 107 , the mating end 112 opposite the mounting end 108 and spaced from the mounting end 108 along transverse direction T, and an intermediate region 109 that extends between the mounting end 108 and mating end 112 , for instance along the transverse direction T, such that the mating end 108 and the mounting end 112 are spaced from each other along the third direction. The mating end 112 of each electrical signal contact 104 can be substantially aligned with the respective mounting end 108 along the third direction, such that the electrical signal contact is a vertical electrical signal contact. Each of the plurality of electrical signal contacts 104 can be supported by the connector housing 102 , such that the mounting end 108 is disposed proximate the mounting interface 118 and the mating end 112 is disposed proximate the mating interface 116 .
[0063] The contact body 107 of each electrical signal contact 104 can define respective first and second ones of opposed broadsides 126 that are spaced apart from one another along the longitudinal direction and respective first and second ones of opposed edges 128 that are spaced apart from one another along the lateral direction A. In accordance with the illustrated embodiment, each of the first and second ones of the broadsides 126 has a first length along the lateral direction A from the first one of the edges 128 to the second one of the edges 128 , and each of the first and second ones of the edges 128 has a second length that extends along the longitudinal direction L from a first one of the broadsides 126 to a second one of the broadsides 126 , wherein the first length is greater than the second length.
[0064] The plurality of electrical signal contacts 104 can include at least one pair 113 such as a plurality of pairs 113 of electrical signal contacts 104 . For example, the connector housing 102 can be configured to support at least one pair 113 such as a first pair 113 a and a second pair 113 b of electrical signal contacts 104 . At least one or both of the first and second pairs 113 a and 113 b of electrical signal contacts 104 can include a first electrical signal contact 104 and a second electrical signal contact 104 that are disposed on opposed sides of the centerline CR 3 of the connector housing 102 . In accordance with the illustrated embodiment, the connector housing 102 can support a first row R 1 of electrical signal contacts 104 that are disposed on a first side of the centerline CR 3 , and a second row R 2 of electrical signal contacts 104 that disposed on an opposed second side of the centerline CR 3 , such that the first and second rows R 1 and R 2 of electrical signal contacts 104 are spaced from each other along the column direction C. The first row R 1 of electrical signal contacts 104 is supported by the connector housing 102 such that the first row R 1 is disposed closer to the second side 103 d than the first side 103 c of the housing body 103 , and the second row R 2 of electrical signal contacts 104 is supported by the connector housing 102 such that the second row R 2 is disposed closer to the first side 103 c than the second side 103 d of the housing body 103 .
[0065] At least a portion of the first electrical signal contacts of the first and second pairs 113 a and 113 b , for instance mating ends 112 of the first electrical signal contacts of the first and second pairs 113 a and 113 b , can be spaced from each other along the longitudinal direction L, and thus spaced from each other along a direction that is substantially perpendicular to the first and second broadsides 126 of each of the first electrical signal contacts of the first and second pairs 113 a and 113 b . Similarly, at least a portion of the second electrical signal contacts of the first and second pairs, for instance the mating ends 112 of the second electrical signal contacts of the first and second pairs 113 a and 113 b , can be spaced from each other along the longitudinal direction L, and thus spaced from each other along a direction that is substantially perpendicular to the first and second broadsides 126 of each of the second electrical signal contacts of the first and second pairs 113 a and 113 b . Furthermore, at least a portion up to all of the first and second electrical signal contacts of each of the first and second pairs 113 a and 113 b , including the mounting ends 108 and the mating ends 112 , can be spaced from each other along the lateral direction A.
[0066] For instance, the first pair 113 a of electrical signal contacts 104 includes a first electrical signal contact 104 a and a second electrical signal contact 104 b . Similarly, the second pair 113 b of electrical signal contacts 104 includes a first electrical signal contact 104 c (which can define a third electrical signal contact) and a second electrical signal contact 104 d (which can define a fourth electrical signal contact). In accordance with the illustrated embodiment, the first electrical signal contacts 104 a and 104 c are disposed on a first side of the centerline CR 3 of the connector housing 102 , and the second electrical signal contacts 104 b and 104 d are disposed on a second side of the centerline CR 3 that is opposite the first side. Further in accordance with the illustrated embodiment, the mating ends 112 of the first and second electrical signal contacts 104 a and 104 c are spaced from each other along the longitudinal direction L in accordance with the illustrated embodiment. Furthermore, both the mounting end 108 and the mating end 112 of the first electrical signal contact 104 a of the first pair 113 a are spaced from the corresponding mounting end 108 and mating end 112 of the second electrical signal contacts 104 b of the first pair 113 a along the lateral direction A. Similarly, both the mounting end 108 and the mating end 112 of the first electrical signal contact 104 c of the second pair 113 b are spaced from the corresponding mounting end 108 and mating end 112 of the second electrical signal contact 104 d of the second pair 113 b along the lateral direction A.
[0067] Each pair 113 of electrical signal contacts 104 can include a first electrical signal contact 104 that is disposed in the first row R 1 of electrical signal contacts 104 and a second electrical signal contact 104 that is disposed in the second row R 2 of electrical signal contacts 104 . For example, in accordance with the illustrated embodiment, the first electrical signal contacts 104 a and 104 c of the first and second pairs 113 a and 113 b , respectively, are disposed in the second row R 2 of electrical signal contacts 104 , and the second electrical signal contacts 104 b and 104 d of the first and second pairs 113 a and 113 b , respectively, are disposed in the first row R 1 of electrical signal contacts 104 .
[0068] In accordance with illustrated embodiment, the ground plates 106 can define first and second ground plates 106 a and 106 b that are successive along the longitudinal direction L, such that no other ground plate 106 is disposed between the first and second ground plates 106 a and 106 b along the longitudinal direction L. The plurality of electrical contacts 105 are supported by connector housing 102 such that the first and second pairs 113 a and 113 b of electrical signal contacts 104 are disposed between the first and second ground plates 106 a and 106 b , respectively, along the longitudinal direction L. For example, at least a portion up to all of the electrical signal contacts 104 of the first and second pairs 113 a and 113 b of electrical signal contacts 104 can be disposed between the first and second ground plates 106 a and 106 b , respectively, when the first and second pairs 113 a and 113 b and the first and second successive ground plates 106 a and 106 b are supported by the connector housing 102 . In this regard, the first pair 113 a of electrical signal contacts 104 is disposed adjacent the first ground plate 106 a (and thus closer to the first ground plate 106 a than the second ground plate 106 b , for instance along the longitudinal direction L) and the second pair 113 b of electrical signal contacts 104 is disposed adjacent the second ground plate 106 b (and thus closer to the second ground plate 106 b than the first ground plate 106 a , for instance along the longitudinal direction L). It should be appreciated that the first and second pairs 113 a and 113 b and the first and second ground plates 106 a and 106 b can define a pattern of a ground (for instance defined by one of the first and second ground plates 106 a and 106 b ), a first pair 113 a , and a second pair 113 b along the longitudinal direction L, such that the pattern can be repeated along the longitudinal direction in the connector housing 102 . Accordingly, the connector housing 102 can support each of the plurality of electrical signal contacts 104 and the plurality of ground plates 106 such that only two pairs 113 of electrical signal contacts 104 are disposed between successive ground plates 106 of the plurality of ground plates 106 .
[0069] The electrical signal contacts 104 of each pair 113 can be aligned along the lateral direction A when supported by the connector housing 102 , such that the electrical signal contacts 104 face each other along the lateral direction A. For example, the broadsides of the first and second electrical signal contacts of each pair 113 can be substantially coplanar with respect to one another in a plane defined by the longitudinal direction L and the lateral direction A. For instance, the broadsides of the first and second electrical signal contacts 104 a and 104 b of the first pair 113 a can be substantially coplanar with respect to one another in a plane defined by the longitudinal direction L and the lateral direction A, and the broadsides of the first and second electrical signal contacts 104 c and 104 d of the second pair 113 b can be substantially coplanar with respect to one another in a plane defined by the longitudinal direction L and the lateral direction A
[0070] The electrical signal contacts 104 can be constructed such that the respective mating ends 112 of the electrical signal contacts on each side of the longitudinal centerline CR 3 are substantially aligned with one another along the longitudinal direction L. Furthermore, respective pairs 113 electrical signal contacts 104 disposed adjacent one another between respective first and second ground plates 106 can be constructed such that the respective mounting ends 108 are jogged toward each other along the longitudinal direction L and jogged away from each other along the lateral direction A. For example, in accordance with the illustrated embodiment, the mounting end 108 of a first electrical signal contact 104 a of the first pair 113 a is jogged forward along the longitudinal direction L toward the first end 103 a of the housing body 103 and inward along the lateral direction A toward the longitudinal centerline CR 3 , and the mounting end 108 of a first electrical signal contact 104 c of the second pair 113 b is jogged rearward along the longitudinal direction L toward the second end 103 b of the housing body 103 and outward along the lateral direction A away from the longitudinal centerline CR 3 . The mounting end 108 of a second electrical signal contact 104 b of the first pair 113 a is jogged forward along the longitudinal direction L toward the first end 103 a of the housing body 103 and outward along the lateral direction A away from the longitudinal centerline CR 3 , and the mounting end 108 of a second electrical signal contact 104 d of the second pair 113 b is jogged rearward along the longitudinal direction L toward the second end 103 b of the housing body 103 and inward along the lateral direction A toward the longitudinal centerline CR 3 . Furthermore, in accordance with the illustrated embodiment, the first electrical signal contact 104 a of the first pair 113 a is constructed substantially identically to the second electrical signal contact 104 d of the second pair 113 b and the second electrical signal contact 104 b of the first pair 113 a is constructed substantially identically to the first electrical signal contact 104 c of the second pair 113 b.
[0071] The contact bodies 107 electrical signal contacts 104 can be constructed as resilient contact beams that extend between the mounting ends 108 and the mating ends 112 . At least a portion of the contact body 107 of each electrical signal contact 104 , for instance proximate the mating end 112 , can be curved inward along the lateral direction A so as to define a contact region 115 , the contact region 115 configured to engage with at least one electrical contact of a complementary electrical component, for example an edge card, that is mated to the electrical connector 100 . The respective contact regions 115 of each pair 113 of electrical signal contacts 104 can be curved inward along the lateral direction A toward each other so as to define a narrowed portion between the opposed resilient contact beams of the pair 113 at the respective contact regions 115 . Furthermore, the contact region 115 of each electrical signal contact 104 is defined substantially at the mating interface 116 . Thus, the electrical connector 100 can be configured as a receptacle connector configured to receive a complementary electrical component at the mating interface 116 so as to mate the electrical connector 100 to the complementary electrical component. It should be appreciated, however, that the electrical connector 100 can alternatively be configured as a plug connector that is configured to be received by the complementary electrical component at the mating interface 116 so as to mate the electrical connector 100 to the complementary electrical component. It should be appreciated that the electrical connector 100 is not limited to the illustrated contact body geometry, and that the electrical signal contacts 104 can be alternatively constructed using any other suitable contact body geometry as desired.
[0072] The mounting end 108 of at least one such as each of the electrical signal contacts 104 can include a mounting element such as a tail 111 that extends out from the mounting end 108 , for example downward along the transverse direction T. The tail 111 can be integral, such as monolithic, with the contact body 107 . In this regard, it can be said that the tail 111 extends out from the mounting end 108 . Alternatively, the tail 111 can be separate and can be attached to the mounting end 108 . In accordance with the illustrated embodiment, the tail 111 can be constructed as a press-fit tail, for instance an eye of the needle tail configured to be inserted into a corresponding electrical signal via 208 such that a press fit engagement is created between the tail 111 and the respective electrical signal via 208 upon insertion. It should be appreciated that the electrical signal contacts 104 of the electrical connector 100 are not limited to the illustrated tails 111 , and that the mounting ends 108 of the electrical signal contacts 104 can be constructed with any other mounting element geometry as desired.
[0073] The plurality of electrical signal contacts 104 can be arranged in broadside-coupled differential signal pairs 117 . For example, in accordance with the illustrated embodiment, the first electrical signal contact 104 a of the first pair 113 a of electrical signal contacts 104 and the first electrical signal contact 104 c of the second pair 113 b of electrical signal contacts 104 define a first differential signal pair 117 a , and the second electrical signal contact 104 b of the first pair 113 a of electrical signal contacts 104 and the second electrical signal contact 104 d of the second pair 113 b of electrical signal contacts 104 define a second differential signal pair 117 b.
[0074] In accordance with the illustrated embodiment, the first differential signal pair 117 a is defined in the second row R 2 of electrical signal contacts 104 , and the second differential signal pair 117 b is defined in the first row R 1 of electrical signal contacts 104 . Further in accordance with the illustrated embodiment, the first row R 1 of electrical signal contacts 104 can define a first plurality of differential signal pairs 117 of the electrical connector 100 , and the second row R 1 of electrical signal contacts 104 can define a second plurality of differential signal pairs 117 of the electrical connector 100 that is spaced from the first plurality of differential signal pairs 117 along the column direction C.
[0075] Respective pairs of differential signal pairs 117 that are disposed opposite one another in the first and second rows R 1 and R 2 , respectively, for instance the first and second differential signal pairs 117 a and 117 b , and are disposed between successive ground plates 106 , for instance the first and second ground plates 106 a and 106 b , can be spaced along the longitudinal direction L from successive pairs of differential signal pairs 117 that are disposed opposite one another in the first and second rows R 1 and R 2 and are disposed between respective successive ground plates 106 , such that no other differential signal pairs 117 are disposed between successive pairs of differential signal pairs 117 that are disposed opposite one another in the first and second rows R 1 and R 2 along the longitudinal direction L. In this regard, the connector housing 102 can support each of the plurality of electrical signal contacts 104 and the plurality of ground plates 106 such that only two differential signal pairs 117 are disposed between successive ground plates 106 . For example, in accordance with the illustrated embodiment, only the first and second pairs 117 a and 117 b of differential signal pairs 117 are disposed between the first and second ground plates 106 a and 106 b . It should be appreciated that the electrical connector 100 is not limited to the illustrated broadside-coupled differential signal pairs, and that the plurality of electrical signal contacts 104 can alternatively be configured as desired, for example as edge-coupled differential signal pairs.
[0076] With continued reference to FIGS. 3A-3D , each ground plate 106 of the plurality of ground plates 106 includes a plate body 120 that defines opposed upper and lower ends 120 a and 120 b that are spaced apart from one another along the transverse direction T, opposed first and second sides 120 c and 120 d that are spaced apart from one another along the lateral direction A, and opposed first and second outer plate body surfaces 120 e and 120 f that are spaced apart from one another along the longitudinal direction L so as to define a plate body thickness PT. In accordance with the illustrated embodiment, the first and second outer plate body surfaces 120 e and 120 f can extend along respective first and second planes defined by the longitudinal direction L and the lateral direction A, so as to define the plate body thickness PT. The plate body thickness PT can be referred to as a material thickness pertaining to a respective thickness of the material of which the plate body 120 is constructed. The plate body 120 can define any suitable shape as desired, for example a substantially rectangular shape such that the plate body 120 is elongate between the first and second sides 120 c and 120 d.
[0077] Each ground plate 106 , can further include at least one mounting end 110 and at least one mating end 114 such as a pair of mating ends 114 that can define ground mating ends, the at least one mounting end 110 opposite the at least one mating end 114 and spaced from the at least one mating end 114 along the transverse direction T. For example, in accordance with the illustrated embodiment, each ground plate 106 can include at least one mounting end 110 that is disposed proximate the lower end 120 b , and a pair of mating ends 114 that extend out from the plate body 120 , for example upward with respect to the upper end 120 a . Each of the plurality of ground plates 106 can be supported by the connector housing 102 , such that the at least one mounting end 110 is disposed proximate the mounting interface 118 and the at least one mating end 114 is disposed proximate the mating interface 116 .
[0078] The pair of mating ends 114 of each ground plate 106 can include a first mating end 114 a and a second mating end 114 b . In accordance with the illustrated embodiment, the first and second mating ends 114 a and 114 b can be constructed as resilient contact beams that extend out from the plate body 120 , upward along the transverse direction T, and are spaced from one another along the lateral direction A. In this regard, the first and second mating ends 114 a and 114 b can be referred to as free mating ends that are cantilevered with respect to the plate body 120 . In accordance with the illustrated embodiment, the first and second mating ends 114 a and 114 b can be integral, such as monolithic, with the plate body 120 . Alternatively, the first and second mating ends 114 a and 114 b can be separate and can be attached to the plate body 120 .
[0079] Each ground plate 106 can be constructed such that the first and second mating ends 114 a and 114 b are disposed on the first and second sides of the longitudinal centerline CR 3 , respectively, and are substantially aligned with the corresponding mating ends 112 of the plurality of electrical signal contacts 104 along the longitudinal direction L. The first and second mating ends 114 a and 114 b can be constructed substantially similarly to the corresponding regions of the contact bodies 107 of the plurality of electrical signal contacts 104 . For example, each of the first and second mating ends 114 a and 114 b of the ground plates 106 can define respective pairs of opposed broadsides 125 and opposed edges 127 that are substantially identical to the respective first and second opposed broadsides 126 and first and second opposed edges 128 of each of the plurality of electrical signal contacts 104 .
[0080] Furthermore, at least a portion of each of the first and second mating ends 114 a and 114 b can be curved inward along the lateral direction A so as to define respective contact regions 119 , the contact regions 119 configured to engage with at least one electrical contact of a complementary electrical component, for example an edge card, that is mated to the electrical connector 100 . In accordance with the illustrated embodiment, the respective contact regions 119 of each of the first and second mating ends 114 a and 114 b define a narrowed portion between the opposed resilient contact beams of the first and second mating ends 114 a and 114 b at the respective contact regions 119 . Furthermore, the respective contact regions 119 of the first and second mating ends 114 a and 114 b are defined substantially at the mating interface 116 .
[0081] It should be further appreciated that the electrical connector 100 illustrated in FIGS. 3A-4D can define a plurality of mating ends 95 that include collectively the mating ends 112 of the electrical signal contacts 104 and the mating ends 114 of the ground plates 106 . The electrical connector 100 is constructed as a card edge electrical connector 100 that defines one hundred seventy mating ends 95 , such that the mating ends 95 define a column pitch of approximately 0.75 mm. Thus, the mating ends 95 can be said to be constructed in accordance with the existing MicroTCA® standard, such that the electrical connector 100 is mating compatible with complementary electrical components constructed in accordance with the MicroTCA® standard. In accordance with the illustrated embodiment, the mating ends 95 of the electrical contacts 105 collectively define eighty-five columns and two rows that extend along the row direction R and can be, for instance, the first and second rows R 1 and R 2 . Additionally, because the ground plates 106 can be mounted onto a printed circuit board 202 configured in accordance with the industry standard MicroTCA® PF footprint, the illustrated electrical connector 100 can be said to be footprint compatible with the MicroTCA® standard.
[0082] In accordance with the illustrated embodiment, the respective contact regions 119 of the first and second mating ends 114 a and 114 b of each ground plate 106 are located a first distance from the upper end 103 e of the connector housing 102 that is substantially equal to a second distance that the respective contact regions 115 of the plurality of electrical signal contacts 104 are located from the upper end 103 e , such that when a complementary electrical component is mated to an assembled electrical connector 100 , complementary electrical contacts of the complementary electrical component engage substantially simultaneously with the respective contact regions 119 and 115 . It should be appreciated that at least one such as each of the plurality of electrical signal contacts 104 or at least one such as each of the plurality of ground plates 106 can be alternatively constructed with the first distance not substantially equal to the second distance, such that as the complementary electrical component is mated to the electrical connector 100 the electrical contacts of the complementary electrical component engage the respective contact regions 119 before the respective contact regions 115 , engage the respective contact regions 115 before the respective contact regions 119 , or engage the respective contact regions 119 and 115 in any order as desired. It should be appreciated that the ground plate 106 is not limited to the illustrated mating ends 114 , and that the ground plate 106 can alternatively be constructed with any other suitable mating end geometry as desired.
[0083] At least one ground plate 106 such as each of the plurality of ground plates 106 can further include a tab 122 that extends out from the plate body 120 . The tab 122 can have a tab body 123 that defines a proximal end 123 a that is disposed at a respective location along the first outer plate body surface 120 e , a distal end 123 b that is spaced from the proximal end 123 a along the longitudinal direction L, opposed first and second side surfaces 123 c and 123 d that are spaced from one another along the lateral direction A and can define opposed first and second outer tab surfaces that are spaced so as to define a tab thickness, and opposed upper and lower surfaces 123 e and 123 f that are spaced from one another along the transverse direction T. In accordance with the illustrated embodiment, the first and second outer tab surfaces can extend along respective third and fourth planes defined by the longitudinal direction L and the transverse direction T. Further in accordance with the illustrated embodiment, the tab thickness is substantially equal to the plate body thickness PT, the tab thickness is defined along the lateral direction A and the plate body thickness PT is defined along the longitudinal direction L. Thus, the tab thickness can be defined along a direction that is angularly offset with respect to a direction in which the plate body thickness PT is defined, and can be defined along a direction that is substantially perpendicular with respect to a direction in which the plate body thickness PT is defined. The proximal end 123 a of the tab body 123 can be disposed at any desired location along the first outer plate body surface 120 e . In this regard, the tab 122 can extend out from the plate body 120 at any location along the first outer plate body surface 120 e . For example, in accordance with the illustrated embodiment, the tab 122 extends out from the plate body 120 at a location that is substantially equidistant between the first and second sides 120 c and 120 d along the first direction, and extends out from the plate body 120 substantially at the lower end 120 b.
[0084] The tab body 123 is oriented such that the first and second side surfaces 123 c and 123 d are substantially parallel to one another and substantially coplanar with a plane defined by the longitudinal direction L and the transverse direction T, and such that the upper and lower surfaces 123 e and 123 f are substantially parallel to one another and substantially coplanar with a plane defined by the longitudinal direction L and the lateral direction A. Thus, in accordance with the illustrated embodiment, the first and second side surfaces 123 c and 123 d are substantially perpendicular with respect to the first and second outer plate body surfaces 120 e and 120 f of the plate body 120 and are substantially perpendicular with respect to the upper surface 204 e of the printed circuit board 202 when the electrical connector 100 is mounted to the printed circuit board 202 . Furthermore, the upper and lower surfaces 123 e and 123 f are substantially perpendicular with respect to the first and second outer plate body surfaces 120 e and 120 f of the plate body 120 and are substantially parallel with respect to the upper surface 204 e of the printed circuit board 202 when the electrical connector 100 is mounted to the printed circuit board 202 . It should be appreciated that the tab body 123 can be alternatively oriented as desired.
[0085] In accordance with the illustrated embodiment, the upper and lower surfaces 123 e and 123 f of the tab body 123 are spaced along the third direction and define a tab height TH of the tab 122 , and the first and second side surfaces 123 c and 123 d are spaced along the first direction and define a tab width TW of the tab 122 . Further in accordance with the illustrated embodiment, the tab width TW is substantially equal to the plate thickness PT of the plate body 120 , and the tab height TH is greater than the tab width TW, and thus greater than the tab thickness.
[0086] The first and second side surfaces 123 c and 123 d can define respective first and second ones of opposed broadsides 129 a of the tab 122 and the upper and lower surfaces 123 e and 123 f can define respective first and second ones of opposed edges 129 b of the tab 122 . Thus, in accordance with the illustrated embodiment, the first and second ones of the broadsides 129 a of the tab 122 are substantially perpendicular with respect to the upper surface 204 e of the printed circuit board 202 when the electrical connector 100 is mounted to the printed circuit board 202 , and the first and second ones of the edges 129 b of the tab 122 are substantially parallel with respect to the upper surface 204 e of the printed circuit board 202 when the electrical connector 100 is mounted to the printed circuit board 202 . Furthermore, each of the first and second ones of the broadsides 129 a has a first length along the transverse direction T from the first one of the edges 129 b to the second one of the edges 129 b , and each edge 129 b has a second length that extends along the lateral direction A from a first one of the broadsides 129 a to a second one of the broadsides 129 a , wherein the first length is greater than the second length.
[0087] In accordance with the illustrated embodiment, the tab 122 can be integral, such as monolithic, with the plate body 120 . Alternatively, the tab 122 can be separate and can be attached to the plate body 120 . In accordance with the illustrated embodiment, the tab 122 can be defined by removing sections of material from the plate body 120 , for example by making at least one cut 124 such as a plurality of cuts 124 in the plate body 120 . The cuts 124 can comprise a first cut 124 a that extends upward into the lower end 120 b of the plate body 120 along the transverse direction T to a location between the upper and lower ends 120 a and 120 b , for example along a distance from the lower end 120 b equal to the tab height TH. The first cut 124 a can be made at a location between the first and second sides 120 c and 120 d so as to define the distal end 123 b of the tab body 123 . The cuts 124 can further comprise a second cut 124 b that extends along the lateral direction A from an upper end of the first cut 124 a to a desired location of the proximal end 123 a of the tab body 123 . The second cut 124 b can define the upper surface 123 e of the tab body 123 . After the first and second cuts 124 a and 124 b have been made, the tab 122 can be bent out from the plate body 120 around a bend axis that extends along the transverse direction T and can be defined proximate the proximal end 123 a of the tab body 123 . The first and second cuts 124 a and 124 b can be located such that the tab 122 is located substantially equidistantly between the first and second sides 120 c and 120 d when the tab 122 is bent out from the plate body 120 . It should be appreciated that the ground plate 106 is not limited to the illustrated tab geometry, and that the tab 122 can be alternatively constructed as desired.
[0088] The plate body 120 of at least one ground plate 106 such as each of the plurality of ground plates 106 can further include at least one retention member 138 supported by the plate body 120 and configured to interface with a complementary retention member of the connector housing 102 so as to retain the ground plate 106 in an inserted position in the connector housing 102 . For example, in accordance with the illustrated embodiment, the plate body 120 includes a pair of retention members 138 constructed as generally triangular shaped wings 140 that extend out along the lateral direction A from the first and second sides 120 c and 120 d of the plate body 120 , respectively. The wings 140 can be configured to be received in the retention slots 139 of the connector housing 102 .
[0089] The at least one mounting end 110 of each ground plate 106 can be disposed proximate the lower end 120 b . For example, the at least one mounting end 110 can extend from the tab 122 , and thus can be said to extend out from the plate body 120 , such as downward with respect to the plate body 120 . In accordance with the illustrated embodiment, the at least one mounting end 110 extends downward from the lower surface 123 f of the tab body 123 along the transverse direction T. Thus, the at least one mounting end 110 extends out from the lower end 120 b of the plate body 120 and downward from the lower end 120 b of the plate body 120 . The at least one mounting end 110 can include a mounting element that can be configured as a press-fit mounting element such as a press-fit tail 111 that is downwardly elongate along the transverse direction T. The tail 111 can be integral, such as monolithic, with the tab body 123 . In this regard, it can be said that the tail 111 extends out from the at least one mounting end 110 . Alternatively, the tail 111 can be separate and can be attached to the at least one mounting end 110 . In accordance with the illustrated embodiment, the tail 111 can be constructed as a press-fit tail, for instance an eye of the needle tail configured to be inserted into a corresponding ground via 210 such that a press fit engagement is created between the tail 111 and the respective ground via 210 upon insertion. It should be appreciated that the ground plate 106 is not limited to the illustrated tails 111 , and that the at least one mounting end 110 of the ground plate 106 can be constructed with any other mounting element geometry as desired.
[0090] Referring now to FIGS. 3A-3C , when a respective one of the plurality of ground plates 106 and corresponding first and second pairs 113 a and 113 b of electrical signal contacts 104 are supported by the connector housing 102 , at least a portion of the tab 122 , such as the distal end 123 b of the tab body 123 , can be disposed between the mounting ends 108 of the first and second pairs 113 a and 113 b of electrical signal contacts 104 , respectively, such that the mounting ends 108 of the first and second pairs 113 a and 113 b of electrical signal contacts 104 and the mounting end 110 disposed on the tab 122 of the ground plate 106 are substantially aligned along the first direction and thus extend substantially parallel to the first and second outer plate body surfaces 120 e and 120 f . The electrical signal contacts 104 of each of the first and second pairs 113 a and 113 b of electrical signal contacts 104 are spaced apart along the first direction, and the respective mounting ends 108 of the first and second pairs 113 a and 113 b of electrical signal contacts 104 and the mounting end 110 of the ground plate 106 are spaced along the second direction when the first and second pairs 113 a and 113 b of electrical signal contacts 104 and the ground plate 106 are supported by the connector housing 102 . Furthermore, the first direction extends substantially parallel to the first and second outer plate body surfaces 120 e and 120 f when the first and second pairs 113 a and 113 b of electrical signal contacts 104 and the ground plate 106 are supported by the connector housing 102 . Furthermore, the second direction extends substantially parallel to the first and second outer tab surfaces when the first and second pairs 113 a and 113 b of electrical signal contacts 104 and the ground plate 106 are supported by the connector housing 102 .
[0091] For example, in accordance with the illustrated embodiment, when the first ground plate 106 a and the first and second pairs 113 a and 113 b of electrical signal contacts 104 are supported by the connector housing 102 , the mounting end 110 that extends from the tab 122 is disposed between the respective mounting ends 108 of the first and second electrical signal contacts 104 a and 104 b of the first pair 113 a and between the respective mounting ends 108 of the first and second electrical signal contacts 104 c and 104 d of the second pair 113 b . Furthermore, the tail 111 of the mounting end 110 disposed on the tab 122 is oriented substantially perpendicular with respect to the tails 111 that extend from the respective mounting ends 108 of the first and second pairs 113 a and 113 b of electrical signal contacts 104 . In accordance with the illustrated embodiment, when a respective one of the plurality of ground plates 106 and corresponding first and second pairs 113 a and 113 b of electrical signal contacts 104 are supported by the connector housing 102 , the tails 111 that extend from the respective mounting ends 108 of the electrical signal contacts 104 and the tail 111 of the mounting end 110 are aligned with respect to each other along the first direction.
[0092] The illustrated arrangement of electrical contacts 105 , including the first and second pairs 113 a and 113 b of electrical signal contacts 104 and the ground plate 106 can be mounted to the industry standard MicroTCA® press fit footprint. For example, in accordance with the illustrated embodiment, when the first and second pairs 113 a and 113 b of electrical signal contacts 104 and the ground plate 106 are supported by the connector housing 102 , the tails 111 that extend out from the respective mounting ends 108 of the first and second pairs 113 a and 113 b of electrical signal contacts 104 can be inserted into corresponding ones of the first and second pairs 212 a and 212 b of electrical signal vias 208 of a first column of vias 206 , and the tail 111 of the mounting end 110 of the ground plate 106 can be inserted into the electrical ground via 210 of the first column of vias 206 .
[0093] Referring again to FIGS. 3A-3D , each ground plate 106 can define asymmetrical first and second ground return flow paths SP 1 and SP 2 . For instance, the first mating end 114 a can define the first ground flow return path SP 1 from the first mating end 114 a to the mounting end 110 , and the second mating end 114 b can define the second ground flow return path SP 2 from the second mating end 314 b to the mounting end 110 . The first and second ground flow return paths SP 1 and SP 2 can define respect paths to ground for corresponding electrical signal contacts 104 disposed proximate the first and second mating ends 114 a and 114 b , respectively. For example, in accordance with the illustrated embodiment, electrical signal contacts 104 disposed proximate the first mating end 114 a , such as the first electrical signal contacts 104 a and 104 c of the first and second pairs 113 a and 113 b , respectively, that define the first differential signal pair 117 a , will follow the first ground return flow path SP 1 to the mounting end 110 , and electrical signal contacts 104 disposed proximate the second mating end 114 b , such as the second electrical signal contacts 104 b and 104 d of the first and second pairs 113 a and 113 b , respectively, that define the second differential signal pair 117 b , will follow the second ground return flow path SP 2 to the mounting end 110 . The first ground flow return path SP 1 is shorter the second ground flow return path SP 2 , at least in part due to the geometry of the tab 122 . Because the second ground flow return path SP 2 adjacent to or near the second differential signal pair 117 b is longer than the first ground flow return path SP 1 adjacent to or near the first differential signal pair 117 a , the first and second ground flow return paths SP 1 and SP 2 are asymmetrical, and the second differential signal pair 117 b will exhibit higher inductance levels than the first differential signal pair 117 a , thereby impacting performance of the electrical connector 100 constructed utilizing a plurality of the ground plates 106 .
[0094] Referring now to FIGS. 4A-4C , the illustrated electrical connector 100 can include at least one, such as a plurality of leadframe assemblies 130 configured to be supported by the connector housing 102 . Each leadframe assembly 130 can include a dielectric or electrically insulative leadframe housing 132 and at least one such as a plurality of electrical contacts 105 that can be configured as electrical signal contacts 104 that are supported by the leadframe housing 132 . In accordance with the illustrated embodiment, each leadframe assembly 130 includes a pair of electrical signal contacts 104 that are spaced apart from one another along the column direction C. The leadframe assemblies 130 can be configured as insert molded leadframe assemblies (IMLAs) whereby the respective leadframe housings 132 are overmolded onto respective ones of the plurality of electrical signal contacts 104 . For instance, the leadframe housing 132 of each leadframe assembly 130 can be overmolded onto the corresponding electrical signal contacts 104 such that the leadframe housing 132 is overmolded onto, and thus encloses, at least a portion of the contact body 107 , for instance the intermediate region 109 , of each of the respective electrical signal contacts 104 supported by the leadframe housing 132 . Alternatively, the respective ones of the electrical signal contacts 104 can be stitched into the leadframe housings 132 or otherwise supported by the respective leadframe housings 132 .
[0095] A plurality up to all of the leadframe assemblies 130 can include at least one pair 131 such as a plurality of pairs 131 of first and second leadframe assemblies 130 a and 130 b , respectively. The first and second leadframe assemblies 130 a and 130 b of each pair 131 can be constructed substantially identically. The first leadframe assembly 130 a and the second leadframe assembly 130 b of each pair 131 can be disposed adjacent each other, for instance along the row direction R, when supported by the connector housing 102 , so as to define the first and second differential signal pairs 117 a and 117 b . For example, in accordance with the illustrated embodiment, the first leadframe assembly 130 a can have a first leadframe housing 132 a that is overmolded onto the first pair 113 a of electrical signal contacts 104 and the second leadframe assembly 130 b can have a second leadframe housing 132 b that is overmolded onto the second pair 113 b of electrical signal contacts 104 . Accordingly, the first electrical signal contact 104 a of the first leadframe assembly 130 a and the first electrical signal contact 104 c of the second leadframe assembly 130 b can define the first differential signal pair 117 a , and the second electrical signal contact 104 b of the first leadframe assembly 130 a and the second electrical signal contact 104 d of the second leadframe assembly 130 b can define the second differential signal pair 117 b.
[0096] The first and second leadframe assemblies 130 a and 130 b of each pair 131 can be configured to interface with one another when disposed adjacent to one another in the connector housing 102 . For example, the leadframe housing 132 of each of the first and second leadframe assemblies 130 a and 130 b , respectively, of each pair 131 can include at least one interface member 135 that is configured to receive a complementary at least one interface member 135 supported by the leadframe housing 132 of the other of the first and second leadframe assemblies 130 a and 130 b , respectively, of the pair 131 . Thus, the first leadframe housing 132 a of the first leadframe assembly 130 a can be at least partially received by the second leadframe housing 132 b of the second leadframe assembly 130 b , and the second leadframe housing 132 b of the second leadframe assembly 130 b can be at least partially received by the first leadframe housing 132 a of the first leadframe assembly 130 a . In accordance with the illustrated embodiment, the leadframe housing 132 of each leadframe assembly 130 includes respective pairs of interface members 135 configured as a pair of projecting portions 134 and a pair pocket portions 136 , respectively. The projecting portions 134 of each pair can be constructed the same or differently, and the pocket portions 134 of each pair can be constructed the same or differently. In accordance with the illustrated embodiment, the first leadframe housing 132 a of the first leadframe assembly 130 a can include a pair of first projection portions 134 a and a pair of first pocket portions 136 a , and the second leadframe housing 132 b of the second leadframe assembly 130 b can include a pair of second projection portions (not shown) and a pair of second pocket portions (not shown). The pair of first projection portions 134 a of the first leadframe housing 132 a can be configured to be received in respective ones of the pair of second pocket portions of the second leadframe housing 132 b and the pair of second projection portions of the second leadframe housing 132 b can be configured to be received in the pair of first pocket portions 136 a of the first leadframe housing 132 a.
[0097] In accordance with the illustrated embodiment, when the first and second leadframe assemblies 130 a and 130 b of each pair 131 are supported by the connector housing 102 , the first leadframe assembly 130 a of each respective pair 131 can be oriented in a first orientation and the second leadframe assembly 130 b of the corresponding pair 131 can be oriented in a second orientation relative to the first leadframe assembly 130 a that is rotated 180 degrees about an axis that is substantially perpendicular to the first direction and substantially parallel to the transverse direction T. When the first and second leadframe assemblies 130 a and 130 b are oriented in the first and second orientations, respectively, and supported by the connector housing 102 , the pair of first projection portions 134 a of the first leadframe housing 132 a can be at least partially received in respective ones of the pair of second pocket portions of the second leadframe housing 132 b and the pair of second projection portions of the second leadframe housing 132 b can be at least partially received in the pair of first pocket portions 136 a of the first leadframe housing 132 a.
[0098] Any suitable dielectric material, such as air or plastic, may be used to isolate the respective electrical signal contacts 104 of the first leadframe assembly 130 a of a pair 131 from the respective electrical signal contacts 104 of the second leadframe assembly 130 b of the pair 131 . In accordance with the illustrated embodiment, the first and second leadframe assemblies 130 a and 130 b of each pair 131 abut each other when supported by the connector housing 102 . However it should be appreciated that at least one or both of the first and second leadframe assemblies 130 a and 130 b or the connector housing 102 can be alternatively constructed such that the first and second leadframe assemblies 130 a and 130 b are spaced from each other when supported by the connector housing 102 .
[0099] At least one such as both of the first and second leadframe assemblies 130 a and 130 b of each pair 131 can further include at least one retention member 138 supported by the respective first and second leadframe housings 132 a and 132 b and configured to interface with a complementary retention member of the connector housing 102 so as to retain the ground plate 106 in an inserted position in the connector housing 102 . For example, in accordance with the illustrated embodiment, both the first and second leadframe housings 132 a and 132 b of each pair each include a pair of retention members 138 constructed as generally triangular shaped wings 142 that extend out along the lateral direction A from the first and second leadframe housings 132 a and 132 b . The wings 142 can be constructed substantially identically to the wings 140 of the plurality of ground plates 106 and thus can be configured to be received in the retention slots 139 of the connector housing 102 .
[0100] Referring now to FIGS. 4B-4C , each pair 131 of leadframe assemblies 130 of the plurality of leadframe assemblies 130 can be supported by the connector housing 102 between respective ground plates 106 . In this regard, the connector housing 102 supports successive first and second pairs 113 a and 113 b of electrical signal contacts 104 and ground plates 106 when the first and second pairs 113 a and 113 b of electrical signal contacts 104 and ground plates 106 are supported by the connector housing 102 . The respective pluralities of leadframe assemblies 130 and ground plates 106 can be arranged such that a ground plate 106 is disposed between successive adjacent pairs 131 of first and second leadframe assemblies 130 a and 130 b , such that the plurality of electrical contacts 105 of the electrical connector 100 define a repeating ground-signal-signal (G-S-S) arrangement of ground plates 106 and electrical signal contacts 104 along the row direction R. The ground plates 106 can be disposed between adjacent pairs 131 of leadframe assemblies 130 along the row direction R such that the ground plates 106 can reduce crosstalk between adjacent differential signal pairs 117 of the adjacent pairs 131 of leadframe assemblies 130 that are aligned along the row direction R.
[0101] Referring now to FIGS. 5A-5D , a ground plate 306 that can be mounted onto a printed circuit board 202 configured in accordance with the industry standard MicroTCA® PF footprint is illustrated. In the interest of succinctness, elements of the ground plate 306 that are constructed substantially identically to corresponding elements of the industry standard MicroTCA® ground plate 106 are labeled with reference numbers that are incremented by 200. For example, the mating ends 314 of the ground plate 306 can be constructed substantially identically to the mating ends 114 of the ground plate 106 , such that the mating ends 314 are disposed into respective positions that are substantially identical to the mating ends 114 of the ground plate 106 when the ground plate 306 is supported by the connector housing 102 . In this regard, the ground plate 306 can be said to be mating compatible with complementary electrical components configured to be mated to the industry standard industry standard MicroTCA® electrical connector 100 . The illustrated electrical signal contacts 104 can be constructed substantially identically to the industry standard MicroTCA® electrical signal contacts 104 described above and illustrated in FIGS. 3A-3E , and thus the reference numerals associated therewith are repeated in FIGS. 5A-5D .
[0102] In accordance with the illustrated embodiment, the electrical connector 100 can be constructed utilizing at least one such as a plurality of the ground plates 306 . In this regard, at least one such as a plurality of ground plates 306 can be substituted for respective ones of the plurality of ground plates 106 , and the plurality of ground plates 306 can be supported by the connector housing 102 adjacent to corresponding pairs 113 of electrical signal contacts 104 . The electrical connector 100 can be constructed using respective pluralities of electrical signal contacts 104 and ground plates 306 , supported by the connector housing 102 . For example, the electrical connector 100 can be constructed using a repeating sequence of a ground plate 306 , followed by corresponding first and second pairs 113 a and 113 b of electrical signal contacts 104 configured as respective differential signal pairs 117 , followed by another ground plate 306 , and so on. Accordingly, the connector housing 102 can support each of the plurality of electrical signal contacts 104 and the plurality of ground plates 306 such that only two differential signal pairs 117 are disposed between successive ground plates 306 .
[0103] Using this repeating sequence, the electrical connector 100 can be constructed as a card edge electrical connector 100 that defines one hundred seventy mating ends 95 that can be collectively defined by the mating ends 112 of the electrical signal contacts 104 and the mating ends 114 of the ground plates 306 , the mating ends 95 defining a column pitch of approximately 0.75 mm. Thus, the mating ends 95 can be said to be constructed in accordance with the existing MicroTCA® standard, such that the electrical connector 100 is mating compatible with complementary electrical components constructed in accordance with the MicroTCA® standard. Thus, in accordance with the illustrated embodiment, the mating ends of the electrical contacts 105 collectively define eighty-five columns and two rows. Additionally, because the ground plates 306 can be mounted onto a printed circuit board 202 configured in accordance with the industry standard MicroTCA® PF footprint, the illustrated electrical connector 100 can be said to be footprint compatible with the MicroTCA® standard.
[0104] In accordance with the illustrated embodiment, the ground plate 306 includes a tab 348 that is constructed differently than the tab 122 of the ground plate 106 . The tab 348 extends out from the plate body 320 . The tab 348 can have a tab body 349 that defines a proximal end 349 a that is disposed at a respective location along the first outer plate body surface 320 e , a distal end 349 b that is spaced from the proximal end 349 a along the longitudinal direction L, opposed first and second side surfaces 349 c and 349 d that are spaced from one another along the lateral direction A, and opposed upper and lower surfaces 349 e and 349 f that are spaced from one another along the transverse direction T and can define opposed first and second outer tab surfaces that are spaced so as to define a tab thickness. In accordance with the illustrated embodiment, the first and second outer tab surfaces can extend along respective third and fourth planes defined by the longitudinal direction L and the lateral direction A. Further in accordance with the illustrated embodiment, the tab thickness is substantially equal to the plate body thickness PT, the tab thickness is defined along the transverse direction A and the plate body thickness PT is defined along the longitudinal direction L. Thus, the tab thickness can be defined along a direction that is angularly offset with respect to a direction in which the plate body thickness PT is defined, and can be defined along a direction that is substantially perpendicular with respect to a direction in which the plate body thickness PT is defined. The proximal end 349 a can be disposed at any desired location along the first outer plate body surface 320 e . In this regard, the tab 348 can extend out from the plate body 320 at any location along the first outer plate body surface 320 e . For example, in accordance with the illustrated embodiment, the tab 348 extends out from the plate body 320 at a location that is substantially equidistant between the first and second sides 320 c and 320 d , and extends out from the plate body 320 at a location that is between the upper and lower ends 320 a and 320 b.
[0105] The tab body 349 is oriented such that the first and second side surfaces 349 c and 349 d are substantially parallel to one another and substantially coplanar with a plane defined by the longitudinal direction L and the transverse direction T, and such that the upper and lower surfaces 349 e and 349 f are substantially parallel to one another and substantially coplanar with a plane defined by the longitudinal direction L and the lateral direction A. Thus, in accordance with the illustrated embodiment, the first and second side surfaces 349 c and 349 d are substantially perpendicular with respect to the first and second outer plate body surfaces 320 e and 320 f of the plate body 320 and are substantially perpendicular with respect to the upper surface 204 e of the printed circuit board 202 when the electrical connector 100 is mounted to the printed circuit board 202 . Furthermore, the upper and lower surfaces 349 e and 349 f are substantially perpendicular with respect to the first and second outer plate body surfaces 320 e and 320 f of the plate body 320 and are substantially parallel with respect to the upper surface 204 e of the printed circuit board 202 when the electrical connector 100 is mounted to the printed circuit board 202 . It should be appreciated that the tab body 349 can be alternatively oriented as desired.
[0106] In accordance with the illustrated embodiment, the upper and lower surfaces 349 e and 349 f of the tab body 349 are spaced along the third direction and define a tab height TH of the tab 348 , and the first and second side surfaces 349 c and 349 d are spaced along the first direction and define a tab width TW of the tab 348 . Further in accordance with the illustrated embodiment, the tab height TH is substantially equal to the plate thickness PT of the plate body 320 , and the tab width TW is greater than the tab height TH, and thus greater than the tab thickness.
[0107] The upper and lower surfaces 349 e and 349 f can define respective first and second ones of opposed broadsides 350 of the tab 348 and the first and second side surfaces 349 c and 349 d can define respective first and second ones of opposed edges 352 of the tab 348 . Thus, in accordance with the illustrated embodiment, the first and second edges 352 of the tab 348 are substantially perpendicular with respect to the upper surface 204 e of the printed circuit board 202 when the electrical connector 100 is mounted to the printed circuit board 202 , and the first and second broadsides 350 of the tab 348 are substantially parallel with respect to the upper surface 204 e of the printed circuit board 202 when the electrical connector 100 is mounted to the printed circuit board 202 . Furthermore, each of the first and second ones of the broadsides 350 has a first length along the lateral direction A from the first one of the edges 352 to the second one of the edges 352 , and each of the first and second ones of the edges 352 has a second length that extends along the transverse direction T from a first one of the broadsides 350 to a second one of the broadsides 350 , wherein the first length is greater than the second length.
[0108] The tab 348 can be integral, such as monolithic, with the plate body 320 . Alternatively, the tab 348 can be separate and can be attached to the plate body 320 . In accordance with the illustrated embodiment, the tab 348 can be defined by removing sections of material from the plate body 320 , for example by making at least one cut 324 such as a plurality of cuts 324 in the plate body 320 . The cuts 324 can comprise first and second cuts 324 a and 324 b that extend upward into the lower end 320 b of the plate body 320 along the transverse direction T to respective locations between the upper and lower ends 320 a and 320 b , the first and second cuts 324 a and 324 b spaced from one another along the lateral direction a distance substantially equal to the tab width TW. The first cut 324 a can be made at a location between the first and second sides 320 c and 320 d so as to define the first side 349 c of the tab body 349 . The second cut 324 b can be made at a location between the first cut 324 a and the second side 320 d so as to define the second side 349 d of the tab body 349 . After the first and second cuts 324 a and 324 b have been made, the tab 348 can be bent out from the plate body 320 around a bend axis that extends along the lateral direction A and can be defined proximate the proximal end 349 a of the tab body 349 , such that the lower end 320 b of the plate body 320 defines a void 320 g that extends upward into the plate body 320 along the transverse direction T. The first and second cuts 324 a and 324 b can be located such that the tab 348 is located substantially equidistantly between the first and second sides 320 c and 320 d when the tab 348 is bent out from the plate body 320 . It should be appreciated that the ground plate 306 is not limited to the illustrated tab geometry, and that the tab 348 can be alternatively constructed as desired.
[0109] Similarly to the ground plate 106 , the ground plate 306 can include at least one mounting end 310 that can extend from the tab 348 , and thus can be said to extend out from the plate body 320 . In accordance with the illustrated embodiment, the at least one mounting end 310 can define a first mounting end extends downward from the lower surface 349 f of the tab body 349 along the transverse direction T, and is located substantially at the distal end 349 b of the tab body 349 , such that the at least one mounting end 310 is substantially aligned with the void 320 g along the longitudinal direction L and spaced from the first outer plate body surface 320 e of the plate body 320 a distance D along the longitudinal direction L. The at least one mounting end 310 can include a mounting element that can be configured as a press-fit mounting element such as a press-fit tail 311 that is downwardly elongate along the transverse direction T. The tail 311 can be integral, such as monolithic, with the tab body 349 . In this regard, it can be said that the tail 311 extends out from the at least one mounting end 310 . Alternatively, the tail 311 can be separate and can be attached to the at least one mounting end 310 . In accordance with the illustrated embodiment, the tail 311 can be constructed as a press-fit tail, for instance an eye of the needle tail configured to be inserted into a corresponding ground via 210 such that a press fit engagement is created between the tail 311 and the respective ground via 210 upon insertion. It should be appreciated that the ground plate 306 is not limited to the illustrated tails 311 , and that the at least one mounting end 310 of the ground plate 306 can be constructed with any other mounting element geometry as desired.
[0110] Referring now to FIGS. 5A-5C , when a respective one of the plurality of ground plates 306 and corresponding first and second pairs 113 a and 113 b of electrical signal contacts 104 are supported by the connector housing 102 , at least a portion of the tab 348 , such as the distal end 349 b of the tab body 349 , can be disposed between the mounting ends 108 of the first and second pairs 113 a and 113 b of electrical signal contacts 104 , respectively, such that the mounting ends 108 of the first and second pairs 113 a and 113 b of electrical signal contacts 104 and the mounting end 310 disposed on the tab 348 of the ground plate 306 are substantially aligned along the first direction. For example, in accordance with the illustrated embodiment, when the first ground plate 306 a and the first and second pairs 113 a and 113 b of electrical signal contacts 104 are supported by the connector housing 102 , the mounting end 310 disposed on the tab 348 is disposed between the respective mounting ends 108 of the first and second electrical signal contacts 104 a and 104 b of the first pair 113 a and between the respective mounting ends 108 of the first and second electrical signal contacts 104 c and 104 d of the second pair 113 b . Furthermore, the tail 311 of the mounting end 310 that extends from the tab 348 is oriented substantially parallel with respect to the tails 111 that extend from the respective mounting ends 108 of the first and second pairs 113 a and 113 b of electrical signal contacts 104 (see FIG. 6 ).
[0111] The illustrated arrangement of electrical contacts 105 , including the first and second pairs 113 a and 113 b of electrical signal contacts 104 and the ground plate 306 can be mounted to the industry standard MicroTCA® press fit footprint. Therefore, it can be said that the illustrated electrical connector 100 is footprint compatible with the MicroTCA® standard. For example, in accordance with the illustrated embodiment, when the first and second pairs 113 a and 113 b of electrical signal contacts 104 and the ground plate 306 are supported by the connector housing 102 , the tails 111 that extend out from the respective mounting ends 108 of the first and second pairs 113 a and 113 b of electrical signal contacts 104 can be inserted into corresponding ones of the first and second pairs 212 a and 212 b of electrical signal vias 208 of a first column of vias 206 , and the tail 311 of the mounting end 310 of the ground plate 306 can be inserted into the electrical ground via 210 of the first column of vias 206 . In accordance with the illustrated embodiment, the mounting ends 108 of the plurality of the electrical signal contacts 104 define respective ones of a first plurality of press-fit tails 111 , and the mounting end 311 of the tabs 348 of each of the ground plates 306 defines a respective one of a second plurality of press-fit tails 311 , such that each of the first and second pluralities of press-fit tails are positioned to be inserted into complementary vias 206 of a printed circuit 202 board that are arranged in accordance with the MicroTCA® standard, such as the MicroTCA® specification Rev. 1.0, and are thus footprint compatible with the industry standard MicroTCA® PF footprint.
[0112] Referring again to FIGS. 5A-5D , each ground plate 306 can define symmetrical first and second ground return flow paths SP 3 and SP 4 . For instance, a first mating end 314 a can define a first ground mating end that defines the first ground flow return path SP 3 from the first mating end 314 a to the mounting end 310 , and a second mating end 314 b can define a second ground mating end that defines the second ground flow return path SP 4 from the second mating end 314 b to the mounting end 310 . The first and second ground flow return paths SP 3 and SP 4 can define respect paths to ground for corresponding electrical signal contacts 104 disposed proximate the first and second mating ends 314 a and 314 b , respectively. For example, in accordance with the illustrated embodiment, electrical signal contacts 104 disposed proximate the first mating end 314 a , such as the first electrical signal contacts 104 a and 104 c of the first and second pairs 113 a and 113 b , respectively, that define the first differential signal pair 117 a , will follow the first ground return flow path SP 3 to the mounting end 310 , and electrical signal contacts 104 disposed proximate the second mating end 314 b , such as the second electrical signal contacts 104 b and 104 d of the first and second pairs 113 a and 113 b , respectively, that define the second differential signal pair 117 b , will follow the second ground return flow path SP 4 to the mounting end 310 .
[0113] The first and second ground flow return paths SP 3 and SP 4 can be symmetrical with respect to each other due to one or both of substantially equal physical length of the first and second ground flow return paths SP 3 and SP 4 or substantially equal electrical length of the first and second ground flow return paths SP 3 and SP 4 . For example, in accordance with the illustrated embodiment, first and second the ground flow return paths SP 3 and SP 4 are substantially equal in physical length, at least in part due to the symmetry of the plate body 320 , including the first and second mating ends 314 a and 314 b , with respect to the tail 311 . Further in accordance with the illustrated embodiment, the first and second ground flow return paths SP 3 and SP 4 are substantially equal in electrical length. For example, a first electrical signal that propagates from a first location in the first mating end 314 a of the ground plate 306 to the tail 311 will reach the tail 311 in substantially the same amount of time required for a second electrical signal to propagate from a second location in the second mating end 314 b of the ground plate 306 to the tail 311 , wherein the first location with respect to the first mating end 314 a substantially corresponds with the second location with respect to the second mating end 314 b . It should be appreciated that it is possible to alternatively construct the ground plate 306 such that the first and second ground flow return paths SP 3 and SP 4 are substantially equal in electrical length but not substantially equal in physical length. Because the first and second differential signal pairs 117 a and 117 b are adjacent to or near substantially equal length first and second ground flow return paths SP 3 and SP 4 , respectively, the inductance levels exhibited by the first and second differential signal pairs 117 a and 117 b can be substantially the same, resulting in an overall performance increase over an electrical connector 100 constructed utilizing a plurality of ground plates 106 .
[0114] Referring generally now to FIGS. 7A-9D , the ground plate of the electrical connector 100 can be differently constructed in accordance with additional alternative embodiments, so as to improve the path to ground characteristics associated with the plurality of electrical signal contacts 104 supported by the connector housing 102 . To improve the ground path characteristics of the electrical connector 100 , the ground plates can be differently constructed to introduce additional symmetries to the respective ground flow return paths defined by the ground plates of the electrical connector 100 . In order to maintain compatibility between printed circuit board 202 and the electrical connectors 100 utilizing the alternatively constructed ground plates, the plurality of vias 206 can be disposed along the printed circuit board 202 in accordance with corresponding alternative arrangements, so as to define respective alternative footprints that differ from the industry standard MicroTCA® PF footprint, as described in more detail below. It should be further appreciated that electrical connectors 100 illustrated in FIGS. 7A-9D define mating ends 95 that are constructed in accordance with the existing MicroTCA® standard, such that the respective electrical connectors 100 are mating compatible with complementary electrical components constructed in accordance with the MicroTCA® standard as described above with respect to FIGS. 5A-C . Thus, in accordance with the illustrated embodiments illustrated in FIGS. 7A-9D , the mating ends 95 of the electrical contacts 105 collectively define eighty-five columns and two rows.
[0115] Referring now to FIGS. 7A-7D , a ground plate 406 constructed in accordance with an alternative embodiment is illustrated. In the interest of succinctness, elements of the ground plate 406 that are constructed substantially identically to corresponding elements of the ground plate 306 are labeled with reference numbers that are incremented by 100. The illustrated electrical signal contacts 104 can be constructed substantially identically to the electrical signal contacts 104 described above and illustrated in FIGS. 3A-3E , and thus the reference numerals associated therewith are repeated in FIGS. 7A-7D . The electrical connector 100 can be constructed utilizing at least one such as a plurality of the ground plates 406 . In this regard, a plurality of ground plates 406 can be substituted for the plurality of ground plates 106 , and the plurality of ground plates 406 can be supported by the connector housing 102 adjacent to corresponding pairs 113 of electrical signal contacts 104 .
[0116] In accordance with the illustrated embodiment, the ground plate 406 includes a tab 448 that is constructed substantially identically to the tab 348 of the ground plate 306 . The ground plate 406 can further include a plurality of mounting ends 410 , for instance first, second, and third mounting ends 410 a , 410 b , and 410 c . The first and second mounting ends 410 a and 410 b can be disposed substantially at the lower end 420 b of the plate body 420 , proximate the first and second sides 420 c and 420 d , respectively, such that the first mounting end 410 a extends from the plate body 420 at a location closer to the first side 420 c than the second side 420 d , and the second mounting end 410 b extends from the plate body 420 at a location closer to the second side 420 d than the first side 420 c . The first and second mounting ends 410 a and 410 b can extend out from the lower end 420 b of the plate body 420 , for instance downward from the lower end 420 b along the transverse direction T. The third mounting end 410 c can extend from the tab 448 , substantially at the distal end 449 b , and can extend out from the distal end 449 b , for instance downward from the distal end 449 b along the transverse direction T.
[0117] The first, second, and third mounting ends 410 a , 410 b , and 410 c can include a first, second, and third tail 411 a , 411 b , and 411 c , respectively. The first, second, and third tail 411 a , 411 b , and 411 c extend out from the first, second, and third mounting ends 410 a , 410 b , and 410 c , respectively, for example downward along the transverse direction T. The first, and second tails 411 a and 411 b can be integral, such as monolithic, with the first and second mounting ends 410 a and 410 b , respectively, and thus monolithic with the plate body 420 . The third tail 411 c can be can be integral, such as monolithic, with the third mounting end 410 c , and thus monolithic with the tab body 349 and the plate body 420 . In this regard, it can be said that the first, second, and third tails 411 a , 411 b , and 411 c extend out from the first, second, and third mounting ends 410 a , 410 b , and 410 c , respectively. Alternatively, the first, second, and third tails 411 a , 411 b , and 411 c can be separate and can be attached to the first, second, and third mounting ends 410 a , 410 b , and 410 c , respectively. In accordance with the illustrated embodiment, the first, second, and third tails 411 a , 411 b , and 411 c can be constructed as press-fit tails, for instance eye of the needle tails configured to be inserted into corresponding electrical ground vias 210 such that press fit engagement is created between each of the first, second, and third tails 411 a , 411 b , and 411 c and respective ones of the electrical ground vias 210 upon insertion. It should be appreciated that the ground plate 406 is not limited to the illustrated tails 411 , and that the first, second, and third mounting ends 410 a , 410 b , and 410 c can be constructed with any other mounting element geometry as desired.
[0118] Further in accordance with the illustrated embodiment, when respective pluralities of the electrical signal contacts 104 and the ground plates 406 are supported by the connector housing 102 , the tails 111 that extend from the plurality of electrical signal contacts 104 can define a first plurality of press-fit tails of the electrical connector 100 . Additionally, the third tails 411 c that extend from the tab 448 of each ground plate 406 can define a second plurality of press-fit tails of the electrical connector 100 . Moreover, the first and second tails 411 a and 411 b of each ground plate 406 can define a third plurality of press-fit tails of the electrical connector 100 . It should be appreciated that the first and second pluralities of press-fit tails are configured to be inserted into complementary vias 206 of a printed circuit board 202 that are arranged in accordance with the MicroTCA®, such as the MicroTCA® specification Rev. 1.0, and are thus footprint compatible with the industry standard MicroTCA® PF footprint. It should further be appreciated that the third plurality of press-fit tails are positioned so as to not be insertable into complementary vias 206 of the printed circuit board 202 that are arranged in accordance with MicroTCA specification Rev. 1.0. Furthermore, select ones of the third plurality of press-fit tails includes first and second press-fit tails that are disposed on opposite sides of each of select ones of the first and second pluralities of press-fit tails, such that the mating ends 112 and 314 of the respective electrical signal contacts 104 and ground plates 306 that defines the select ones of the first, second, and third pluralities of the press-fit tails are aligned along the column direction C.
[0119] When a respective one of the plurality of ground plates 406 and corresponding first and second pairs 113 a and 113 b of electrical signal contacts 104 are supported by the connector housing 102 , at least a portion of the tab 448 , such as the distal end 449 b of the tab body 449 and thus the third mounting end 410 c , can be disposed between the mounting ends 108 of the first and second pairs 113 a and 113 b of electrical signal contacts 104 , respectively, such that the mounting ends 108 of the first and second pairs 113 a and 113 b of electrical signal contacts 104 and the third mounting end 410 c disposed on the tab 448 of the ground plate 406 are substantially aligned along the first direction.
[0120] Additionally, when a respective pair of successive first and second ground plates 406 a and 406 b and corresponding first and second pairs 113 a and 113 b of electrical signal contacts 104 are supported by the connector housing 102 , respective ones of the mounting ends 108 of the first and second pairs 113 a and 113 b of electrical signal contacts 104 can be disposed between respective ones of the first and second mounting ends 410 a and 410 b of the first and second ground plates 406 a and 406 b . For example, in accordance with the illustrated embodiment, the first electrical signal contact 104 a of the first pair 113 a of electrical signal contacts 104 and the first electrical signal contact 104 c of the second pair 113 b of electrical signal contacts 104 are disposed proximate to, such as between the first mounting end 410 a of the first ground plate 406 a and the first mounting end 410 a of the second ground plate 406 b , and the second electrical signal contact 104 b of the first pair 113 a of electrical signal contacts 104 and the second electrical signal contact 104 d of the second pair 113 b of electrical signal contacts 104 are disposed proximate to, such as between the second mounting end 410 b of the first ground plate 406 a and the second mounting end 410 b of the second ground plate 406 b.
[0121] The electrical connector 100 can further include third and fourth pairs 113 of electrical signal contacts 104 supported by the connector housing 102 . For example, when the third and fourth pairs 113 of electrical signal contacts are supported by the connector housing 102 adjacent to the second ground plate 406 b and on the opposite side of the second ground plate 406 b from the first and second pairs 113 a and 113 b of electrical signal contacts 104 , that the third mounting end 410 c of the second ground plate 406 b of the pair of ground plates 406 can be disposed between the respective mounting ends 108 of the third and fourth pairs 113 of electrical signal contacts, respectively.
[0122] The industry standard MicroTCA® PF footprint can be modified to operate with the illustrated configuration of electrical signal contacts 104 and ground plates 406 . For example, the plurality of vias 206 can be disposed along the printed circuit board so as to define a first alternative footprint FP 1 . In accordance with the illustrated embodiment, the first and second pairs 212 a and 212 b of electrical signal vias 208 and the central electrical ground via 210 of the industry standard MicroTCA® PF footprint are retained. In this regard, the alternative footprint FP1 is backwards compatible with existing industry standard MicroTCA® PF electrical connectors. In order to make the alternative footprint FP 1 compatible with the illustrated configuration of electrical signal contacts 104 and ground plates 406 , columns of additional electrical ground vias 210 can be disposed between each column of the industry standard MicroTCA® PF footprint. For example, in accordance with the illustrated embodiment, each column of additional electrical ground vias 210 comprises a pair of electrical ground vias 210 disposed along a centerline CR 4 that is spaced substantially equidistantly along the longitudinal direction L between respective adjacent centerlines CR 1 of the industry standard MicroTCA® PF footprint. A first electrical ground via 210 a of each column is disposed proximate the first and second electrical signal vias 208 a and 208 b of the first pair 212 a , and a second electrical ground via 210 b can be spaced from the first electrical ground via 210 a along the lateral direction A and disposed proximate the second electrical signal vias 208 c and 208 d of the second pair 212 b.
[0123] Referring now to FIGS. 8A-8D , a ground plate 506 constructed in accordance with another alternative embodiment is illustrated. In the interest of succinctness, elements of the ground plate 506 that are constructed substantially identically to corresponding elements of the ground plate 306 are labeled with reference numbers that are incremented by 200. The illustrated electrical signal contacts 104 can be constructed substantially identically to the electrical signal contacts 104 described above and illustrated in FIGS. 3A-3E , and thus the reference numerals associated therewith are repeated in FIGS. 8A-8D . The electrical connector 100 can be constructed utilizing at least one such as a plurality of the ground plates 506 . In this regard, a plurality of ground plates 506 can be substituted for the plurality of ground plates 106 , and the plurality of ground plates 506 can be supported by the connector housing 102 adjacent to corresponding pairs 113 of electrical signal contacts 104 .
[0124] In accordance with the illustrated embodiment, the ground plate 506 is constructed without a tab, such that the lower end is substantially straight along the lateral direction A. The ground plate 506 can include a first mounting ends 510 a . The first mounting end 510 a can be disposed substantially at the lower end 520 b of the plate body 520 , and can be located substantially equidistantly between the first and second sides 520 c and 520 d , respectively. The first mounting ends 510 a can extend out from the lower end 520 b of the plate body 520 , for instance downward from the lower end 520 b along the transverse direction T. The first mounting end 510 a can extend from the plate body 520 so as to be substantially inline with the plate body 520 , such that the at least one mounting end 510 a is spaced from the first outer plate body surface 520 e of the plate body 520 a distance that is shorter than the distance D along the longitudinal direction L, and thus is positioned so as to not be insertable into any of the complementary vias of a printed circuit board that are arranged in accordance with MicroTCA specification Rev. 1.0. For example, in accordance with the illustrated embodiment, the distance D that the first mounting end 510 a is spaced from the first outer plate body surface 520 e of the plate body 520 can be zero, such that the first mounting end 510 a is substantially coplanar with the plate body 520 . Further in accordance with the illustrated embodiment, the first mounting end 510 a extends downwardly from the lower end 520 b of the plate body 520 substantially along the transverse direction T.
[0125] The first mounting end 510 a can include a mounting element that can be configured as a press-fit mounting element such as a press-fit tail 511 that is downwardly elongate along the transverse direction T. The tail 511 can be integral, such as monolithic, with the first mounting end 510 a , and thus monolithic with the plate body 520 . In this regard, it can be said that the tail 511 extends out from the first mounting end 510 a . Alternatively, the tail 511 can be separate and can be attached to the first mounting end 510 a . In accordance with the illustrated embodiment the tail 511 can be constructed as a press-fit tail, for instance an eye of the needle tail configured to be inserted into a corresponding ground via 210 such that a press fit engagement is created between the tail 511 and a respective one of the electrical ground vias 210 upon insertion. It should be appreciated that the ground plate 506 is not limited to the illustrated tail 511 , and that the first mounting end 510 a can be constructed with any other mounting element geometry as desired.
[0126] Further in accordance with the illustrated embodiment, when respective pluralities of the electrical signal contacts 104 and the ground plates 506 are supported by the connector housing 102 , the tails 111 that extend from the plurality of electrical signal contacts 104 can define a first plurality of press-fit tails of the electrical connector 100 . Additionally, the tails 511 that extend from the ground plates 506 can define a second plurality of press-fit tails of the electrical connector 100 . It should be appreciated that the first plurality of press-fit tails is configured to be inserted into complementary vias 206 of a printed circuit board 202 that are arranged in accordance with the MicroTCA®, such as the MicroTCA® specification Rev. 1.0, and are thus footprint compatible with the industry standard MicroTCA® PF footprint. It should further be appreciated that the second plurality of press-fit tails are positioned so as to not be insertable into complementary vias 206 of the printed circuit board 202 that are arranged in accordance with MicroTCA specification Rev. 1.0. Furthermore, select ones of the second plurality of press-fit tails includes first and second press-fit tails that are disposed on opposite sides of each of select ones of the first and second pluralities of press-fit tails, such that the mating ends 112 and 514 of the respective electrical signal contacts 104 and ground plates 506 that defines the select ones of the first and second pluralities of the press-fit tails are aligned along the column direction C.
[0127] When a respective pair of successive first and second ground plates 506 a and 506 b and corresponding first and second pairs 113 a and 113 b of electrical signal contacts 104 are supported by the connector housing 102 , the respective first mounting ends 510 a of the first and second ground plates 506 a and 506 b are disposed between the respective mounting ends 108 of the first and second pairs 113 a and 113 b of electrical signal contacts 104 , respectively. For example, in accordance with the illustrated embodiment, the first electrical signal contact 104 a of the first pair 113 a of electrical signal contacts 104 and the first electrical signal contact 104 c of the second pair 113 b of electrical signal contacts 104 are disposed on a first side of the centerline CR 3 and the second electrical signal contact 104 b of the first pair 113 a of electrical signal contacts 104 and the second electrical signal contact 104 d of the second pair 113 b of electrical signal contacts 104 are disposed on a second side of the centerline CR 3 that is opposite and spaced along the lateral direction A from the first side of the centerline CR3.
[0128] The industry standard MicroTCA® PF footprint can be modified to operate with the illustrated configuration of electrical signal contacts 104 and ground plates 506 . For example, the plurality of vias 206 can be disposed along the printed circuit board 202 so as to define a second alternative footprint FP2. In accordance with the illustrated embodiment, the first and second pairs 212 a and 212 b of electrical signal vias 208 of the industry standard MicroTCA® PF footprint are retained. In order to make the alternative footprint FP2 compatible with the illustrated configuration of electrical signal contacts 104 and ground plates 506 , additional electrical ground vias 210 can be disposed between the columns of electrical signal vias 208 of the industry standard MicroTCA® PF footprint. For example, in accordance with the illustrated embodiment, the alternative footprint FP2 defines a plurality of centerlines CR 4 , each centerline CR 4 spaced substantially equidistantly along the row direction R between successive centerlines CR 1 of the industry standard MicroTCA® PF footprint. At least one electrical ground via 210 is disposed along each of the plurality of centerlines CR 4 , such that each of the at least one electrical ground vias 210 is disposed between successive columns of electrical signal vias 208 . Additionally, the central electrical ground via 210 of the industry standard MicroTCA® PF footprint can be omitted if backwards compatibility is not desired.
[0129] It should be appreciated that the printed circuit board 202 can alternatively be constructed in accordance with the alternative footprint FP2. For example, the printed circuit 202 constructed in accordance with the alternative footprint FP2 and configured to receive mounting tails of only a single connector can include a first pair of electrical signal vias 208 , such as electrical signal vias 208 a and 208 c , respectively, that are arranged inline with respect to each other along a first column that extends along the column direction C and can be coincident with the centerline CR 1 . The printed circuit 202 constructed in accordance with the alternative footprint FP2 can further include a second pair of electrical signal vias 208 , such as electrical signal vias 208 b and 208 d that are arranged inline with respect to each other along a second column that extends along the column direction C and can be coincident with the centerline CR 2 . The first and second columns are spaced apart from each other along the row direction. The printed circuit 202 constructed in accordance with the alternative footprint FP2 can further include at least a first electrical ground via 210 a , such as no more than a pair of first electrical ground vias 210 , disposed in a third column that extends substantially along the column direction C and can be coincident with a first one of the centerlines CR 4 . The printed circuit 202 constructed in accordance with the alternative footprint FP2 can further include at least a second electrical ground via 210 b , such as no more than a pair of second electrical ground vias 210 , disposed in a fourth column that extends substantially along the column direction C and can be coincident with a second one of the centerlines CR 4 . Further in accordance with the illustrated embodiment, the first and second ground vias 210 a and 210 b are each disposed between each of the first pair of signal vias along the column direction C, and are further disposed between each of the second pair of signal vias along the column direction C, and the first and second columns are disposed between the third and fourth columns.
[0130] Referring now to FIGS. 9A-9D , a ground plate 606 constructed in accordance with still another alternative embodiment is illustrated. In the interest of succinctness, elements of the ground plate 606 that are constructed substantially identically to corresponding elements of the ground plate 506 are labeled with reference numbers that are incremented by 100. The illustrated electrical signal contacts 104 can be constructed substantially identically to the electrical signal contacts 104 described above and illustrated in FIGS. 3A-3E , and thus the reference numerals associated therewith are repeated in FIGS. 8A-8D . The electrical connector 100 can be constructed utilizing at least one such as a plurality of the ground plates 606 . In this regard, a plurality of ground plates 606 can be substituted for the plurality of ground plates 106 , and the plurality of ground plates 606 can be supported by the connector housing 102 adjacent to corresponding pairs 113 of electrical signal contacts 104 .
[0131] In accordance with the illustrated embodiment, the ground plate 606 can include a plurality of mounting ends 610 , for instance first and second mounting ends 610 a and 610 b . The first and second mounting ends 610 a and 610 b can be disposed substantially at the lower end 620 b of the plate body 620 , proximate the first and second sides 620 c and 620 d , respectively, such that the first mounting end 610 a extends from the plate body 620 at a location closer to the first side 620 c than the second side 620 d , and the second mounting end 610 b extends from the plate body 620 at a location closer to the second side 620 d than the first side 620 c . The first and second mounting ends 610 a and 610 b can extend out from the lower end 620 b of the plate body 620 , for instance downward from the lower end 620 b along the transverse direction T. The first and second mounting ends 610 a and 610 b can extend from the plate body 620 so as to be substantially inline with the plate body 620 , as described above with respect to the first mounting end 510 a of the ground plate 506 . For example, in accordance with the illustrated embodiment, the distance D that the first and second mounting ends 610 a and 610 b are spaced from the first outer plate body surface 620 e of the plate body 620 can be zero, such that the first and second mounting ends 610 a and 610 b are substantially coplanar with the plate body 620 . Further in accordance with the illustrated embodiment, the first and second mounting ends 610 a and 610 b extend downwardly from the lower end 620 b of the plate body 620 substantially along the transverse direction T.
[0132] The first and second mounting ends 610 a and 610 b can include first and second tails 611 a and 611 b , respectively. The first and second tails 611 a and 611 b can extend out from the first and second mounting ends 610 a and 610 b , respectively, for example downward along the transverse direction T. The first and second tails 611 a and 611 b can be integral, such as monolithic, with the first and second mounting ends 610 a and 610 b , respectively, and thus monolithic with the plate body 620 . In this regard, it can be said that the first and second tails 611 a and 611 b extend out from the first and second mounting ends 610 a and 610 b , respectively. Alternatively, the first and second tails 611 a and 611 b can be separate and can be attached to the first and second mounting ends 610 a and 610 b , respectively. In accordance with the illustrated embodiment, the first and second tails 611 a and 611 b can be constructed as press-fit tails, for instance eye of the needle tails configured to be inserted into corresponding electrical ground vias 210 such that press fit engagement is created between each of the first and second tails 611 a and 611 b and respective ones of the electrical ground vias 210 upon insertion. It should be appreciated that the ground plate 606 is not limited to the illustrated tails 611 , and that the first and second mounting ends 610 a and 610 b can be constructed with any other mounting element geometry as desired.
[0133] Further in accordance with the illustrated embodiment, when respective pluralities of the electrical signal contacts 104 and the ground plates 606 are supported by the connector housing 102 , the tails 111 that extend from the plurality of electrical signal contacts 104 can define a first plurality of press-fit tails of the electrical connector 100 . Additionally, the first and second tails 611 a and 611 b that extend from the ground plates 606 can define a second plurality of press-fit tails of the electrical connector 100 . It should be appreciated that the first plurality of press-fit tails is configured to be inserted into complementary vias 206 of a printed circuit board 202 that are arranged in accordance with the MicroTCA®, such as the MicroTCA® specification Rev. 1.0, and are thus footprint compatible with the industry standard MicroTCA® PF footprint. It should further be appreciated that the second plurality of press-fit tails are positioned so as to not be insertable into complementary vias 206 of the printed circuit board 202 that are arranged in accordance with MicroTCA specification Rev. 1.0. Furthermore, select ones of the second plurality of press-fit tails includes first and second pairs of press-fit tails that are disposed on opposite sides of each of select ones of the first plurality of press-fit tails, such that the mating ends of the respective electrical signal contacts and ground plates that defines the select ones of the first and second pluralities of the press-fit tails are aligned along the column direction C.
[0134] When a respective pair of successive first and second ground plates 606 a and 606 b and corresponding first and second pairs 113 a and 113 b of electrical signal contacts 104 are supported by the connector housing 102 , respective ones of the mounting ends 108 of the first and second pairs 113 a and 113 b of electrical signal contacts 104 can be disposed between respective ones of the first and second mounting ends 610 a and 610 b of the first and second ground plates 606 a and 606 b . For example, in accordance with the illustrated embodiment, the first electrical signal contact 104 a of the first pair 113 a of electrical signal contacts 104 and the first electrical signal contact 104 c of the second pair 113 b of electrical signal contacts 104 are disposed proximate to, such as between the first mounting end 610 a of the first ground plate 606 a and the first mounting end 610 a of the second ground plate 606 b , and the second electrical signal contact 104 b of the first pair 113 a of electrical signal contacts 104 and the second electrical signal contact 104 d of the second pair 113 b of electrical signal contacts 104 are disposed proximate to, such as between the second mounting end 610 b of the first ground plate 606 a and the second mounting end 610 b of the second ground plate 606 b.
[0135] The industry standard MicroTCA® PF footprint can be modified to operate with the illustrated configuration of electrical signal contacts 104 and ground plates 606 . For example, the plurality of vias 206 can be disposed along the printed circuit board so as to define a third alternative footprint FP3. In accordance with the illustrated embodiment, the first and second pairs 212 a and 212 b of electrical signal vias 208 of the industry standard MicroTCA® PF footprint are retained.
[0136] In order to make the alternative footprint FP3 compatible with the illustrated configuration of electrical signal contacts 104 and ground plates 606 , additional electrical ground vias 210 can be disposed between the columns of electrical signal vias 208 of the industry standard MicroTCA® PF footprint. For example, in accordance with the illustrated embodiment, the alternative footprint FP3 defines a plurality of centerlines CR 4 , each centerline CR 4 spaced substantially equidistantly along the row direction R between successive centerlines CR 1 of the industry standard MicroTCA® PF footprint. At least one electrical ground via 210 such as a pair of electrical ground vias 210 is disposed along each of the plurality of centerlines CR 4 , such that each of the at least one electrical ground vias 210 is disposed between successive columns of electrical signal vias 208 . Additionally, the central electrical ground via 210 of the industry standard MicroTCA® PF footprint can be omitted if backwards compatibility is not desired.
[0137] It should be appreciated that the printed circuit board 202 can alternatively be constructed in accordance with the alternative footprint FP3. For example, the printed circuit 202 constructed in accordance with the alternative footprint FP3 and configured to receive mounting tails of only a single connector can include a first pair of electrical signal vias 208 , such as electrical signal vias 208 a and 208 c , respectively, that are arranged inline with respect to each other along a first column that extends along the column direction C and can be coincident with the centerline CR 1 . The printed circuit 202 constructed in accordance with the alternative footprint FP3 can further include a second pair of electrical signal vias 208 , such as electrical signal vias 208 b and 208 d that are arranged inline with respect to each other along a second column that extends along the column direction C and can be coincident with the centerline CR 2 . The first and second columns are spaced apart from each other along the row direction. The printed circuit 202 constructed in accordance with the alternative footprint FP3 can further include a first pair of electrical ground vias 210 a and 210 b , that are each inline with each other along a third column that extends substantially along the column direction C and can be coincident with the a first one of the centerlines CR 4 . The printed circuit 202 constructed in accordance with the alternative footprint FP3 can further include a second pair of electrical ground vias 210 c and 210 d , that are each inline with each other along a fourth column that extends substantially along the column direction C and can be coincident with the a second one of the centerlines CR 4 . Further in accordance with the illustrated embodiment, the first pair of electrical ground vias is disposed between each of the first pair of electrical signal vias 208 along the column direction C, and the second pair of ground vias are further disposed between the second pair of electrical signal vias 208 along the column direction C, and the first and second columns are disposed between the third and fourth columns.
[0138] Further in accordance with the illustrated embodiment, each electrical ground via 210 of the first and second pairs of electrical ground vias 210 is disposed substantially equidistantly between one of the first pair of electrical signal vias 208 and one of the second pair of electrical signal vias 208 along the column direction C. For instance, a first electrical ground via 210 a of the first pair of electrical ground vias 210 is disposed substantially equidistantly between a first electrical signal via 208 a of the first pair of electrical signal vias 208 and a first electrical signal via 208 b of the second pair of electrical signal vias 208 . Similarly, a first electrical ground via 210 c of the second pair of electrical ground vias 210 is disposed substantially equidistantly between the first electrical signal via 208 a of the first pair of electrical signal vias 208 and the first electrical signal via 208 b of the second pair of electrical signal vias 208 . Additionally, a second electrical ground via 210 b of the first pair of electrical ground vias 210 is disposed substantially equidistantly between a second electrical signal via 208 c of the first pair of electrical signal vias 208 and a second electrical signal via 208 d of the second pair of electrical signal vias 208 . Similarly, a second electrical ground via 210 d of the second pair of electrical ground vias 210 is disposed substantially equidistantly between the second electrical signal via 208 c of the first pair of electrical signal vias 208 and the second electrical signal via 208 d of the second pair of electrical signal vias 208 .
[0139] Referring now to FIGS. 10A-10G , a plurality of electrical signal contacts 704 constructed in accordance with an alternative embodiment is illustrated. In the interest of succinctness, elements of the electrical signal contacts 704 that are constructed substantially identically to corresponding elements of the electrical signal contacts 104 are labeled with reference numbers that are incremented by 600. It should be appreciated that at least one such as a plurality of the electrical signal contacts 704 can be supported by the connector housing 102 of the electrical connector 100 along with at least one such as a plurality of any of the ground plates described herein, for instance any of the ground plates 106 , 306 , 406 , 506 , or 606 , as desired. In accordance with the illustrated embodiment, the electrical signal contacts 704 are depicted in a configuration of electrical contacts 105 utilizing a pair of the ground plates 606 , including a first ground plate 606 a and a second ground plate 606 b.
[0140] In accordance with the illustrated embodiment, at least one such as each electrical signal contact 704 of the plurality can be twisted about a respective twist axis that extends through at least a portion of the contact body 707 . For example, the twist axis can extend substantially along the third direction, and can extend through at least a portion of the intermediate region 709 of the contact body 707 . Accordingly, the contact body 707 of each of the plurality of electrical signal contacts 704 can define at least one twisted region 754 that is twisted about the respective twist axis. The twisted region 754 can be located along the contact body 707 . For example, the twisted region 754 can be located between the mating end 712 and the mounting end 708 . In accordance with one embodiment, the twisted region 754 can be located closer to the mounting end 708 than the mating end 712 , such as closer to the mounting end 708 than to a midpoint of the contact body 707 that is disposed equidistantly between the mating end 712 and the mounting end 708 along the transverse direction T. In this regard, it can be said that the twisted region 754 of each contact body 707 is located nearer the respective mounting end 708 than the respective mating end 712 . It should be appreciated that the electrical signal contacts 704 are not limited to the illustrated twisted region 754 , and that the electrical signal contacts 704 can be alternatively constructed with any other twist geometry as desired.
[0141] The contact body 707 of each of the electrical signal contacts 704 can be twisted about a respective twist axis such that the first and second ones of the broadsides 726 at the mating end 712 of each of the electrical signal contacts 704 are angularly offset with respect to the first and second ones of the broadsides 726 at the mounting end 708 of the electrical signal contact 704 . For example, in accordance with the illustrated embodiment, the first and second ones of the broadsides 726 are oriented along the first direction at the mating end 712 , and the first and second ones of the broadsides 726 at the mounting end 708 can define a portion of the mounting end 708 , such as a first portion 708 a that is offset from the first and second ones of the broadsides 726 at the mating end 712 along the second direction. Furthermore, the first and second ones of the broadsides 726 at the mounting end 708 can define a second portion 708 b of the mounting end 708 that is substantially aligned with the first and second ones of the broadsides 726 at the mating end 712 along the third direction.
[0142] Additionally, the first and second broadsides 726 of each electrical signal contact 704 can define a first region at the respective mounting end 708 and a second region at the respective mating end 712 , such that the first region is angularly offset with respect to the second region. Furthermore, the first and second edges 728 of the each electrical signal contact 704 can define a first region at the respective mounting end 708 and a second region at the respective mating end 712 , such that the first region is angularly offset with respect to the second region. In this regard, it can thus be said that the mounting end 708 of each electrical signal contact 704 is out of plane with respect the corresponding mating end 712 . It can further be said that the mating end 712 of each electrical signal contact 704 is oriented along the first direction, and that the mounting end 708 of each electrical signal contact 704 can be oriented along a second direction that is angularly offset relative to the first direction.
[0143] Furthermore, the first region of the broadside 726 of at least one or more, up to all, of the electrical signal contacts 704 can extend substantially parallel with the first region of the broadsides 726 of at least one or more, up to all, of the others of the electrical signal contacts 704 . Similarly, the first region of the edges 728 of at least one or more, up to all, of the electrical signal contacts 704 can extend substantially parallel with the first region of the edges 728 of at least one or more, up to all, of the others of the electrical signal contacts 704 .
[0144] With continuing reference to FIGS. 10A-10G , a plurality of leadframe assemblies 756 constructed in accordance with an alternative embodiment are illustrated. The leadframe assemblies 756 can be supported by the connector housing 102 , as described above with reference to the leadframe assemblies 130 . Each leadframe assembly 756 can include a dielectric or electrically insulative leadframe housing 758 and at least one such as a plurality of electrical contacts 105 that can be configured as electrical signal contacts 704 that are supported by the leadframe housing 758 . In accordance with the illustrated embodiment, each leadframe assembly 756 includes a pair of electrical signal contacts 704 that are spaced apart from one another along the column direction C. The leadframe assemblies 756 can be configured as insert molded leadframe assemblies (IMLAs) whereby the respective leadframe housings 758 are overmolded onto respective ones of the plurality of electrical signal contacts 704 . For instance, the leadframe housing 758 of each leadframe assembly 756 can be overmolded onto the corresponding electrical signal contacts 704 such that the leadframe housing 758 is overmolded onto, and thus encloses, at least a portion of the contact body 707 , for instance the twisted regions 754 , of each of the respective electrical signal contacts 704 supported by the leadframe housing 758 . Alternatively, the respective ones of the electrical signal contacts 704 can be stitched into the leadframe housings 758 or otherwise supported by the respective leadframe housings 758 .
[0145] A plurality up to all of the leadframe assemblies 756 can include at least one pair 757 such as a plurality of pairs 757 of first and second leadframe assemblies 756 a and 756 b , respectively. The first and second leadframe assemblies 756 a and 756 b of each pair 757 can be constructed substantially identically. The first leadframe assembly 756 a and the second leadframe assembly 756 b of each pair 757 can be disposed adjacent each other, for instance along the row direction R, when supported by the connector housing 102 , so as to define the first and second differential signal pairs 717 a and 717 b . For example, in accordance with the illustrated embodiment, the first leadframe assembly 756 a can have a first leadframe housing 758 a that is overmolded onto the first pair 713 a of electrical signal contacts 704 and the second leadframe assembly 756 b can have a second leadframe housing 758 b that is overmolded onto the second pair 713 b of electrical signal contacts 704 . Accordingly, the first electrical signal contact 704 a of the first leadframe assembly 756 a and the first signal electrical contact 704 c of the second leadframe assembly 756 b can define the first differential signal pair 717 a , and the second electrical signal contact 704 b of the first leadframe assembly 756 a and the second electrical signal contact 704 d of the second leadframe assembly 756 b can define the second differential signal pair 717 b.
[0146] The first and second leadframe assemblies 756 a and 756 b of each pair 757 can be configured to interface with one another when disposed adjacent to one another in the connector housing 102 . For example, the leadframe housing 758 of each of the first and second leadframe assemblies 756 a and 756 b , respectively, of each pair 757 can include at least one interface member 735 that is configured to receive a complementary at least one interface member 735 supported by the leadframe housing 758 of the other of the first and second leadframe assemblies 756 a and 756 b , respectively, of the pair 757 . Thus, the first leadframe housing 758 a of the first leadframe assembly 756 a can be at least partially received by the second leadframe housing 758 b of the second leadframe assembly 756 b , and the second leadframe housing 758 b of the second leadframe assembly 756 b can be at least partially received by the first leadframe housing 758 a of the first leadframe assembly 756 a . In accordance with the illustrated embodiment, the leadframe housing 758 of each leadframe assembly 756 includes respective pairs of interface members 735 configured as a pair of projecting portions 760 and a pair of pocket portions 762 , respectively. The projecting portions 760 of each pair can be constructed the same or differently, and the pocket portions 762 of each pair can be constructed the same or differently. In accordance with the illustrated embodiment, the first leadframe housing 758 a of the first leadframe assembly 756 a can include a pair of first projection portions 760 a and a pair of first pocket portions 762 a , and the second leadframe housing 758 b of the second leadframe assembly 756 b can include a pair of second projection portions 760 b and a pair of second pocket portions 762 b . The pair of first projection portions 760 a of the first leadframe housing 758 a can be configured to be received in respective ones of the pair of second pocket portions 762 b of the second leadframe housing 758 b and the pair of second projection portions 760 b of the second leadframe housing 758 b can be configured to be received in the pair of first pocket portions 762 a of the first leadframe housing 758 a.
[0147] In accordance with the illustrated embodiment, when the first and second leadframe assemblies 756 a and 756 b of each pair 757 are supported by the connector housing 102 , the first leadframe assembly 756 a of each respective pair 757 can be oriented in a first orientation and the second leadframe assembly 756 b of the corresponding pair 757 can be oriented in a second orientation relative to the first leadframe assembly 756 a that is rotated 180 degrees about an axis that extends substantially perpendicular to the first direction and substantially parallel to the transverse direction T. When the first and second leadframe assemblies 756 a and 756 b are oriented in the first and second orientations, respectively, and supported by the connector housing 102 , the pair of first projection portions 760 a of the first leadframe housing 758 a can be at least partially received in respective ones of the pair of second pocket portions 762 b of the second leadframe housing 758 b and the pair of second projection portions 760 b of the second leadframe housing 758 b can be at least partially received in the pair of first pocket portions 762 a of the first leadframe housing 758 a.
[0148] The projecting portions 760 of the illustrated leadframe housings 758 can at least partially enclose the mounting ends 708 of the respective electrical signal contacts 704 of the leadframe assemblies 756 . Any suitable dielectric material, such as air or plastic, may be used to isolate the respective electrical signal contacts 704 of the first leadframe assembly 756 a of a pair 757 from the respective electrical signal contacts 704 of the second leadframe assembly 756 b of the pair 757 . In accordance with the illustrated embodiment, the first and second leadframe assemblies 756 a and 756 b of each pair 757 are spaced from each other when supported by the connector housing 102 . However it should be appreciated that at least one or both of the first and second leadframe assemblies 756 a and 756 b or the connector housing 102 can be alternatively constructed such that the first and second leadframe assemblies 756 a and 756 b abut one another when supported by the connector housing 102 .
[0149] In accordance with the illustrated embodiment, each pair 757 of leadframe assemblies 756 of the plurality of leadframe assemblies 756 can be supported by the connector housing 102 between respective ground plates, for instance ground plates 606 . In this regard, the connector housing 102 supports successive first and second pairs 713 a and 713 b of electrical signal contacts 704 and ground plates 606 when the first and second pairs 713 a and 713 b of electrical signal contacts 704 and ground plates 606 are supported by the connector housing 102 . The respective pluralities of leadframe assemblies 756 and ground plates 606 can be arranged such that a ground plate 606 is disposed between successive adjacent pairs 757 of first and second leadframe assemblies 756 a and 756 b , such that the plurality of electrical contacts 105 of the electrical connector 100 define a repeating ground-signal-signal (G-S-S) arrangement of ground plates 606 and electrical signal contacts 704 along the row direction R. The ground plates 606 can be disposed between adjacent pairs 757 of leadframe assemblies 756 along the row direction R such that the ground plates 606 can reduce crosstalk between adjacent differential signal pairs 717 of the adjacent pairs 757 of leadframe assemblies 756 that are aligned along the row direction R.
[0150] Furthermore, when respective pairs of leadframe assemblies 756 , for instance first and second leadframe assemblies 756 a and 756 b , respectively, are supported by the connector housing 102 in accordance with the illustrated embodiment, the mounting ends 708 of each electrical signal contacts 704 of the respective first and second leadframe assemblies 756 a and 756 b are aligned along a column that extends along the column direction C, which can be substantially parallel to the lateral direction A. Accordingly, a plane defined by the lateral direction A and the transverse direction T can extend through the mounting end 708 of each electrical signal contact 704 of each of the first and second leadframe assemblies 756 a and 756 b of a given pair 757 . Thus also, a straight line that extends along the lateral direction A extends through the mounting end 708 of each electrical signal contact 704 of each of the first and second leadframe assemblies 756 a and 756 b of a given pair 757 . The plane and the straight line can extend substantially parallel to one or both of the first and second ground plates 606 a and 606 b.
[0151] Additionally, the mounting ends 708 of each electrical signal contact 704 of each of the first and second leadframe assemblies 756 a and 756 b of a given pair 757 can be evenly spaced from one or both of the adjacent first and second ground plates 606 a and 606 b . For instance, the mounting ends 708 of each electrical signal contact 704 of each of the first and second leadframe assemblies 756 a and 756 b of a given pair 757 can support a tail 711 , and the tails 711 can be evenly spaced from one or both of the adjacent first and second ground plates 606 . The straight line and the plane can extend through the tail 711 of each electrical signal contact 704 of each of the first and second leadframe assemblies 756 a and 756 b of a given pair 757 . The plane and the straight line can extend through the same respective portion of the tail 711 of each of the electrical signal contacts 704 , such that the tails 711 of the electrical signal contacts 704 are substantially inline along the lateral direction A, for example along centerline CR 1 (see FIG. 10G ). For instance, the straight line and the plane can extend through the eye of the needle opening of the tail 711 of each of the electrical signal contacts 704 .
[0152] Accordingly, the tails 711 of each electrical signal contact 704 of each of the first and second leadframe assemblies 756 a and 756 b of a given pair 757 can be said to be inline relative to each other along the column direction C, for example along a column. In this regard, it can be said that the respective tails 711 of the first and second pairs 713 a and 713 b of electrical signal contacts 704 are aligned with respect to each other along the first direction. Moreover, it should be appreciated that the first and second mounting ends 610 a and 610 b of each of the ground plates 606 are aligned along respective columns that extend along the column direction C. For example, in accordance with the illustrated embodiment, the mounting ends 708 of the electrical signal contacts 704 of the first and second leadframe assemblies 756 a and 756 b are aligned along a first column C 1 , the first and second mounting ends 610 a and 610 b of the first ground plate 606 a that is disposed adjacent the first leadframe assembly 756 a are aligned along a second column C 2 that is disposed adjacent to the first column C 1 and substantially parallel to the first column C 1 , and the first and second mounting ends 610 a and 610 b of the second ground plate 606 b that is disposed adjacent the second leadframe assembly 756 b are aligned along a third column C 3 that is disposed adjacent and substantially parallel to the first column C 1 . Thus, the first column C 1 is disposed between the second and third columns C 2 and C 3 . It should be appreciated that the electrical connector 100 is not limited to the illustrated columns C 1 , C 2 , C 3 , and that the electrical connector 100 can define more or fewer columns of electrical contacts 105 , for instance in accordance with the number of ground plates 606 and the number of pairs of leadframe assemblies 756 supported by the connector housing 102 .
[0153] The ground plates 606 and the pairs 757 of leadframe assemblies 756 can be spaced apart from one another in the connector housing 102 along the longitudinal direction L in accordance with a pre-determined column pitch. For instance, in accordance with the illustrated embodiment, the electrical connector 100 is constructed with a column pitch of between approximately 0.6 mm to approximately 1.4 mm, including approximately 0.75 mm, such that the mounting ends 708 of the electrical signal contacts 704 of a first one of the pairs 757 of leadframe assemblies 756 are spaced from the mounting ends 610 of a first ground plate 606 a approximately 0.75 mm along the row direction R, and spaced from the mounting ends 610 of a second ground plate 606 b approximately 0.75 mm along the row direction R, such that the first column C 1 is spaced from each of the second and third columns C 2 and C 3 approximately 0.75 mm along the row direction R. In accordance with an alternative embodiment, the electrical connector 100 can be alternatively constructed with a column pitch of approximately 1 mm.
[0154] The industry standard MicroTCA® PF footprint can be modified to operate with the illustrated configuration of electrical signal contacts 704 and ground plates 606 . For example, the plurality of vias 206 can be disposed along the printed circuit board so as to define a fourth alternative footprint FP4. It should be appreciated that in accordance with the illustrated embodiment, the contact bodies 707 of the electrical signal contacts 704 are twisted such that the mounting ends 708 of the respective electrical signal contacts 704 of the first and second leadframe assemblies 756 a and 756 b of each pair 757 are substantially aligned with respect to each other along the lateral direction A, and thus can be said to be inline with respect to each other along the first direction.
[0155] In order to make the alternative footprint FP4 compatible with the illustrated configuration of electrical signal contacts 704 and ground plates 606 , the respective electrical signal vias 208 of the first and second pairs 212 a and 212 b of the industry standard MicroTCA® PF footprint can be repositioned and aligned with respect to each other along the centerline CR 1 . For example, in accordance with the industry standard MicroTCA® PF footprint, the electrical signal vias 208 a and 208 c can be said to be inline with each other in a first column that is coincident with the centerline CR 1 and the electrical signal vias 208 b and 208 d can be said to be inline with each other in a second column that is coincident with the centerline CR 2 . In accordance with the alternative footprint FP4, the electrical signal vias 208 b and 208 d can be repositioned such that the first and second columns are coincident with each other; so that the electrical signal vias 208 a - 208 d of each column are inline with each other in the column direction C along respective centerlines CR 1 . In this regard, it can be said that each centerline CR 1 passes through the geometric center of each of the respective electrical signal vias 208 of the first and second pairs 212 a and 212 b of electrical signal vias 208 of each column, and thus that the first and second pairs 212 a and 212 b or electrical signal vias 208 are centrally disposed along respective centerlines CR 1 . This arrangement increases available routing channel width, for instance the channel width available for routing electrical traces, within a printed circuit board 202 constructed in accordance with the alternative footprint FP4, as compared to a printed circuit board 202 constructed in accordance with the industry standard MicroTCA® PF footprint, wherein the vias 206 are not inline with respect to one another along the column direction C.
[0156] In order to further make the alternative footprint FP4 compatible with the illustrated configuration of electrical signal contacts 704 and ground plates 606 , additional electrical ground vias 210 can be disposed between the columns of electrical signal vias 208 of the industry standard MicroTCA® PF footprint. For example, in accordance with the illustrated embodiment, the alternative footprint FP4 defines a plurality of centerlines CR 4 , each centerline CR 4 spaced substantially equidistantly along the row direction R between successive centerlines CR 1 of the industry standard MicroTCA® PF footprint. At least one electrical ground via 210 such as a pair of electrical ground vias 210 is disposed along each of the plurality of centerlines CR 4 , such that each of the at least one electrical ground vias 210 is disposed between successive columns of electrical signal vias 208 .
[0157] It should be appreciated that the printed circuit board 202 can alternatively be constructed in accordance with the alternative footprint FP4. For example, the printed circuit 202 constructed in accordance with the alternative footprint FP4 and configured to receive mounting tails of only a single connector can include a first pair of electrical signal vias 208 , such as electrical signal vias 208 a and 208 c , and a second pair of electrical signal vias 208 , such as electrical signal vias 208 b and 208 d , wherein the electrical signal vias 208 of the first and second pairs are arranged inline with respect to each other along respective first and second columns that extend along the column direction C and can be coincident with each and coincident with the centerline CR 1 . The printed circuit 202 constructed in accordance with the alternative footprint FP4 can further include a first pair of electrical ground vias 210 a and 210 b , that are each inline with each other along a third column that extends substantially along the column direction C and can be coincident with the a first one of the centerlines CR 4 . The printed circuit 202 constructed in accordance with the alternative footprint FP3 can further include a second pair of electrical ground vias 210 c and 210 d , that are each inline with each other along a fourth column that extends substantially along the column direction C and can be coincident with the a second one of the centerlines CR 4 . It should be appreciated that the first and second columns are disposed substantially equidistantly between the third and fourth columns.
[0158] Further in accordance with the illustrated embodiment, each electrical ground via 210 of the first and second pairs of electrical ground vias 210 is disposed substantially equidistantly between one of the first pair of electrical signal vias 208 and one of the second pair of electrical signal vias 208 along the column direction C. For instance, a first electrical ground via 210 a of the first pair of electrical ground vias 210 is disposed substantially equidistantly between a first electrical signal via 208 a of the first pair of electrical signal vias 208 and a first electrical signal via 208 b of the second pair of electrical signal vias 208 . Similarly, a first electrical ground via 210 c of the second pair of electrical ground vias 210 is disposed substantially equidistantly between the first electrical signal via 208 a of the first pair of electrical signal vias 208 and the first electrical signal via 208 b of the second pair of electrical signal vias 208 . Additionally, a second electrical ground via 210 b of the first pair of electrical ground vias 210 is disposed substantially equidistantly between a second electrical signal via 208 c of the first pair of electrical signal vias 208 and a second electrical signal via 208 d of the second pair of electrical signal vias 208 . Similarly, a second electrical ground via 210 d of the second pair of electrical ground vias 210 is disposed substantially equidistantly between the second electrical signal via 208 c of the first pair of electrical signal vias 208 and the second electrical signal via 208 d of the second pair of electrical signal vias 208 .
[0159] The embodiments illustrated and described herein, for example the embodiments of the electrical connector 100 , when utilized with the corresponding printed circuit board 202 footprints, for instance the industry standard MicroTCA® PF footprint or the alternative footprints FP1, FP2, FP3, or FP4, can exhibit enhanced electrical performance with respect to the industry standard MicroTCA® PF footprint and the existing industry standard MicroTCA® PF electrical connectors utilized therewith. For instance, electrical simulation has demonstrated that the herein described embodiments of electrical connectors 100 and printed circuit board 202 footprints, for instance electrical connectors 100 constructed using the electrical contacts 105 illustrated in FIGS. 9A-9D and in FIGS. 10A-10F and printed circuit boards 202 constructed in accordance with the alternative footprints FP3 and FP4, respectively, can operate to transfer data, for example between the respective mating and mounting ends of each electrical contact, in the range between and including approximately 8 Gigabits/sec (including approximately 9 Gigabits/sec) and approximately 30 Gigabits/sec, such as at a minimum of approximately 12.5 Gigabits/sec (with a range of about 20 through 60 picosecond rise times, such as about 25 picosecond rise times), at a minimum of approximately 20.0 Gigabits/sec (with a range of about 20 through 60 picosecond rise times, such as about 25 picosecond rise times), and at a minimum of approximately 25 Gigabits/sec (with a range of about 20 through 60 picosecond rise times, such as about 25 picosecond rise times), including any 0.25 Gigabits/sec increments between approximately therebetween, with worst-case, multi-active crosstalk on a victim pair of between 1%-6%, including all sub ranges and all integers, for instance 1%-2%, 2%-3%, 3%-4%, 4%-5%, and 5%-6%, including 1%, 2%, 3%, 4%, 5%, and 6% within acceptable crosstalk levels of the MicroTCA® standard, for instance somewhere below about four percent (4%), such as below about three percent (3%), approximately. Furthermore, the herein described embodiments of electrical connectors 100 and printed circuit board 202 footprints can operate in the range between and including approximately 1 and 15 GHz, including any 0.25 GHz increments between 1 and 15 GHz.
[0160] Referring now to FIGS. 12A-12B , in accordance with the MicroTCA® standard, the accepted level of crosstalk, such as near end crosstalk, can be dependent upon the particular type of MicroTCA® electrical assembly. For instance, an electrical assembly 20 constructed as an AdvancedMC Backplane Connector in accordance with the MicroTCA® standard can include a printed circuit board 202 and an electrical connector 100 mounted to the printed circuit board 202 . In accordance with the illustrated embodiment, the electrical assembly 20 further includes a complementary electrical component in the form of an edge card configured as an AdvancedMC module 900 that is mated to the mating interface 116 of the electrical connector 100 so as to place the AdvancedMC module 900 in electrical communication with the electrical connector 100 , and thus with the printed circuit board 202 . It should be appreciated that the electrical connector 100 of the electrical assembly 20 can be constructed in accordance with any of the herein described embodiments of the electrical connectors 100 and can be configured as an AdvancedMC Backplane Connector configured to operate in accordance with the acceptable levels of crosstalk specified in accordance with the MicroTCA® standard. Similarly, the printed circuit board 202 of the electrical assembly 20 can be configured with any of the herein described printed circuit board footprints, such that the electrical connector 100 of the electrical assembly 20 can be mounted onto the printed circuit board 202 of the electrical assembly 20 .
[0161] The crosstalk of the electrical connector 100 of the illustrated electrical assembly 20 should be measured under environment impedance of approximately 100 Ohms differential and at twenty to eighty percent (20%-80%) twenty five picosecond maximum input rise time. The crosstalk amplitude should be measured in a multi aggressor condition. For example the connector housing 102 can support a plurality of ground plates 306 that are spaced from each other along the row direction R, a first row R 1 of electrical signal contacts 104 arranged in respective differential signal pairs 117 that are spaced from each other along the row direction R, with each differential signal pair 117 disposed between successive ones of the ground plates 306 , and a second row R 2 of electrical signal contacts 104 arranged in respective differential signal pairs 117 that are spaced from each other along the row direction R, with each differential signal pair 117 disposed between successive ones of the ground plates 306 . The first and second rows R 1 and R 2 of electrical signal contacts 104 are spaced from each other along the column direction C, with corresponding differential signal pairs 117 in the first and second rows R 1 and R 2 that are disposed between respective successive ones of the ground plates 306 substantially aligned with respect to each other along the column direction C.
[0162] In accordance with the illustrated embodiment, the electrical connector 100 comprises a first ground plate 306 a supported by the connector housing 102 substantially at the second end 103 b of the housing body 103 and respective pairs 113 of electrical signal contacts configured as first and second differential signal pairs 117 a and 117 b are disposed between the first ground plate 306 a and a second ground plate 306 b that is successive with respect to the first ground plate 306 a . The first differential signal pair 117 a is disposed in the second row R 2 of electrical signal contacts 104 , and the second differential signal pair 117 b is disposed in the first row R 1 of electrical signal contacts 104 . The illustrated electrical connector 100 further comprises third and fourth differential signal pairs 117 c and 117 d that are disposed between the second ground plate 306 b and a third ground plate 306 c that is successive with respect to the second ground plate 306 b . The third differential signal pair 117 c is disposed in the second row R 2 of electrical signal contacts 104 and is successive with respect to the first differential signal pair 117 a , and the fourth differential signal pair 117 d is disposed in the first row R 1 of electrical signal contacts 104 and is successive with respect to the second differential signal pair 117 b . The illustrated electrical connector 100 further comprises fifth and sixth differential signal pairs 117 e and 117 f that are disposed between the third ground plate 306 c and a fourth ground plate 306 d that is successive with respect to the third ground plate 306 c . The fifth differential signal pair 117 e is disposed in the second row R 2 of electrical signal contacts 104 and is successive with respect to the third differential signal pair 117 c , and the sixth differential signal pair 117 f is disposed in the first row R 1 of electrical signal contacts 104 and is successive with respect to the fourth differential signal pair 117 d.
[0163] In order to measure the crosstalk amplitude of the electrical assembly 20 in a multi aggressor condition, and therefore in accordance with the MicroTCA® standard, the crosstalk induced by five differential signal pairs designated as multi-aggressor differential signal pairs at a single differential signal pair designated as a victim differential signal pair should be measured. In accordance with the illustrated embodiment, the third differential signal pair 117 c is designated as the victim differential signal pair, and the first, second, fourth, fifth, and sixth differential signal pairs 117 a , 117 b , 117 d , 117 e , and 117 f , respectively, are designated as the five multi-aggressor differential signal pairs that induce crosstalk at the victim differential signal pair. In accordance with the MicroTCA® standard, the differential crosstalk amplitude induced by the five multi-aggressor differential signal pairs at the victim differential signal pair should be less than three percent (3%). It should be appreciated that the crosstalk amplitude at the victim, or third, differential signal pair 117 c should be less than 3% for an electrical connector 100 including electrical contacts having any type of mounting elements, for example press-fit mounting elements such as eye of the needle tails, surface mounting elements such as solder balls, or any other suitable mounting elements. The differential attenuation profile, or insertion loss, of the electrical assembly 20 should be greater than −1 dB at 6.5 GHz, greater than −2 dB at 12 GHz and greater than −4 dB at 14.5 GHz. It should be appreciated that the differential attenuation profile should be substantially equal to the above for an electrical connector 100 including electrical contacts having any type of mounting elements, for example press-fit mounting elements such as eye of the needle tails, surface mounting elements such as solder balls, or any other suitable mounting elements.
[0164] Referring now to FIGS. 13A-13B , in accordance with the MicroTCA® standard, the accepted level of crosstalk, such as near end crosstalk, is different for an electrical assembly 30 constructed as a MicroTCA® Carrier Hub (MCH) than for the electrical assembly 20 . The electrical assembly 30 can include a printed circuit board 202 and first and second electrical connectors 100 and 100 ′ mounted to the printed circuit board 202 and spaced apart from each other along the lateral direction A. In accordance with the illustrated embodiment, the first and second electrical connectors 100 and 100 ′ are constructed substantially identically and are mounted to the printed circuit board 202 such that the connector housings 102 and 102 ′ of the first and second electrical connectors 100 and 100 ′ are substantially parallel with respect to each other and with respect to the longitudinal direction L, and such that the first and second ends 103 a and 103 b of the housing body 103 of the connector housing 102 of the first electrical connector 100 are substantially aligned with the first and second ends 103 a ′ and 103 b ′, respectively, of the housing body 103 ′ of the connector housing 102 ′ of the second electrical connector 100 ′ along the lateral direction A.
[0165] In accordance with the illustrated embodiment, the electrical assembly 30 further includes a pair of complementary electrical components in the form of first and second edge cards configured as first and second AdvancedMC modules 900 and 900 ′ that are mated to the first and second electrical connectors 100 and 100 ′, respectively, so as to place the first and second AdvancedMC modules 900 and 900 ′ in electrical communication with the respective first and second electrical connectors 100 and 100 ′, and thus with the printed circuit board 202 . The electrical assembly 30 further includes complementary electrical connectors 1000 and 1000 ′ mounted to the first and second AdvancedMC modules 900 and 900 ′, respectively. The complementary electrical connectors 1000 and 1000 ′ are configured to be mated to each other so as to place the first and second AdvancedMC modules 900 and 900 ′ in electrical communication with each other.
[0166] The first and second electrical connectors 100 and 100 ′ can be constructed substantially the same or differently, for example in accordance with any of the herein described embodiments of the electrical connector 100 . Similarly the respective footprints on the printed circuit board 202 that correspond to the first and second electrical connectors 100 and 100 ′ can be arranged substantially the same or differently. For example, it should be appreciated that one or both of the first and second electrical connectors 100 and 100 ′ of the electrical assembly 30 can be constructed in accordance with any of the herein described embodiments of the electrical connectors 100 , and can be configured as a MicroTCA® Carrier Hub (MCH) configured to operate in accordance with the acceptable levels of crosstalk specified in accordance with the MicroTCA® standard. Similarly, the printed circuit board 202 of the electrical assembly 30 can be configured with one or more of any of the herein described printed circuit board footprints, such that the first and second electrical connectors 100 and 100 ′ of the electrical assembly 30 can be mounted onto the printed circuit board 202 of the electrical assembly 30 . It should be further be appreciated that a MicroTCA® Carrier Hub (MCH) is not limited to two electrical connectors, and that a MicroTCA® Carrier Hub (MCH) can be alternatively constructed including more than two, such as four, electrical connectors.
[0167] The crosstalk of the first electrical connector 100 of the illustrated electrical assembly 30 should be measured under environment impedance of approximately 100 Ohms differential and at twenty to eighty percent (20%-80%) twenty five picosecond maximum input rise time. The crosstalk amplitude should be measured in a multi aggressor condition. In accordance with the illustrated embodiment, the electrical connector 100 of the electrical assembly 30 is constructed substantially identically to the electrical connector 100 of the electrical assembly 20 . Furthermore, the electrical connector 100 ′ is constructed substantially identically to the electrical connector 100 , and includes first, second, third, and fourth ground plates 306 a ′, 306 b ′, 306 c ′, and 306 d ′, and first, second, third, fourth, fifth, and sixth differential signal pairs 117 a ′, 117 b ′, 117 c ′, 117 d ′, 117 e ′, and 117 f , disposed in the connector housing 102 ′ along respective first and second rows R 1 ′ and R 2 ′ of electrical signal contacts 104 ′.
[0168] In order to measure the crosstalk amplitude of the electrical assembly 30 in a multi aggressor condition, and therefore in accordance with the MicroTCA® standard, the crosstalk induced by eight differential signal pairs designated as multi-aggressor differential signal pairs at a single differential signal pair designated as a victim differential signal pair should be measured. In accordance with the illustrated embodiment, the fourth differential signal pair 117 d of the first electrical connector 100 is designated as the victim differential signal pair, and the first, second, third, fifth, and sixth differential signal pairs 117 a , 117 b , 117 c , 117 e , and 117 f of the first electrical connector 100 , and the first, third, and fifth differential signal pairs 117 a ′, 117 c ′, and 117 e ′ of the second electrical connector 100 ′, respectively, are designated as the eight multi-aggressor differential signal pairs that induce crosstalk at the victim differential signal pair. In accordance with the MicroTCA® standard, the differential crosstalk amplitude induced by the eight multi-aggressor differential signal pairs at the victim differential signal pair should be less than four percent (4%). It should be appreciated that the crosstalk amplitude at the victim, or fourth, differential signal pair 117 d should be less than 4% for first and second electrical connectors 100 and 100 ′ including electrical contacts having any type of mounting elements, for example press-fit mounting elements such as eye of the needle tails, surface mounting elements such as solder balls, or any other suitable mounting elements. The differential attenuation profile, or insertion loss, of the electrical assembly 30 should be greater than −1 dB at 6.5 GHz, greater than −2 dB at 12 GHz and greater than −4 dB at 14.5 GHz. It should be appreciated that the differential attenuation profile should be substantially equal to the above for first and second electrical connectors 100 and 100 ′ including electrical contacts having any type of mounting elements, for example press-fit mounting elements such as eye of the needle tails, surface mounting elements such as solder balls, or any other suitable mounting elements.
[0169] A method of fabricating an electrical connector 100 in accordance with the herein described embodiments can include supporting a plurality electrical signal contacts 704 in the connector housing 102 , wherein respective pairs 113 of the plurality of electrical signal contacts 704 define differential signal pairs 717 . The method can further include supporting first and second ground plates 606 a and 606 b , respectively, in the connector housing 102 , such that the electrical connector includes one hundred seventy mating ends 95 that are spaced along two columns that each extend along the row direction R collectively from the mating ends 712 of the plurality of electrical signal contacts 704 and the ground mating ends 614 of the first and second ground plates 606 a and 606 b , the one hundred seventy mating ends 95 defining a 0.75 mm column pitch. The method further includes positioning the plurality of electrical signal contacts 704 and the ground plates 606 in the connector housing 102 such that the signal mounting tails 711 and the ground mounting tails 611 a and 611 b define a footprint that differs from a footprint defined by vias 206 of a printed circuit board 202 that are arranged in accordance with MicroTCA specification Rev. 1.0, such that the electrical signal contacts 704 are configured to transfer data between the mounting tails and the mating ends at a minimum of approximately 12.5 Gigabits/second at an acceptable level of near-end crosstalk. The acceptable level of near-end cross talk can be, for instance, less than approximately four percent (4%), for instance less than approximately three percent (3%). The method can further include configuring the electrical signal contacts 704 to transfer data at higher speeds, such as a minimum of approximately 20 Gigabits/second at the acceptable level of near-end crosstalk, and a minimum of approximately 25 Gigabits/second at the acceptable level of near-end crosstalk.
[0170] An electrical connector, for instance an electrical connector constructed in accordance with the above-described method, can include a connector housing and a plurality electrical signal contacts supported in the connector housing. The electrical signal contacts can define signal mounting tails and mating ends. Respective pairs of the plurality of electrical signal contacts define differential signal pairs. The electrical connector further includes first and second ground plates supported in the connector housing. Each of the plurality of first and second ground plates including ground mounting tails and ground mating ends. The electrical signal contacts and the first and second ground plates can collectively define one hundred seventy mating ends that are spaced along two columns that each extend along a row direction collectively from the mating ends of the plurality of electrical signal contacts to the ground mating ends. The one hundred seventy mating ends can define a 0.75 mm column pitch. The electrical signal contacts and the ground plates can be positioned in the connector housing such that the signal and ground mounting tails define a footprint that differs from a footprint defined by vias of a printed circuit board that are arranged in accordance with MicroTCA specification Rev. 1.0, such that the electrical signal contacts are configured to transfer data between the mounting tails and the mating ends at a minimum of approximately 12.5 Gigabits/second at an acceptable level of near-end crosstalk.
[0171] The acceptable level of near-end cross talk can be less than three percent on one victim differential signal pair with five aggressor differential signal pairs at a 20-80 percent 25 picosecond maximum rise time. The acceptable level of near-end cross talk can be less than four percent on one victim differential signal pair with eight aggressor differential signal pairs at a 20-80 percent 25 picosecond maximum rise time. The electrical signal contacts can be configured to transfer data between the mounting tails and the mating ends a minimum of approximately 20 Gigabits/second at the level of near-end crosstalk. The electrical signal contacts can be configured to transfer data between the mounting tails and the mating ends a minimum of approximately 25 Gigabits/second at the level of near-end crosstalk.
[0172] The embodiments described in connection with the illustrated embodiments have been presented by way of illustration, and the present application is therefore not intended to be limited to the disclosed embodiments. For example, one or both of the electrical connectors 100 or the printed circuit board 202 footprints described herein may also be applicable to other types of card edge, back panel, or other connectors. Additionally, it should be appreciated that the various embodiments of the electrical contacts 105 herein illustrated and described are not limited to press-fit tail mounting elements, and that the electrical contacts 105 of any of the herein described embodiments can be alternatively constructed with any other suitable mounting elements as desired. For example, the mounting elements can alternatively be configured as surface mount mounting elements, including fusible elements such as solder balls 800 (see FIG. 11 ) that are configured to be solder reflowed to complementary electrical contact pads on the printed circuit board 202 . Thus, it should be appreciated that the electrical connector 100 constructed in accordance with any of the embodiments described herein can include mounting elements that can be configured as press fit elements such as mounting tails, fusible elements such as solder balls 800 that can define a ball grid array (BGA) of solder balls 800 , or any other suitable constructed mounting elements.
[0173] Furthermore, the structure and features of each the embodiments described above can be applied to the other embodiments described herein, unless otherwise indicated. In one example, the contact bodies 107 of the electrical signal contacts 104 of one or more of any of the other illustrated embodiments of the electrical connector 100 , such as the embodiments illustrated in FIG. 3A-3D , 5 A- 5 D, 7 A- 7 C, 8 A- 8 C, or 9 A- 9 C can be twisted as described with respect to FIGS. 10A-10G such that the mounting ends 108 of the electrical signal contacts 104 are angularly offset relative to the respective mating ends 112 of the electrical signal contacts 104 . It should further be appreciated that if the contact bodies 107 of the electrical signal contacts 104 of one or more of any of the other illustrated embodiments of the electrical connector 100 are twisted in accordance with the illustrated embodiment, corresponding alternative footprints to those illustrated in FIG. 7D , 8 D, or 9 D can be defined in which the electrical signal vias 208 are substantially aligned along the longitudinal direction L with respect to each other along the column direction C.
[0174] Accordingly, those skilled in the art will realize that the application is intended to encompass all modifications and alternative arrangements included within the spirit and scope of the application, for instance as set forth by the appended claims.
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Electrical connectors that are mating compatible with the MicroTCA® standard and configured to be mounted to an underlying substrate are provided. Certain of the electrical connectors can be configured to be mounted to a substrate configured in accordance with the MicroTCA® press fit footprint. Additionally, electrical connectors that are mating compatible with the MicroTCA® standard and configured to be mounted to respective alternative footprints, and substrates configured in accordance with the respective alternative footprints are provided. The disclosed electrical connectors and corresponding substrate footprints can operate to transmit data at speed up to and in excess of 25 Gigabits per second.
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This application is a divisional application of application Ser. No. 096,782, filed Sept. 14, 1987, now U.S. Pat. No. 4,846,114, which was a continuation of application Ser. No. 778,069, filed Sept. 30, 1985, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to a method for delivery of fuel into the combustion chamber of a diesel engine with which both fuel and compressed air are admitted by an injection nozzle, and equipment for realizing this method.
DESCRIPTION OF THE PRIOR ART
If fuel is injected into the combustion chamber of a diesel engine through the usual round-hole nozzles a smooth stream is ejected from the nozzle orifice which expands conically for a short distance and is then followed by a part that is also conical but whose surface is roughened by the air that is carried along. Ignition first takes place in this part. It propagates at high velocity in the direction of the stream and at a lower velocity against it. Against the direction of the stream the flame travels up to the smooth part. The smooth part does not burn during injection, apparently due to a lack of oxygen. It does leave individual sparks after the injection process, however, which are probably caused by unburned particles, such as coke particles.
SUMMARY OF THE INVENTION
This is the point of departure of the present invention whose aim it is to burn up the fuel as completely as possible and to minimize noxious emissions. Basically, the invention provides that the fuel stream which is injected into the combustion chamber via the fuel nozzle should be followed by a quantity of compressed air which is small compared to the stroke volume of the diesel engine. In this way fuel particles which would otherwise remain in the injection nozzle and which are responsible to a high degree for the hydrocarbons contained in the exhaust gases, are removed from the nozzle and burned, during which process the nozzle holes are cleared of fuel as well. Besides, the compressed air which is blown through after the fuel will aid combustion of the red-hot particles of the fuel stream that have formed immediately beyond the nozzle.
The invention thus is concerned with a method of direct fuel injection in which the fuel is injected under high pressure either by a separate pump and a fuel line, or by a pump which is integrated with the injection nozzle. The energy required for the injection process is solely delivered by this pump, and no additional air is introduced during injection.
A contrast to the above is presented by conventional air injection methods in which a certain quantity of fuel, which is metered by a separate pump, is delivered to the nozzle unit, from where it is blown into the combustion chamber by means of compressed air. This produces a mixture of fuel and air; the main energy source for pushing the fuel into the combustion space being the compressed air. This method is complicated in view of the separate compressor required in addition to the fuel metering pump. In this known system of air injection the pressure of the fuel is less important; usually, it is lower than the air pressure needed for injection. The relatively small amount of compressed air necessary for the method according to the invention may be obtained without the use of a separate compressor.
A particularly simple realization of the invention is achieved by taking the compressed air which is blown in after the fuel from the cylinder chamber of the diesel engine, preferably at a time of high pressure in this area, and storing it until injection time. In this variant no separate compressor is needed for the compressed air, whose higher temperature has a favorable influence on the injection process according to the invention.
In a device for realizing the method of the invention a check valve is provided at the cylinder for taking compressed air from the cylinder chamber of the diesel engine, which valve communicates via a line with an air cell, which may be heat insulated. The air cell in turn may be connected with the openings of the injection nozzle via channels and a control unit operating in dependence of the pressure in the air cell and the pressure in the fuel feeder bore of the injection nozzle, the control unit connecting the openings of the injection nozzle either with the air cell or with the fuel feeder bore, depending on the pressure level in the air cell and in the fuel feeder bore of the injection nozzle. Thus, compressed air is taken from the cylinder when a suitable level of pressure has been reached in the cylinder. As the compressed air is only required when the injection of fuel has terminated and the pressure in the cylinder has dropped during the expansion phase, the compressed air is stored in the state in which it was taken during the compression stroke and is fed back to the cylinder at a later time. This is done automatically via the control unit, depending on the pressure in the air cell and that in the fuel feeder bore in the injection nozzle. No separate compressor is required for this purpose.
In a favorable development of this device the injection valve is configured as a lapped-in fuel needle with a conical seat, and the fuel is fed to the nozzle holes through a ring-shaped groove in the fuel needle connected with a center bore, and the air feeder line from the second check valve is linked to the ring-shaped groove.
A preferred variant of the invention provides that the check valve, the bore and the air cell be located in the cylinder head and that connections and bores lead from the air cell to the second check valve in the nozzle body. This design is suitable for a pump/nozzle unit as well as for a configuration with a separate injection pump.
For the separate arrangement of pump and nozzle, but also for an integrated pump/nozzle design, a further development of the device is particularly suited, wherein the injection valve comprises a lapped-in fuel needle with a conical seat and a center bore for feeding fuel to the nozzle holes, and is further provided with a cross-bore in which slides a cylindrical valve body or similar element whose length is shorter by at least half the diameter of the center bore of the nozzle than half the length of the cross-bore, and wherein the cross-bore is connected (a) to the fuel feeder line of the injection nozzle, and (b) to the connecting channel towards the air cell. Instead of the cylindrical slide a ball could be used which should fit tightly into the bore. In this variant the injection of fuel and that of compressed air following the fuel are distinctly separated, which will enhance the efficiency of the system.
DESCRIPTION OF THE DRAWINGS
Following is a more detailed description of the equipment according to the invention, as illustrated by the accompanying drawings, in which
FIG. 1 shows a device for delivery of fuel and compressed air into a combustion chamber according to a first embodiment of the invention the device comprising a pump/nozzle unit,
FIG. 2 presents a simplified view of a fuel stream,
FIG. 3 presents characteristic curves explaining the injection process according to the invention,
FIG. 4 shows a device for delivery of fuel and compressed air into a combustion chamber according to a second embodiment of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
From the cylinder chamber 1 air or a lean fuel/air mixture is delivered via the check valve 2 and a connecting bore 3 to an air cell 4 on account of the excess pressure in the cylinder. The check valve 2 has a ring 5, a valve disk 6 and a helical spring 7 whose load on the valve disk 6 is such that the check valve will open only when the excess pressure in the cylinder has reached a certain limit. From the air cell 4 a connection line 8 leads to the pump/nozzle unit 9 in which a bore 10 leads to a second check valve 11 which in this variant consists of a ball 11' loaded by a helical spring 12; other designs of the check valve are possible. The second check valve 11 communicates with the ring-shaped groove 14 in the fuel needle 15 through a bore 13.
The pump/nozzle unit 9 comprises a pump body 16 and a nozzle body 17, between which is inserted a plate 18 polished on both sides, and which are fastened together by means of a screw sleeve 19. The nozzle body 17 has an axial bore 20 starting at the end adjacent to plate 18, in which the fuel needle 15 is guided axially. The entire pump/nozzle unit may be inserted into a bore 22 at the cylinder head 23 of the diesel engine, and may be sealed by the sealing rings 24 carried by the pump body 16. The pump plunger 25 is fitted into the pump body 16 in such a way that it may be moved axially. It is actuated by a cam (not shown) acting on its top 26, which top 26 is pre-loaded by a spring 29 via washers 27, 28.
For control of the quantity of fuel injected the pump plunger 25 has a conventional sloping edge 30 which cooperates with the bypass port 31. By means of the lever 32 the pump plunger 25 may be turned, thus regulating the amount of fuel injected. The fuel metered in this way passes through the relief valve 33 which is provided with a valve disk 34 against which is pressing the load spring 35. The relief valve 33 opens into the chamber 36 which is connected with the feeder bore 39 in the nozzle body 17 via the groove 37 and a bore 38 in plate 18. Starting from plate 18 the feeder bore 39 opens into a ring space which is situated between nozzle body 17 and fuel needle 15 and is formed by a recess in the needle, and which is bounded by the ring-shaped groove 14 and the nozzle body 17. In the area of the ring-shaped groove 14 the fuel needle 15 has a cross-bore 40 which is connected with the axial bore 41 of the needle 15 opening into a pressure chamber 43 in the nozzle body 17 on the side away from the cross-bore, i.e., at the conical front end 42 of the fuel needle 15.
The bore 13 starting at the second check valve 11 communicates with the ring space formed by the ring-shaped groove 14 and the nozzle body 17 in the same way as the fuel feeder bore 39.
The stream of fuel which is ejected from a bore 58 of the nozzle body 17 has the shape presented in FIG. 2. In the initial part 44 it is conical, with a smooth surface. Further on, mixing takes place with the air streaming in from the sides. This mixing zone has the number 45. Combustion approximately begins at the point marked 46, propagating in either direction: downwards at a higher, and upwards at a lower rate. At the initial part 44 it comes to a standstill, i.e., it does not propagate further towards the nozzle.
Whereas below the initial part 44 the stream will burn due to its mixing with air, sparks 47 will develop in the upper part, i.e., in the initial part 44, probably consisting of carbon particles of coke or soot.
By blowing in air according to the invention, oxygen is added to these particles of coke or soot whose temperatures are high enough to make them burn up partially or even completely as a consequence.
For the sake of completeness the dilution zone of the fuel stream is indicated by 48, and the overall length, i.e., the length of penetration of the fuel stream, is marked 49.
FIG. 3 presents pressure p(bar) and temperature T(K) curves as a function of the crank angle °KW. In this diagram 50 denotes the pressure in the cylinder, 51 the injection pressure, 54 the pressure of the compressed air in the air cell 4 and in the connecting lines, and 52 the residual pressure in the injection system. The temperature curve in the cylinder is marked 53.
During fuel injection the connection between the air cell 4 and the nozzle bores 58 is closed between points 55 and 56 by the check valve 11 (FIG. 1) and the cylindrical slide 63 (FIG. 4); it will open after point 56 only, and between points 56 and 57 air from the air cell 4 will flow into the injection system through line 8, and into the cylinder chamber 1 through bores 10, 13 and 41 via nozzle bores 58. The dimensions of the spring 21 are such that the residual pressure in the injection system approximately corresponds to the value represented by the horizontal branches 52, which means that the fuel needle 15 and the relief valve 33 will close at this pressure. After point 59 a comparatively small amount of air will flow through the check valve 11 until the injection pressure of the fuel has risen and the valve closes at point 55 with the beginning of fuel injection. Between points 56 and 57 air will stream through the nozzle bores 58 into the combustion chamber; during this phase the space around the relief valve 33 and the bore 39 will remain filled with fuel. This is due to the surface tension of the fuel and the very short period during which air is blown in.
At the beginning of fuel injection the cross-bore 40 and the axial bore 41 as well as the nozzle bores 58 fill up with fuel; the air in bore 13 and in the space around the second check valve 11 is compressed by the fuel to a very small volume as a consequence of the high pressure of injection. Thus fuel injection takes place between points 55 and 56, while air is injected between points 56 and 57.
The injection system is supplied with fuel via bore 31 which is closed by the sloping edge 30 of the pump plunger in the usual way. In order to prevent overheating of the check valve 2 it may be placed further along the bore 3 such that it is located within the cylinder head. In this instance part of the bore 3 will lead from the cylinder chamber 1 to the check valve 2 which will be located in the cooled part of the cylinder head.
Since the compressed air which has been taken from the cylinder chamber 1 and stored in the air cell 4 should return to the cylinder chamber without having cooled off parts of the air system, above all the air cell 4, may be heat-insulated,
The quantity of air which is blown in after injection of the fuel may be varied with the dimensions of the air cell 4 and the check valve 2. It will also be possible to vary the volume of the air cell 4 during operation, for instance by moving a fitted plunger, in order to achieve certain effects.
According to the invention the method of blowing in air by means of the pump/nozzle unit shown in FIG. 1 can also be used for an injection system in which pump and nozzle are configured separately. In this instance the air cell and the necessary check valves are located in the vicinity of the nozzle, and the pump is connected to the nozzle via an injection line.
The nozzle unit presented in FIG. 4 of an injection system with a separate pump and nozzle, comprises a nozzle body 60 with connection 61 for the injection line arriving from the injection pump, and connection 62 for the air feeder line. As regards the remaining part of the nozzle, the configuration is similar to that in FIG. 1, and identical parts have identical reference numbers. The only difference is that cross-bore 40 contains a cylindrical slide 63 which is in the left position shown here during fuel injection.
As soon as the injection process has ceased and the air pressure in bore 13 is higher than the fuel pressure, the cylindrical slide 63 moves to the right, thus opening the axial bore 41 for the entrance of air which will press the fuel still remaining in the axial bore 41 and the nozzle bores 58 into the cylinder chamber, and will then flow into the cylinder chamber 1 through the nozzle bores 58. This process of blowing in air ends once the pressure in the air system has dropped to the level of the residual pressure 52--cf. point 57 in FIG. 3. The cylindrical slide 63 thus effects a separation of the air system and the fuel system in the injection nozzle, and is automatically actuated by the fuel pressure on the one hand and the air pressure on the other. The fuel needle 15 must be prevented from turning by a suitable device.
This device can also be used for pump/nozzle units, of course.
Presentation of the pressure and temperature curves as a function of the crank angle as in FIG. 3 also applies to the variant according to FIG. 4, the cylindrical slide 63 being in the left position after point 55 and in the right stop position after point 56. The fuel needle 15 is lifted from its seat between the points 64 (open) and 57 (close). The hatched area 65 in FIG. 3 indicates the range of pressures and crankshaft angles within which air injection takes place.
The device according to the invention is suited for both an integrated pump/ nozzle unit and a separate pump and nozzle system in which the beginning and end of the injection process are controlled electrically.
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The delivery of fuel into the combustion chamber of a diesel engine is aided by blowing in an amount of compressed air which is small compared to the stroke volume of the diesel engine after the stream of fuel has been injected into the combustion chamber via the fuel nozzle. In this way fuel particles which would otherwise remain in the injection nozzle and considerably increase the hydrocarbon content of the exhaust are removed from the nozzle and burned, at the same time clearing the nozzle holes of any remaining fuel. The compressed air blown in after fuel injection will assist combustion of the red-hot particles of the fuel stream which have formed immediately beyond the nozzle.
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CROSS REFERENCE TO RELATED APPLICATION
This application claims priority from U.S. Provisional Patent Application No. 60/110,833 filed Dec. 3, 1998 and Canadian Application No. 2,263,062 filed Feb. 26, 1999 titled Flush Mounted Flip Top Telecommunication And Electrical Station For Board Room Tables.
FIELD OF THE INVENTION
This invention relates to the field of electrical, data and telecommunication service boxes, and in particular service boxes which may be flush mounted within the surface of a board room table.
BACKGROUND OF THE INVENTION
With the need for rapid access to up-to-date information, business executives are utilising personal computers and telecommunication devices in boardrooms for access to and retrieval of information as well as for video conferencing. At the present time personal computers, cellular telephones or the like when brought into a board room for use during a meeting are usually battery powered since there is insufficient telecommunication or electrical connections in most boardrooms to accommodate individual connections for each person in attendance. If connections of this type are available they are usually limited in number and are of the conventional wall mounted type which require extension cords or computer cables of some length so as to typically interfere with passage around the boardroom table.
It is desirable, therefore, to have outlets for telecommunications, data and electricity accessible to each person seated around the board room table. Consequently, it is an object of the present invention to provide electrical, data and telecommunication service stations which are mounted through or under a hole in the table, and which are accessible through an opening in the station which is flush with the upper surface of the table.
SUMMARY OF THE INVENTION
The telecommunication, data and electrical station of the present invention includes a rigid container, mountable within an aperture formed through an upper, horizontal work surface of a table, such as a boardroom table. The container may be a rectangular box having surrounding an upper perimeter edge thereof, a container support such as a lip projecting outwardly therefrom. The upper surface of the lip may, in one embodiment, lie in a first plane parallel to an upper surface of the table when the container is mounted in the table through the aperture in the table. The lip may be a circumferential lip extending contiguously around the upper perimeter edge.
The container will typically include perimeter walls secured to and depending from the container support, for example in planes at right angles to the first plane, and a bottom wall connected to a lower edge of the perimeter walls spaced from the container support. The bottom wall has a conduit aperture therein to provide insertion access for data, including audio and video, electrical and telecommunication conduit. The container support and the perimeter walls defining an upper access aperture for access into the container. A service outlet support is mounted or mountable into the container for mounting thereon data, electrical and telecommunication service outlets in co-operation with the data, electrical and telecommunication conduit. The service outlet support has an upper mounting face recessed below the first plane when the service outlet support is mounted into the container.
Preferably, inside the telecommunication, data, and electrical station the upper mounting face lies in a plane which is canted with respect to the first plane so that the service outlets are generally in a line of sight through the upper access with a user sitting at the table when the station is mounted in the table. Insertion and removal of electrical plugs and telecommunication jacks is thereby facilitated.
In the preferred embodiment the telecommunication, data and electrical station further includes a selectively positionable lid which pivots between a closed position closing or covering the upper access aperture and an open position wherein the lid is pivoted completely into the container. In the closed position the lid lies within the upper access aperture flush and coplanar with the first container support. In the open position the lid allows unobstructed access through the upper access aperture to the upper mounting face when the service outlet support is mounted in the container.
In the structure of one preferred embodiment the service outlet support has depending therefrom support arms which are spaced inwardly from the perimeter walls, so that the perimeter walls and the support arms define a lid receiving cavity therebetween. The lid may then be pivoted about an axis of rotation, the axis of rotation generally parallel to the first plane, so that in the open position the lid is fully retracted into the lid receiving cavity so as to be stored below the first plane.
The upper mounting face may have an inwardly facing perimeter portion joined at the medial point thereof by a transverse strip thereby defining a pair of apertures under which conventional electrical and telecommunication service outlets are mounted. Depending from the transverse strip may be a divider wall dividing the container into separate electrical and telecommunication compartments.
Advantageously, securing means are provided to secure the station within the aperture formed in the table. In one embodiment the securing means are selectively positionable in vertical relation to the underside of the table and mountable on the perimeter walls. In particular, the securing means may be rigid flanges having threaded apertures for the threaded engagement therethrough of threaded bolts at right angles to the first plane so as to compress the table between an upper end of the bolt and the container support at right angles to the first plane.
The lid may in one embodiment have downwardly and outwardly projecting arms for pivotal connection generally at terminal ends of the arms to opposite walls of the perimeter walls. The lid may then be pivoted about its axis of rotation, which is advantageously parallel to and spaced from the first plane, so as to be rotatable between the open and closed positions. Again, in the open position the lid is fully rotated below the first plane into the container. Rotational stops may be mounted to an inside face of each of the opposite perimeter walls, positioned adjacent a rotation path of the lid, for contact with the lid when the lid is in the closed position.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is an exploded isometric view illustrating the components of the present invention.
FIG. 2 is an exploded isometric view illustrating the present invention partially assembled.
FIG. 3 is a sectional view along line 3 — 3 in FIG. 2 .
FIG. 4 is a sectional view along line 4 — 4 in FIG. 2 .
FIG. 5 is an isometric view illustrating a mounting clip.
FIG. 6 is an exploded isometric view illustrating the device of FIG. 1, having a stepped mounting face.
FIG. 7 is an exploded isometric view illustrating the device of FIG. 7 partially assembled.
FIG. 8 is a sectional view along line 8 — 8 in FIG. 7 .
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
Referring to FIGS. 1-4 , the telecommunication and electrical station of the present invention 10 , is placed within an aperture 12 formed in, or cut through a board room tabletop 14 , desk, or like work surfaces having a generally horizontal planar surface 15 .
For ease of manufacture, the station may comprise a rigid rectangular housing 16 , for example formed out of sheet metal, U-shaped in cross section and having integrally formed front, rear and bottom walls, referenced as 18 , 20 and 22 respectively. Bottom wall 22 may advantageously contain holes or alternatively circular scored areas 24 , of different diameters which can simply be knocked out to provide apertures or insertion points through which ends of electrical and communication, including audio and video, conduits may be inserted for connection to standard electrical and telecommunication receptacles of a type known in the art (not shown). A pair of opposed end walls 26 , each having integrally formed inwardly facing flanges 28 , are provided for separate attachment to the open ends of housing 16 to create a rigid enclosed container.
Electrical and telecommunication mounting means such as frame 32 , for example having a generally inverted “U” shape in cross-section or other rigid supporting members for mounting into the container are provided to support the standard receptacles (for power supply and modem connection for example). Advantageously the mounting means cants the receptacles towards the users at an inclined angle for ease of access through aperture 12 when the user is sitting down at the edge of the table (the typical case). In the particular example of frame 32 , integrally formed flanges 34 , at the extremities of front and rear vertical legs 33 a and 33 b respectively, permit frame 32 to be securely fastened to the bottom portion of housing 16 , such as by spot welding or the like. Flanges 34 space the vertical legs of mounting frame 32 from the front and rear walls of housing 16 , so as to create fore and aft cavities 35 a and 35 b best seen in FIG. 8 . Upper face 38 of mounting frame 32 is recessed below the upper edges of housing 16 and is canted in a direction which would be toward the user when station 10 is mounted into the table top. Upper face 38 contains a plurality of rectangular apertures 40 (illustrated as two, but not intended to be limiting), which electrical and telecommunication standard service outlets or receptacles 41 are mounted to the underside of. With the exception of FIG. 2, the standard receptacles are not illustrated for sake of clarity of illustration.
The inclined slope of the upper face of mounting frame 32 permits ease of connection and removal of conduits such as cords and cables from the service outlets 41 in a more horizontal, line of sight path for a user positioned at an acute angle relative to the table top such as would typically be the case with a user sitting facing the table top.
A solid divider 42 may be provided to divide mounting frame 32 into separate compartments for electrical and telecommunications. In one preferred embodiment, divider 42 is positioned intermediate between apertures 40 on the inside face of mounting frame 32 . Divider 42 extends downward to contact bottom wall 22 and may be fastened thereto.
A lid faceplate 46 , and a rectangular stiffener plate 50 , are secured together such as by spot welding or the like. The rectangular stiffener plate has formed at each end thereof a downwardly projecting hinge arm 52 . The pair of hinge arms are pivotally mounted at their extremities to end walls 26 , so as to allow lid face plate 46 to pivot about a generally horizontal axis 54 , where axis 54 is generally parallel to surface 15 of table 14 . An operating tab 56 is provided on the stiffening plate intermediate arms 52 on the side of the plate which is exposed through aperture 12 when the lid is in its open position, that is, the position allowing access by the user to outlets 41 .
The lid face plate 46 and the stiffener plate 50 , which together form the lid, are rotated in a first rotational direction to align the lid flush and parallel to surface 15 of table 14 (the closed position) and are rotated in a second direction counter to the first direction to fully rotate the lid below the upper edges of container 16 (the open position). In the open position the lid is nested within cavities 35 a and 35 b defined between frame 32 and container 16 , to allow unobstructed access to outlets 41 . Rotation limiting plates 58 , mounted on the inside face of each of the end walls 26 , act as stops which are engaged by hinge arms 52 when the lid is rotated into its closed position to prevent over-rotation of the lid. The engagement of arms 52 with plates 58 at the point of closure ensures that lid faceplate 46 remains flush and coplanar with surface 15 of table 14 .
An upper rectangular supporting flange 60 is secured to the upper perimeter edges of housing 16 by means of attaching angle members 64 . Flange 60 forms a lip which extends around the upper circumference of station 10 and extends generally horizontally cantilevered outwardly therefrom. Supporting flange 60 and lid face 46 may be positioned flush with the upper surface 15 of the table top. Flange 60 may be fitted into a shallow recess or groove machined in upper surface 15 around the perimeter of aperture 12 for an absolutely flush mount. Housing 16 is thereby suspended in the table top with its upper surface flush with the table top surface so as to depend downwardly through aperture 12 .
Station 10 may be secured onto the table top by clamping the edges of the table top around the perimeter of aperture 12 between flange 60 and bolts 62 a projecting upwardly from mounting clips 62 . Projecting tabs 65 better seen in FIG. 5 are insertable into pairs of vertically aligned slots 66 formed through end walls 26 . Threaded bolts 62 a are journalled upwardly in threaded engagement through threaded holes 62 b in the clips to engage the underside of table 14 . As bolt 62 a projects upwardly it presses against the underside of table top 14 . Support flange 60 is thereby drawn down onto the upper surface 15 of table top 14 securing the flange flush and firmly against surface 15 .
An alternative embodiment is illustrated in FIGS. 6-8. In this embodiment the single tier of service outlets 41 mountable to frame 32 are replaced with a double tier of service outlets mountable to a double tier supporting frame 32 ′. This allows for the mounting of a greater number of electrical, audio and visual data and telecommunication service outlets. Upper face 38 ′ of mounting frame 32 ′ is stepped along a longitudinally extending median bisecting housing 16 to create two tiered mounting faces 38 a and 38 b , in the same direction, each of which is canted preferably toward a user. Solid divider 42 ′ is positioned intermediate the apertures and divides the mounting frame into separate compartments for electrical and telecommunications wiring. Divider 42 ′ has apertures 70 which permit through passage of wiring. The lid may be split into a pair of clam-shell doors, each pivoting oppositely from the other between a flush closed position and an open position fully oppositely retracted into the housing and below the upper surface of the table.
As will be apparent to those skilled in the art in the light of the foregoing disclosure, many alterations and modifications are possible in the practice of this invention without departing from the spirit or scope thereof. Accordingly, the scope of the invention is to be construed in accordance with the substance defined by the following claims.
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A telecommunication, data including audio and visual data, and electrical station which can be permanently mounted within an aperture formed in a board room table includes a container having a perimeter flange which supports the station within the table. The container also has separate compartments for electrical plug-ins and data and telecommunication jacks. The upper face of the compartments are tilted toward the user for ease of attaching plugs and jacks. A lid pivots between a closed position flush and coplanar with the table surface and an open position fully rotated below the surface of the table so as to permit unrestricted access by the user to the interior of the station.
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FIELD OF THE INVENTION
[0001] The present invention relates to a spring mattress comprising springs enclosed in casings, referred to as a pocket mattress, as well as a method and a device for manufacturing thereof.
BACKGROUND ART
[0002] A common technique of making spring mattresses is the so-called pocket technique. This means that the springs are enclosed in pockets, that is they are individually surrounded by a casing material. In this way, the springs will be relatively individually resilient so that they can flex individually without affecting the neighbouring springs and, thus, the comfort of the user increases since his weight will be distributed more uniformly over the surface that receives the load.
[0003] A drawback of this type of mattresses is, however, that they are often relatively soft, which makes it difficult to move in the bed as the user is to turn or sit up in the bed for instance. Moreover, there is a risk of falling out of the bed when lying close to the edge or when sitting down on the edge, which may cause injuries and discomfort.
[0004] For example GB 225 225, U.S. Pat. No. 2,878,012 and U.S. Pat. No. 2,359,003 also disclose cushions to be used as vehicle seats with coil springs, where surrounding casings are airtight and check valves or the like are provided to limit the flow of air into the casings. As a result, damping is provided, which makes the returning of the coil springs to an extended position difficult, which reduces swinging and oscillation when the vehicle drives over an uneven road and the like. These cushions are, however, neither intended nor suitable for use in beds and are besides of another type than conventional pocket mattresses, comprising separate enclosed spring units which are widely scattered in the mattress.
[0005] Moreover U.S. Pat. No. 5,467,489 suggests a pocket mattress where coils springs are enclosed in airtight casings and where check valves are arranged in the bottom and exhaust passages at the top. This results in an airflow through the mattress, which gives a cooling effect to the user. However, no damping is achieved. Also this mattress is of another type than conventional pocket mattresses, comprising separate pocket units which are interconnected by flexible links.
[0006] There is thus a need for a pocket mattress which can be made soft and comfortable and still allow the user to move relatively easily and where the risk of the user falling out of the bed is reduced. There is also a need for a pocket mattress which, while maintaining the positive properties of pocket mattresses in general, also has certain properties that remind of mattresses of visco-elastic materials, such as an initially slow sinking into the mattress when laying down on it. It is also desirable that a mattress with the above-mentioned properties can be manufactured relatively easily and cost-effectively.
OBJECT OF THE INVENTION
[0007] It is therefore an object of the present invention to provide a spring mattress of the type mentioned by way of introduction, as well as a method and a device for manufacturing the same, in which the above related drawbacks are eliminated wholly or at least partly.
[0008] This object is achieved by a spring mattress, a method and a device for manufacturing the same according to the claims.
SUMMARY OF THE INVENTION
[0009] According to one aspect of the invention, a spring mattress for beds is provided, comprising a plurality of strings interconnected side by side, said strings comprising a continuous casing material with a plurality of separate pockets with coil springs enclosed therein, wherein the casing material for at least some pockets is at least substantially airtight and a resistance is provided to air being pressed out when the springs of the mattress are loaded, which, with a uniform load during a transition period, results in a gradually increasing depression of the spring to its depressed state.
[0010] By the casing material being airtight or substantially airtight so that there is a resistance to air penetrating through the material, air can enter the pockets and escape from them, but with a resistance so that this does not occur instantaneously, but slowly over a certain period of time. This can be achieved by, for example, using absolutely tight casing materials in which holes or perforations are arranged to allow an adequate airflow, or by using a not completely airtight material, which itself affords adequate damping of the airflow. By choosing a suitable permeability of the material and/or a suitable number and dimension of the holes, the damping provided can be controlled to a suitable level.
[0011] With the construction according to the invention, the air cushion will be filled in an unloaded state by the enclosed spring expanding the material. When the spring is subjected to a load, the air cushion will first absorb most of the force, and air will be pressed out of the pocket. Due to the flow resistance, this will, however, not occur instantaneously, but gradually during a transition period. As the air gradually leaves the pocket, the spring will absorb more and more of the loading force and then finally absorb the entire force. This results in initial damping and an initial resistance when subjected to a load, which then gradually decreases with the continuing load. This makes it easy, for example, to move in the bed and safely, for example, sit down on the edge of the bed. At the same time the mattress soon, for instance after a few seconds, returns to its spring-loaded, normal state, which means that there is no negative effect on the comfort of the user.
[0012] In this way, the user experiences the same feeling as when using mattresses of visco-elastic materials, such as Tempur® mattresses, where the mattress offers an initial resistance and where the user then slowly sinks into the mattress to be surrounded by the same. However, such visco-elastic mattresses suffer from several drawbacks, such as a great temperature dependence of the mattress properties and a tight surface of the mattress. In the mattress according to the invention, the above-mentioned properties are, however, combined with positive features of pocket mattresses, such as airflow through the mattress, which makes it cool and pleasant to use. Furthermore the mattress properties are quite independent of, for instance, temperature, which results in the same mattress properties being obtained irrespective of the surroundings. This means that the mattress properties can already be controlled in manufacture and that they do not change in use.
[0013] The inventive mattress results in an advantageous initial resistance and a desirable slow sinking of the user into the mattress, while at the same time the mattress is air-permeable between the pocket springs, and has substantially fully temperature-independent properties. In the depressed-state, where the springs themselves support the entire weight of their user, the mattress further functions as a normal pocket mattress.
[0014] The transition period in which a gradually increasing depression of the spring to its depressed state occurs, is preferably in the range of 0.5-20 s, more preferred in the range of 1-15 s and most preferred in the range of 4-12 s, when the spring unit is subjected to a uniform load of 20 N.
[0015] Moreover, the casing material, including any perforations, has an air permeability, measured by a standard testing method, of from 0.15 l/m 2 /s to about 1.6 l/m 2 /s, at a differential pressure of 100 Pa through the casing material.
[0016] In a preferred embodiment of the invention, the strings are arranged side by side by interconnection of the surfaces of the casing materials, preferably by gluing or welding. Further the pockets of the strings are preferably separated by welding.
[0017] According to one embodiment of the invention, it is possible to let all the pockets have the same resistance to air being pressed out when the springs of the mattress are subjected to a load. Alternatively, it is, however, possible to provide a mattress where some pockets are arranged to provide a resistance to air being pressed out when the springs of the mattress are loaded, which resistance is different from that of other pockets. In this way, it is possible to provide zones with different properties in the mattress. For instance, it is advantageous to arrange pockets in the vicinity of the edge of the mattress, which provide a resistance to air being pressed out when the springs of the mattress are loaded, which is greater than the resistance of pockets inwardly in the mattress. This means that the edge of the mattress will be initially harder, which reduces the risk of the user falling when sitting down on the edge of the bed, falling out of the bed and the like. It is also possible to arrange zones with different properties to obtain an adaptation to different parts of the user's body, so that for example parts subjected to a high load, corresponding to, for example, the user's shoulders and pelvis, offer less initial resistance than the other parts of the surface of the mattress.
[0018] Preferably the casing material is a weldable textile material.
[0019] The strings of the spring mattress preferably comprise a plurality of separate pockets which are delimited from each other in a relatively airtight manner. However, it is as an alternative possible for two or more neighbouring separate pockets of at least one of the strings to be delimited from each other in such a manner that a direct airflow between these separate pockets is allowed, for example by a duct or opening being provided between them.
[0020] According to a second aspect of the invention, a method is provided for manufacturing spring mattresses for beds, comprising the steps of
[0021] providing a substantially airtight casing material;
[0022] enclosing coil springs ( 5 ) in separate pockets ( 4 ), which pockets are arranged in strings of continuous pieces of the casing material ( 3 ); interconnecting a plurality of strings ( 2 ) side by side; arranging, before or after the enclosing of the coil springs and the interconnecting of the strings, perforations through the casing material of at least some pockets. With this method, advantages are achieved corresponding to those discussed above with respect to the first aspect of the invention.
[0023] According to yet another aspect of the invention, a device is provided for manufacturing spring mattresses for beds, comprising means for enclosing coil springs ( 5 ) in separate pockets ( 4 ) in a substantially airtight casing material, the pockets being arranged in strings of continuous pieces of the casing material ( 3 ); means for interconnecting a plurality of strings ( 2 ) side by side; and means for arranging perforations through the casing material of at least some pockets. With this device, advantages are achieved, corresponding to those discussed above with respect to the first and the second aspect of the invention.
[0024] These and other advantages of the present invention will be evident from the following detailed description of specific embodiments.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] In the accompanying drawings
[0026] FIG. 1 is a perspective view, seen obliquely from above, of part of a mattress according to an embodiment of the invention;
[0027] FIG. 2 is a perspective view, seen obliquely from above, of part of a mattress according to an alternative embodiment of the invention;
[0028] FIG. 3 is a top plan view of a mattress according to another embodiment of the invention, comprising zones with different properties;
[0029] FIG. 4 is a top plan view of a mattress according to yet another embodiment of the invention, comprising zones with different properties; and
[0030] FIG. 5 is a schematic diagram indicating the ratio of spring height to time after subjecting a mattress according to the invention to a load.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0031] For the purpose of exemplification, the invention will now be described in more detail by way of an embodiment and with reference to the accompanying drawings.
[0032] A spring mattress 1 according to the invention comprises, as shown in FIG. 1 , a plurality of strings 2 which are interconnected side by side. The strings are made of a continuous casing material 3 , with a plurality of separate pockets 4 arranged in the same. Coil springs 5 are enclosed in the pockets.
[0033] The strings 2 can advantageously be made by a casing material being folded around the springs, and connecting lines, such as welds, glue strings or the like, being arranged both in the longitudinal direction of the strings—longitudinal connecting lines 21 —and transversely to the longitudinal direction of the strings—transverse connecting lines 22 —to delimit the springs from each other. This results in a separate pocket for each spring. Preferably the connecting lines 21 , 22 are arranged so as a provide a tight delimitation between the pockets. However, it is also possible to let some of the transverse connecting lines 22 offer a certain airflow between the pockets delimited by them, which thus allows an airflow between two or more neighbouring pockets. The longitudinal connecting lines 21 can either be arranged above the ends of the enclosed springs, in a manner as illustrated in FIG. 1 , or alternatively be arranged at the side of the springs.
[0034] The strings of springs are further preferably arranged side by side, as indicated in FIGS. 1 and 2 . Preferably, the strings are connected to each other by 2 - 3 vertically distributed fixing points just opposite of each spring. Of course, a smaller or greater number of fixing points is conceivable. It is also possible to arrange a longer fixing line substantially parallel to the longitudinal direction of the springs instead of a plurality of shorter fixing points. The connection of the strings to each other can occur by welding or gluing. However, the connection can alternatively occur by means of clamps, by Velcro tape or in some other suitable manner.
[0035] Preferably, the mattress as described above is manufactured by strings of interconnected pocket springs in casings first being manufactured automatically, after which these strings are cut in suitable lengths and joined to each other side by side to form mattresses.
[0036] Coil springs of many sizes can be used in connection with the present invention, and basically any size of springs can be used. However, it is preferred to use springs with a diameter of 1-10 cm, and most preferred about 6 cm. The springs comprise preferably at least three turns, and preferably less than 10 turns. Moreover they are advantageously made of spiral wire with a thickness in the range of 0.5-3.0 mm, preferably a thickness in the range of 1.25-2.50 mm.
[0037] The casing material for at least some pockets is further at least substantially airtight, and preferably the casing material for substantially all pockets of the mattress is at least substantially airtight. This can be achieved by using a material which is relatively airtight, but still has a certain air permeability, in which case a certain, limited airflow through the material is made possible. Preferably, however, a substantially fully airtight material is used, but with small perforations 23 or the like to allow a certain, limited airflow into and out of the pockets. Preferably, these holes or perforations 23 are arranged so as to open into the gaps occurring between neighbouring pocket units.
[0038] The casing material preferably comprises a sandwich material, comprising a supporting layer of a durable, and preferably weldable, material, and a sealing layer which is substantially airtight. The supporting layer can suitably be made of a textile material, while the sealing layer suitably can be made of some kind of synthetic material, such as polyurethane. However, it is alternatively possible to use a homogeneous material, which is both relatively durable and relatively airtight.
[0039] The casing material, in combination with the perforations, if any, preferably provides an air permeability which is sufficient to obtain the desired properties of the mattress, as discussed above. The average air permeability of the casing material, including any perforations, can be measured, for example, by a standard method, such as SS-EN ISO 9237:1995, and with a differential pressure of 100 Pa through the casing material. The air permeability is in this case preferably in the range of 0.15-1.6 l/m 2 /s, and most preferred in the range of 0.3-1.4 l/m 2 /s.
[0040] The substantially airtight pockets result in a resistance to air being pressed out when the springs of the mattress are subjected to a load, which, with a uniform load during a transition period, results in a gradually increasing depression of the spring to its depressed state.
[0041] The depression of a spring of the mattress as described above at a constant loading force is schematically illustrated in the diagram in FIG. 5 . When the loading force is introduced, the spring is initially compressed relatively quickly, during a phase A, during which the air expands the side walls of the pocket and the spring absorbs substantially the entire depressing force. The depression occurring during this phase can be controlled, for example, by adaptation of the size of the casing of the pockets etc. After this initial depression, the enclosed air expands the pocket and prevents further depression, and after that depression occurs relatively slowly while the air is being pressed out through the perforations of the pocket and/or through the slightly air-permeable casing material. During this phase B a slow reduction of the height of the spring takes place, while the air cushion forming in the pocket absorbs at least some of the loading force. Eventually, so much air has been pressed out that the spring absorbs substantially the entire depressing force. In this situation, no further air flows out of the pocket, nor does further compression of the spring take place. This state of equilibrium is in FIG. 5 designated phase C.
[0042] The transition from the spring being subjected to a load until the state of equilibrium (phase C) is achieved is due to several factors, such as the air permeability of the casing material, the number and size of perforations, if any, the size of the depressing force, the size of the spring etc. However, these parameters are suitably selected so that in normal use, with the spring unit subjected to a load in the range of 20 N, the transition time amounts to a period in the range of 0.5-20 s, preferably in the range of 1-15 s, and most preferred in the range of 4-12 s. This transition time consists almost exclusively of phase B as discussed above, while phase A takes place so quickly that in terms of time it is substantially negligible in the context.
[0043] In the embodiment according to FIG. 1 , the perforations 23 are arranged substantially in the centre of the circumferential surfaces of the spring units, but radially arranged so as not to be positioned just in front of neighbouring spring units. This embodiment functions excellently for most mattresses, and results in a well-balanced airflow into and out of the mattress. However, many alternative locations of the perforations 23 are conceivable. For example, such an alternative is illustrated in FIG. 2 . In this embodiment, holes or perforations 23 are likewise arranged so as to open into the gaps that arise between neighbouring pocket units, but are also arranged in the upper side and/or the underside of the spring units, that is on or near the ends of the spring units. In the specific embodiment shown, the perforations are arranged in the upper side of the mattress. This embodiment is suitable, for instance, when the spring units are configured so that the spring turns in use can block the perforations when positioned just in front of these. In the embodiment in FIG. 2 , this problem is effectively eliminated since here the perforations are arranged on casing portions which are arranged between spring turns of different sizes. Moreover the perforations are in the shown embodiment not arranged symmetrically scattered, but are offset toward the centre line of the string, preferably toward a longitudinal connecting line which is arranged there.
[0044] This is advantageous since for natural reasons some excess casing material is collected near this connecting line, which further reduces the risk of the perforations being blocked in use.
[0045] It is also possible to use different pockets with different resistances to air flowing into and out of the pockets in different zones of the mattress. An example of a mattress with such different zones is illustrated in FIG. 3 . In this embodiment, the pocket units in a zone 71 along the edge of the bed are configured to have a higher resistance to air flowing out of the pockets than the other pockets of the mattress. This reduces the risk of the user, for instance, falling out of the bed. Moreover, in this example two zones 72 and 73 are provided with pocket units, which are configured to have a lower resistance to air flowing out of the pockets than the other pockets of the mattress. Consequently, the portions of the mattress which in normal use are subjected to high loads, that is where the user's pelvis and shoulders are placed, will have less resistance to changes and will more quickly sink down to the depressed state of equilibrium when the user makes himself comfortable in the bed. However, it will be appreciated that many other divisions into zones over the mattress are possible. These zones have different transition times when subjected to a load until the state of equilibrium is achieved. In a special case, it is possible to let some zones have an almost non-existent resistance to air, such as in conventional pocket units, and/or have zones with an almost total resistance to air, where the pockets do not release the air, or release the air only very slowly, in which case supporting air cushions are formed at least during a longer transition time.
[0046] An alternative division into zones is illustrated in FIG. 4 . In this division into zones, two special zones 72 ′ and 73 ′ are provided with pockets units, which are configured to have a lower resistance to air flowing out of the pockets than the other pockets of the mattress, which zones are arranged to extend over substantially the entire width of the mattress. As a result, the portions of the mattress which in normal use are subjected to high loads, that is where the user's pelvis and shoulders are placed, will have a lower resistance to changes, and more quickly sink down to the depressed state of equilibrium when the user makes himself comfortable in the bed.
[0047] A division into zones is easy to make and adjust by changing, for example, the number or size of the perforations of the pockets. In this way, it is easy to provide different zones in different portions of the mattress, without necessitating any major changes in the manufacturing process. Manufacture will thus be very flexible and controllable and allows, for instance, easy individualisation and custom-design of the mattresses.
[0048] A device for manufacturing spring mattresses of the type described above comprises means for enclosing coil springs in separate pockets in a casing material in such a manner that the pockets are arranged in strings of continuous pieces of the casing material, and means for interconnecting a plurality of strings side by side. Many such means for manufacturing pocket units in strings and for interconnecting such strings are per se already well-known and therefore need not be described in more detail in this patent specification. Furthermore the manufacturing device preferably comprises means for arranging perforations through the casing material of at least some pockets. This perforating means may comprise, for example, one or more puncturing, cutting or burning tips, which are moved towards the casing material so as to make perforations of a suitable shape and size, and in the intended positions relative to the pockets that are formed or are to be formed. Conveniently the device is designed so that perforation occurs after the forming of the strings, that is in the completed pockets, but before connecting the strings to each other. However, it is also possible to perform the perforation after interconnecting the strings, or in the casing material even before the forming of the strings.
[0049] The invention has been described above by way of embodiments. However, several variants of the invention are conceivable. For example, as mentioned above, other types of fastening elements can be used to connect the strings to each other, as well as other casing materials, spring sizes, different divisions into zones etc. Such obvious variants must be considered to be covered by the invention as defined by the appended claims.
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A spring mattress for beds is disclosed. In at least one embodiment, the spring mattress includes a plurality of strings which are interconnected side by side and include a continuous casing material with a plurality of separate pockets with coil springs enclosed therein. Moreover the casing material for at least some pockets is at least substantially airtight, thus providing a resistance to air being pressed out when the springs of the mattress are loaded, which, when subjected to a uniform load during a transition period, results in a gradually increasing depression of the spring to its depressed state. This results in a comfortable mattress, into which the user sinks gradually and which thus is comfortable and safe and allows the user to move easily. A corresponding method and device for manufacturing such a mattress are also described.
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BACKGROUND OF THE INVENTION
The present invention relates to a transporting apparatus with an articulated conveying element, in particular for conveying products for charging packaging machines.
Various developments of transport systems for conveying products, in particular for use in packaging machines, are known from the prior art. These types of transport systems are known, for example, from U.S. Pat. No. 6,876,896 B1 and U.S. Pat. No. 5,225,725 B1. The transport systems, in this case, are to have as compact a design as possible, attempts being made to design the fixed, peripheral running rail, in particular in the curved region, with as small a radius as possible. In order, in this case, however, to keep the air gap between the curved primary part and the permanent magnets, which are located on a flat iron counter plate on the rigid conveying element, approximately constant, certain boundaries are placed on the radii such that the known transport systems take on a relatively large radius of curvature and require a correspondingly large space for installation. In addition, in particular in the curved region there is increased wear caused by the slip movement of the running rollers, which shortens the maintenance intervals for the transport systems.
SUMMARY OF THE INVENTION
In contrast, the advantage of the transporting apparatus for conveying products is that, in particular through the possibility of reducing the radii in the curved regions with a constant air gap between the curved primary parts and the permanent magnets, the design of said transporting apparatus is very compact and takes up little space. This is achieved in that the transporting apparatus comprises transporting elements which have at least one first part element and one second part element, said part elements being connected to one another in an articulated manner by means of an articulation. This means that smaller curve radii are made possible, which results in the above-mentioned saving on installation space. In addition, the articulated conveying elements make it possible for the carrying capacity of the conveying elements to be able to be increased in a significant manner by the relatively large number of running rollers and a larger spacing between the running rollers of the conveying elements. A further advantage of the conveying is that play-free guiding of the conveying elements is also possible in curved regions of the conveying section or at the transition between linear regions and curved regions. In addition, changes in the linear overlap between coils, which are arranged in the conveying section, and permanent magnets, which are arranged on the conveying element and form a linear motor driving device, can be achieved by means of the articulated conveying elements. This means that feeding power losses are avoided and in addition the electromagnet feeding power is not restricted in the case of small turning radii. Direct power flow in the conveying direction is possible without additional torque load such that the conveying elements can circulate at high dynamics. A further big advantage is that conveying elements can now be constructed in a modular manner, it being possible simply to add or leave out individual part elements. This means that there is increased variability in the transport system and the possibility of a modular system for different applications and customers.
In a particularly preferred manner, one running roller is arranged in each case on each part element of a conveying element. This achieves particularly stable and smooth running of the conveying elements. In addition, the running rollers always remain in contact with the rail even in the curved region as a result of the flexibility of the conveying element.
In a further preferred manner, at least one of the running rollers is arranged on an articulated axis between two part elements. This means that an axis of the running roller and the articulated axis are located in a common axis, as a result of which the flexibility of the guide element is increased in a significant manner.
The transporting apparatus comprises a guide device with a guide rail on the running rail and at least one guide element on the conveying element, in particular a guide roller. This means that it is possible to realize secure guiding of the conveying elements. In a particularly preferred manner, the conveying element comprises at least three guide elements, wherein one guide element is arranged on a first side of the guide rail and two guide elements are arranged on a second side of the guide rail for secure guiding.
For as stable a running behavior as possible, each conveying element has at least one first running wheel group and one second running wheel group. The two running wheel groups, in this case, are arranged on a first or second side of the guide element and give the conveying element the necessary stability.
In a further preferred manner, the conveying element comprises a contact element, in particular a protruding pusher finger, for contact with the products to be conveyed, said pusher finger preferably being arranged so as to be interchangeable. Consequently, the product can be conveyed simply and securely and the contact element can be adapted to different products in a simple manner, for example by replacement.
A particularly smooth and stable running behavior is produced when the conveying element preferably has precisely three or precisely five part elements. Precisely three part elements are preferred in particular as a result of the short axial installed length in the conveying direction.
Particularly secure guiding of the conveying element is produced when at least one guide element, in particular a guide roller, is arranged on each of the part elements. The guiding is preferably realized as center guiding.
The permanent magnets on the conveying element are preferably realized in a cuboid shape. In this case, the permanent magnet is preferably arranged in such a manner that an articulated axis of the articulation and a corner of the permanent magnet are located on a straight line, i.e. the articulation axis runs precisely in the center between the pairs of permanent magnets. This means that an inadmissibly large change in the spacing between the permanent magnets and the coils which are arranged in the running rail is able to be avoided in the curved region of the transporting apparatus.
In a further preferred manner, the running rollers of the conveying elements are provided with a plastics material running surface and are realized in a spherical manner. This means that there is no need to lubricate the running rollers and the running rollers are in particular insensitive in relation to contaminants on the running rail, if such are present.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred exemplary embodiments of the invention are described in detail below with reference to the accompanying drawing, in which:
FIG. 1 shows a schematic, perspective view of a conveying element on a running rail according to a first exemplary embodiment of the invention,
FIG. 2 shows a schematic front view of the conveying element,
FIG. 3 shows a schematic top view of the conveying element,
FIG. 4 shows a schematic representation of the conveying element cornering,
FIG. 5 shows a perspective representation of conveying elements cornering,
FIG. 6 shows a perspective representation of a conveying element according to a second exemplary embodiment of the invention, and
FIG. 7 shows a perspective representation of the conveying element of the second exemplary embodiment on a running rail.
DETAILED DESCRIPTION
A transporting apparatus 1 according to a first preferred exemplary embodiment of the invention is described in detail below with reference to FIGS. 1 to 5 .
As can be seen from FIG. 1 , the transporting apparatus 1 comprises a conveying element as well as a running rail 3 , which is only shown in part in FIG. 1 and is provided in a fixed and peripheral manner. The running rail 3 has a design with linear part regions as well as curved regions such that in total an oval-shaped section is produced. In addition, it is also possible to have other forms of running tracks, e.g. shaped in an angular manner, which are assembled from modular linear and curved elements. The running rail 3 comprises a first running track 11 , a second running track 12 and a guide rail 13 which is arranged between the two running tracks. In addition, there is provided a linear motor driving device 4 , which comprises a plurality of coils 6 which are arranged in the running rail 3 and permanent magnets 5 which are arranged on the conveying element 2 . This means that it is possible to realize a transporting apparatus with a plurality of conveying elements 2 which are driven independently of each other. In this case, an electromagnetic moving field is generated by means of the coils 6 , the conveying elements 2 following the moving field by means of magnetic coupling and consequently being moved along the running rail.
The conveying element 2 , which can be seen in particular from FIG. 1 , comprises a first part element 21 , a second part element 22 and a third part element 23 , adjacent part elements being connected to each other in an articulated manner in each case by means of an articulation 7 (see FIG. 3 ). In this case at least one running roller 8 or a permanent magnet is provided on each of the part elements 21 , 22 , 23 . As can be seen from FIG. 3 , in this case the running rollers 8 which are arranged on a first side of the guide rail 13 form a first running roller group 81 and the running rollers 8 which are arranged on a second side of the guide rail 13 form a second running wheel group 82 . As can be seen from FIG. 1 , the first running wheel group 81 runs on the first running track 11 and the second running roller group 82 runs on the second running track 12 . As can also be seen from FIGS. 1 , 2 and 3 , two guide rollers 9 are arranged on the conveying elements 2 , said guide rollers rotating on the second side of the guide rail 13 to guide the conveying element 2 . As can be seen in particular from FIG. 3 , articulated axes 10 , on which the part elements are connected together in an articulated manner, are also the rotation axes of the running rollers 8 . In this case, a maximum pivot angle of the part elements with respect to one another is restricted by the running rollers 8 . As an alternative to this, stops which restrict the pivoting of adjacent part elements with respect to one another can also be provided in the part elements. On the upper surface of the conveying element 2 , interfaces are provided in the individual part elements 21 , 22 , 23 in order to attach format parts such as, for example, a pusher finger. The individual part elements 21 , 22 , 23 , in this case, have an identical basic design such that an arbitrary number of part elements are able to be connected together. In this exemplary embodiment, a three-member conveying element 2 is shown in FIG. 1 . FIG. 5 , in this case, also shows a five-member conveying element 2 ′ along with the three-member conveying element 2 .
A sensor board, which extends around the periphery and is in operative connection with a second permanent magnet 15 (cf. FIG. 2 ), is additionally provided laterally to the running rail 3 in order to determine an exact position of the conveying element 2 on the running rail 3 .
FIG. 4 shows the transition of the conveying element 2 from a linear running rail region to a curve in the running rail 3 . It is possible to provide a small curve radius as a result of the articulated arrangement of the part elements 21 , 22 , 23 . As indicated by the broken line A, in this case spacing between the permanent magnets 5 and the coils 6 which are arranged in rows remains constant even in the curved region. As can be seen from FIG. 4 , in this case the articulated axes 10 , which, at the same time, are also the axes of the running rollers 8 , are arranged in the corner regions of the permanent magnets 5 . The constant spacing can also be ensured in the curved region through this measure.
Consequently, it is possible to realize smaller curve radii by means of the articulated conveying element 2 such that the transporting apparatus 1 overall is designed to be much more compact than in the prior art. The conveying elements 2 , in this case, can be designed in a very compact manner. In particular, in this case, turning radii of 100 mm and less are possible on the curves.
FIGS. 6 and 7 show a transporting apparatus 1 according to a second exemplary embodiment of the invention, identical or functionally identical parts being designated with the identical references as in the first exemplary embodiment.
The second exemplary embodiment corresponds substantially to the first exemplary embodiment, the difference to the first exemplary embodiment being a third guide roller 9 also being provided additionally on the conveying element 2 (see FIG. 6 ). In this case the guide rollers 9 are arranged in such a manner that one guide roller is arranged on one side of the guide rail 13 and two guide rollers are arranged on the other side of the guide rail. This means that a more load-bearing center guiding can be made possible. In addition, the conveying element 2 of the second exemplary embodiment comprises four running rollers 8 per running roller group, in each case two running rollers 8 being arranged on both sides of a plane E in which the articulations 7 are located.
As can also be seen from FIG. 7 , a steel rail 16 is additionally arranged on the running rail 3 extending around the periphery. The steel rail 16 is provided in order to enable amplification of the magnetic attractive force for the individual conveying elements 2 . The steel rail 16 , in this case, as can be seen from FIG. 7 , is arranged on one side of the guide rail 13 , the coils 6 of the linear motor driving device 4 being provided on the other side of the guide rail 13 .
The running rail 3 is also designed in a modular manner and can be realized with an arbitrary length by providing a plurality of linear parts. In addition, curved parts with various radii can be provided in order, in this way, to meet the different demands which are preset by the transporting job.
Otherwise, this exemplary embodiment corresponds to the first exemplary embodiment such that reference can be made to the description given there.
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The invention relates to a transporting apparatus for conveying a product, comprising a movable conveying element ( 2 ) for conveying the product, also comprising a fixed-location running rail ( 3 ), which is arranged all the way round and defines a running track for the conveying element ( 2 ), and further comprising a linear-motor-drive means ( 4 ) for driving the conveying element ( 2 ), wherein the conveying element ( 2 ) has a permanent magnet ( 5 ) which is in operative connection with coils ( 6 ) of the linear-motor-drive means ( 4 ), and wherein the conveying element ( 2 ) has at least a first sub-element ( 22 ) and a second sub-element ( 23 ), which are connected to one another in an articulated manner by means of an articulation ( 7 ).
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CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims priority under 35 U.S.C. §119 to Korean Patent Application No. 10-2013-0018066 filed on Feb. 20, 2013, the subject matter of which is hereby incorporated by reference.
BACKGROUND OF THE INVENTION
[0002] The inventive concept relates generally to electronic memory technologies. More particularly, certain embodiments of the inventive concept relate to memory systems that perform address mapping for a nonvolatile memory device using a bad page map.
[0003] Memory devices may be roughly divided into two categories according to whether they retain stored data when disconnected from power. These categories include volatile memory devices, which lose stored data when disconnected from power, and nonvolatile memory devices, which retain stored data when disconnected from power.
[0004] Examples of volatile memory devices include static random access memory (SRAM) devices, dynamic random access memory (DRAM) devices, and synchronous DRAM (SDRAM) devices. Examples of nonvolatile memory devices include flash memory devices, read only memory (ROM) devices, programmable ROM (PROM) devices, electrically erasable and programmable ROM (EEPROM) devices, and various forms of resistive memory such as phase-change RAM (PRAM), ferroelectric RAM (FRAM), and resistive RAM (RRAM).
[0005] Most nonvolatile memory devices tend to wear out at a rate determined by usage. For instance, flash memory devices tend to wear out at a rate determined by the number of erase or program operations that have been performed. Where certain memory cells are used more often than others, they may wear out sooner, resulting in localized regions of defective or unreliable cells, such as “bad blocks”, “bad pages”, “bad sectors”, and so on.
[0006] To preserve reliability in the face of local deterioration, memory systems that incorporate flash memory devices and other types of nonvolatile memory devices typically include mechanisms for managing memory cells that have worn out. One technique is to remap addresses of defective regions to non-defective regions. Such remapping, however, may unduly increase the overhead of memory management, and it may also prevent some pages of memory from being used because they belong to a block that has been deemed worn out.
SUMMARY OF THE INVENTION
[0007] In one embodiment of the inventive concept, a memory system comprises a nonvolatile memory comprising a memory block having multiple pages, and a controller configured to control the nonvolatile memory to store data in the memory block according to a command and logical address received from an external source. The controller is configured to determine whether the logical address is currently mapped to a bad page of the memory block by referring to a bad page map, and as a consequence of determining that the logical address corresponds to the bad page, remaps the logical address to a different page and stores dummy data in the bad page.
[0008] In another embodiment of the inventive concept, a memory system comprises a nonvolatile memory comprising a memory block having multiple pages, and a controller configured to control the nonvolatile memory to store data in the memory block according to a command and logical address received from an external source. The controller is configured to determine whether the logical address is currently mapped to a bad page of the memory block by referring to a bad page map, and as a consequence of determining that the logical address corresponds to the bad page, remaps the logical address to a different page and stores dummy data in the bad page. The controller is further configured to determine whether a number of times that an erase operation has been performed on the memory block has reached a predetermined reference value, and as a consequence of determining that the number of times that an erase operation has been performed on the memory block has reached the predetermined reference value, update the bad page map based on a bad page list comprising information indicating whether each of multiple different pages is a bad page according to different numbers of erase values.
[0009] In another embodiment of the inventive concept, a method is provided for operating a memory system comprising a nonvolatile memory. The method comprises controlling the nonvolatile memory to store data in the memory block according to a command and logical address received from an external source, determining whether the logical address is currently mapped to a bad page of the memory block by referring to a bad page map, and, as a consequence of determining that the logical address corresponds to the bad page, remapping the logical address to a different page and stores dummy data in the bad page.
[0010] These and other embodiments of the inventive concept can potentially increase the lifetime and performance of memory cells by managing remapping operations on a page-by-page basis.
BRIEF DESCRIPTION OF THE DRAWINGS
[0011] The drawings illustrate selected embodiments of the inventive concept. In the drawings, like reference numbers indicate like features.
[0012] FIG. 1 is a block diagram illustrating a memory system in accordance with an embodiment of the inventive concept.
[0013] FIG. 2 is a diagram illustrating a bad page map in accordance with an embodiment of the inventive concept.
[0014] FIG. 3 is a flowchart illustrating a method of updating a bad page map in accordance with an embodiment of the inventive concept.
[0015] FIG. 4 is a table illustrating an example of a bad page list.
[0016] FIG. 5 is a flowchart illustrating a method of updating a bad page map in accordance with an embodiment of the inventive concept.
[0017] FIG. 6 is a flowchart illustrating a method of updating a bad page map in accordance with an embodiment of the inventive concept.
[0018] FIG. 7 is a flowchart illustrating a method of updating a bad page map in accordance with an embodiment of the inventive concept.
[0019] FIG. 8 is a flowchart illustrating a method of writing data of a nonvolatile memory device in accordance with an embodiment of the inventive concept.
[0020] FIG. 9 is a block diagram illustrating a solid state drive (SSD) comprising a memory system in accordance with an embodiment of the inventive concept.
[0021] FIG. 10 is a block diagram illustrating a memory card comprising a nonvolatile memory device in accordance with an embodiment of the inventive concept.
[0022] FIG. 11 is a drawing illustrating various systems comprising a memory card in accordance with embodiments of the inventive concept.
DETAILED DESCRIPTION
[0023] Embodiments of the inventive concept are described below with reference to the accompanying drawings. These embodiments are presented as teaching examples and should not be construed to limit the scope of the inventive concept.
[0024] FIG. 1 is a block diagram illustrating a memory system 10 in accordance with an embodiment of the inventive concept.
[0025] Referring to FIG. 1 , memory system 10 comprises a nonvolatile memory device 100 and a host 101 . Nonvolatile memory device 100 comprises a controller 110 and a nonvolatile memory 120 . Controller 110 comprises a controller processor 111 and a controller memory.
[0026] During typical operation, nonvolatile memory device 100 classifies a page in which data is damaged or at risk or damage as a bad page. Then, in an address mapping operation, nonvolatile memory device 100 does not map a logical address to a physical address of the page classified as a bad page.
[0027] Because nonvolatile memory device 101 prevents data from being stored in bad pages, it can have improved lifetime and improved accuracy. In a write operation, nonvolatile memory device 101 programs dummy data in a page classified as a bad page to improve a write speed.
[0028] Host 101 is configured to access nonvolatile memory device 100 . Host 101 relies on nonvolatile memory device 100 to store data that is generated or used by various functions it performs. In other words, nonvolatile memory device 100 stores data processed by host 101 .
[0029] Controller 110 provides an interface between nonvolatile memory 120 and host 101 . Controller 110 drives firmware to control nonvolatile memory 120 . Controller 110 controls read, write, and erase operations of nonvolatile memory 120 using the firmware in response to a request of host 101 .
[0030] Controller processor 111 controls operations of controller 110 . In certain implementations, controller processor 111 drives firmware for controlling nonvolatile memory 120 .
[0031] Controller memory 112 can operate as a working memory of controller 110 , a buffer memory between host 101 and nonvolatile memory 120 and a cache memory of nonvolatile memory 120 .
[0032] Nonvolatile memory 120 stores data under control of controller 110 . The type of nonvolatile memory 120 may be, for instance, ROM, programmable ROM (PROM), electrically programmable ROM (EPROM), electrically erasable programmable ROM (EEPROM), flash memory, PRAM, MRAM, RRAM, or FRAM, for example, although it is not limited to these types of memory.
[0033] In a write operation, host 101 provides write-requested data and a logical address of the data to nonvolatile memory device 100 . Nonvolatile memory device 100 stores the data in nonvolatile memory 120 in response to a request of host 101 .
[0034] A flash translation layer (FTL) is stored in controller memory 112 of controller 110 . A bad page map representing a bad page is also stored in controller memory 112 . The FTL and the bad page map may be loaded from a nonvolatile memory into controller 110 into controller memory 112 , or from nonvolatile memory 120 into controller memory 112 .
[0035] Where controller 110 receives a write request, controller 110 maps a logical address LA provided from host 101 to a physical address PA of nonvolatile memory 120 using the FTL. In a mapping operation, controller 110 precludes a logical address from being mapped to a physical address of a bad page by referring to the bad page map.
[0036] In a write operation, controller 110 controls nonvolatile memory 120 so that dummy data is written in a bad page. Where multiple pages are programmed at a time, controller 110 controls nonvolatile memory 120 so that a bad page and a normal page are programmed together with each other by programming dummy data in a bad page.
[0037] Controller 110 updates a bad page map in response to a program/erase cycle or elapsed time. Controller 110 updates a bad page map to continuously classify as bad pages those where data is damaged or at risk of damage.
[0038] Nonvolatile memory device 100 can classify a page in which data is damaged or at risk of damage as a bad page to prevent a logical address from being mapped to the classified bad page. The management of damaged memory cells on a page-by-page basis can potentially improve the lifetime of nonvolatile memory device 100 compared with management on a block-by-block basis.
[0039] Although nonvolatile memory device 100 is described as selecting and managing a bad page, the relevant unit could alternatively be defined by a word line. For example, nonvolatile memory device 100 may classify a word line connected to a page in which data is damaged or at risk of damage as a bad word line and can prevent a logical address from being mapped to pages connected to the classified bad word line. In this case, nonvolatile memory device 100 can classify a bad page as a page sharing a word line with a bad page to exclude that a logical address is mapped.
[0040] Nonvolatile memory device 100 can use various algorithms to classify a page in which data is damaged or at risk of damage as a bad page. Nonvolatile memory device 100 can continuously update a bad page map.
[0041] FIG. 2 is a diagram illustrating a bad page map in accordance with an embodiment of the inventive concept. In the embodiment of FIG. 2 , the bad page map has a form of bitmap. However, this is as an illustration and the inventive concept is not limited to the bitmap. Alternatively, for instance, the bad page map may have a form of a list or tree structure.
[0042] Referring to FIG. 2 , the bad page map comprises bits corresponding to each physical page of nonvolatile memory 120 . In the bad page map, a bit corresponding to a page classified as a bad page may be set to be 1. A bit corresponding to a page classified as a normal page may be set to be 0. With reference to the bad page map, in the case that a page is represented by a bad page, controller 110 may not map a logical address to a physical address of the corresponding page.
[0043] FIG. 3 is a flowchart illustrating a method of updating a bad page map in accordance with an embodiment of the inventive concept. In the method of FIG. 3 , a bad page map is updated according to the number of program/erase cycles performed on a selected block as well as a bad page list. The bad page list indicates pages determined to be unreliable (i.e., damaged or at risk of being damaged) when reaching a certain number program/erase cycles.
[0044] As an example, FIG. 4 is a table illustrating a bad page list. In this example, the bad page list comprises bits representing whether each page is determined to be a bad page or not with respect to different numbers program/erase cycles. For example, a “1” under column labeled “10” indicates that a corresponding page is damaged or at risk of being damaged after 10 program/erase cycles.
[0045] In general, pages of nonvolatile memory 120 have different physical characteristics from each other. A physical characteristic of each of the pages of nonvolatile memory 120 can be evaluated in advance using experimental data with respect to a predetermined sample. Accordingly, the bad page list can be generated with reference to an evaluated physical characteristic of each page.
[0046] In a data processing operation, control processor 111 loads a bad page list in controller memory 112 . Controller processor 111 performs a mapping operation with reference to the bad page list. The bad page list is loaded from nonvolatile memory 120 into controller memory 112 . The bad page list may be loaded from a nonvolatile memory in controller 110 into controller memory 112 .
[0047] Referring to FIG. 3 , the method performs a program or erase operation on a selected page or memory block of nonvolatile memory 120 (S 110 ). Then, the method determines, for the selected page or pages among the selected memory block, whether a corresponding program/erase count is greater than or equal to a corresponding reference value (S 110 ). The corresponding reference value may be determined by consulting a bad page list. Typically, the corresponding reference value, for the selected page or a page among the selected block, is a lowest number of program/erase cycles in the bad page list for which that page is marked as being unreliable. For instance, using the example bad page list of FIG. 4 , the reference value for a fifth page in the list is “10” because the page has a “1” under the column marked “10”.
[0048] If the count is not greater than or equal to the reference value (S 120 =No), the count is increased (S 125 ). After the count increases, the method is completed. Otherwise, if the count is greater than or equal to the reference value, the bad page map is updated with reference to the bad page list (S 130 ). The bad page map classifies pages determined to be bad pages in the bad page list with respect to the current count with reference to the bad page list. Finally, the count is increased (S 140 ), and method is completed.
[0049] As indicated by the above description, the method of FIG. 3 updates of the bad page map based on information stored in the bad page list, in combination with the number of program/erase cycles of each page.
[0050] FIG. 5 is a flowchart illustrating a method of updating a bad page map in accordance with an embodiment of the inventive concept. In the method of FIG. 5 , the bad page map is updated in response to a bit error rate (BER).
[0051] Referring to FIG. 5 , a write operation is performed on nonvolatile memory 120 (S 210 ). Thereafter, data stored in pages on which the write operation of step S 210 is performed is read out (S 220 ). A BER is calculated for the data read from each page.
[0052] Next, pages representing a bit error rate higher than a predetermined threshold value are classified as bad pages (S 230 ). The bad page map is updated based on results of the classification. The predetermined threshold value is stored in nonvolatile memory device 100 . The predetermined threshold value may be set in response to an external signal provided from host 101 .
[0053] A threshold voltage of a memory cell in each page of nonvolatile memory 120 is changed with the lapse of time. A threshold voltage of a memory cell is changed by an interference phenomenon by adjacent memory cells. Examples of the interference phenomenon are a F-poly coupling and lateral charge spreading.
[0054] Besides interference by adjacent memory cells, a threshold voltage of a memory cell may be changed by read disturbance. A threshold voltage of a memory cell may be changed by a reduction of the quantity of charges of a memory cell over time.
[0055] A threshold voltage of a memory cell may be changed by various factors besides the factors described above. A threshold voltage may be changed by factors such as a process fail, distortion due to channel instability and program disturbance.
[0056] Because a threshold voltage of a memory cell is changed as time passes, data stored in each page of nonvolatile memory 120 may become unstable as time goes by. Reliability of data stored in each page of nonvolatile memory 120 may become highest immediately after a write operation is performed.
[0057] The method of FIG. 5 determines whether a page is a bad page or not on the basis of a bit error rate of data read from the page right after a write operation is performed. Because the method reads out data right after a write operation is performed, it can reduce an effect by read disturbance or factors changing a threshold voltage in the process of judging whether a page is a bad page.
[0058] FIG. 6 is a flowchart illustrating a method of updating a bad page map in accordance with an embodiment of the inventive concept. In the method of FIG. 6 , the bad page map is updated in response to a program/erase cycle and a BER.
[0059] Referring to FIG. 6 , a program or erase operation is performed on nonvolatile memory 120 (S 310 ). Thereafter, a count and a reference value are compared with each other (S 320 ). The count represents the number of program/erase cycles that have been performed on a selected block. If the count does not reach the reference value (S 320 =No), the count increases and the method ends (S 325 ). The reference value may be stored in nonvolatile memory device 100 . The reference value may be set in response to an external signal provided from host 101 . If the count is greater than the reference value (S 320 =Yes), data stored in pages of the selected block is read out (S 330 ). A bit error rate is calculated for the read data.
[0060] Next, pages having a bit error rate higher than a predetermined threshold value are classified as bad pages (S 340 ). On the basis of a classification result, a bad page map is updated. Thereafter, a value of the count is reset and the update operation is over (S 350 ).
[0061] As indicated by the above description, the method of FIG. 6 determines whether a page is a bad page or not on the basis of a BER when the number of program/erase cycles reaches the predetermined reference value. In the method, a BER measured in response to a program/erase cycle with respect to the selected block may be considered.
[0062] FIG. 7 is a flowchart illustrating a method of updating a bad page map in accordance with an embodiment of the inventive concept. In the method of FIG. 7 , the bad page map is updated in response to time that elapsed after a write operation is performed and a BER.
[0063] Referring to FIG. 7 , a program or erase operation is performed on nonvolatile memory 120 (S 410 ). Next, an elapsed time and a reference value are compared with each other in a selected page (S 420 ). The elapsed time is time that elapsed after a write operation is performed in the selected page or after the elapsed time is reset. If the elapsed time has not reached the reference value (S 420 =No), the method ends. The reference value is stored in nonvolatile memory device 100 . The reference value may be set in response to an external signal being provided from host 101 .
[0064] If the elapsed time is greater than the reference value (S 420 =Yes), data stored in pages of the selected block is read out (S 430 ). A bit error rate is calculated for the read data.
[0065] Pages having a bit error rate higher than a predetermined threshold value are classified as bad pages (S 440 ). On the basis of a classification result, a bad page map is updated. Thereafter, the elapsed time is reset and the method ends (S 450 ).
[0066] As indicated by the above description, the method of FIG. 7 periodically determines whether a page is a bad page or not at every predetermined time interval. For example, the method can classify pages having a bit error rate higher than a predetermined threshold value when time of a certain percentage, for example, 80%, of data retention time elapsed as a bad page. According to the above method, a bit error rate measured in response to time that elapsed after a write operation is performed may be considered.
[0067] FIG. 8 is a flowchart illustrating a method of writing data of a nonvolatile memory device in accordance with an embodiment of the inventive concept. In the method of FIG. 8 , nonvolatile memory device 100 prevents a logical address from being mapped to a physical address of a page classified as a bad page with reference to a bad page map. Because nonvolatile memory device 100 does not use a page in which data is at risk of damage as a storage space, it may have improved lifetime and improved accuracy.
[0068] Referring to FIG. 8 , a write request is provided from host 101 (S 510 ). Host 101 may provide a write command, file data of write-requested data and a logical address to nonvolatile memory device 100 .
[0069] Next, a logical address provided from host 101 is mapped to a physical address of nonvolatile memory 120 (S 520 ). Nonvolatile memory device 100 maps a logical address to a physical address with reference to the bad page map. Nonvolatile memory device 100 prevents a logical address from being mapped to a physical address classified as a bad page with reference to the bad page map. Subsequently, the write-requested data is written in an area of nonvolatile memory 120 corresponding to the physical address to which the logical address is mapped (S 530 ).
[0070] As indicated by the above description, in the method of FIG. 8 , nonvolatile memory device 100 classifies a page in which data is damaged or at risk of damage as a bad page and stores a classification result in a bad page map. Nonvolatile memory device 100 prevents a page classified as a bad page from being used as a data storage space with reference to the bad page map in the mapping process. Because nonvolatile memory device 100 does not store data in the bad page, it may have improved lifetime and improved accuracy.
[0071] FIG. 9 is a block diagram illustrating an SSD 1000 comprising a memory system in accordance with an embodiment of the inventive concept.
[0072] Referring to FIG. 9 , SSD 1000 comprises a host 1100 and a SSD 1200 . Host 1100 comprises a host interface 1121 , a host controller 1120 and a DRAM 1130 .
[0073] Host 1100 stores data in SSD 1200 or reads data stored in SSD 1200 . Host controller 1120 transmits a signal SGL such as a command, an address, a control signal and an ID representing category of file to SSD 1200 through SSD 1200 . DRAM 1130 is a main memory of host 1100 .
[0074] SSD 1200 exchanges signal SGL with host 1100 through host interface 1211 and receives power from a power supply through a power connector 1221 . SSD 1200 comprises multiple nonvolatile memories 1201 ˜ 120 n , a SSD controller 1210 and an auxiliary power supply 1220 . Nonvolatile memories 1201 ˜ 120 n may be embodied by a PRAM, a MRAM, an ReRAM, a FRAM, etc. besides a NAND type flash memory.
[0075] Nonvolatile memories 1201 ˜ 120 n are used as a storage medium. Nonvolatile memories 1201 ˜ 120 n may be connected to SSD controller 1210 through multiple channels CH 1 ˜CHn, with one or more nonvolatile memories connected to one channel. Nonvolatile memories 1201 ˜ 120 n may also be connected to the same data bus.
[0076] SSD controller 1210 exchanges signal SGL with host 1100 through host interface 1211 . Signal SGL may comprise a command, an address, data, etc. SSD controller 1210 writes data in a corresponding nonvolatile memory or reads data from a corresponding nonvolatile memory according to a command of host 1100 .
[0077] Auxiliary power supply 1220 is connected to host 1100 through power connector 1221 . Auxiliary power supply 1220 can be provided with power from host 1100 to be charged. auxiliary power supply 1220 may be located inside SSD 1200 or outside SSD 1200 . For example, auxiliary power supply 1220 may be located in a main board and may provide an auxiliary power to SSD 1200 .
[0078] SSD 1200 classifies a page in which data is at risk of damage as a bad page and stores a classification result in a bad page map. SSD 1200 prevents a page classified as a bad page from being used as a data storage space with reference to the bad page map in the mapping process. Because SSD 1200 does not store data in the bad page, it may have improved lifetime and improved accuracy.
[0079] FIG. 10 is a block diagram illustrating a memory card 2000 comprising a nonvolatile memory device in accordance with an embodiment of the inventive concept. Memory card 2000 may be, for example, a MMC card, a SD card, a multiuse card, a micro SD card, a memory stick, a compact SD card, an ID card, a PCMCIA card, a SSD card, a chip card, a smart card, a USB card, etc.
[0080] Referring to FIG. 10 , memory card 2000 comprises an interface part 2100 performing an interface with the outside, a controller 2200 having a buffer memory and controlling an operation of memory card 2000 and at least one of nonvolatile memory devices 2300 . Controller 2200 is a processor and can control write and read operations of nonvolatile memory device 2300 . Controller 2200 couples to nonvolatile memory device 2300 and interface part 2100 through a data bus DATA and an address bus ADDRESS.
[0081] Memory card 2000 classifies a page in which data is at risk of damage as a bad page and stores a classification result in a bad page map. Memory card 2000 prevents the page classified as a bad page from being used as a data storage space with reference to the bad page map in a mapping process. Because memory card 2000 does not store data in the bad page, it may have improved lifetime and improved accuracy.
[0082] FIG. 11 is a drawing illustrating various systems using a memory card in accordance with embodiments of the inventive concept.
[0083] Referring to FIG. 11 , memory card 2000 may be used in a video camera, a television, an audio device, a game device, an electronic music device, a cellular phone, a computer, a personal digital assistant (PDA), a voice recorder and a PC card.
[0084] A nonvolatile memory device in accordance with an embodiment of the inventive concept can be mounted using various types of packages such as package on package (PoP), ball grid array (BGA), chip scale package (CSP), plastic leaded chip carrier (PLCC), plastic dual in-line package (PDIP), die in waffle pack, die in wafer form, chip on board (COB), ceramic dual in-line package (CERDIP), plastic metric quad flat pack (MQFP), thin quad flat pack (TQFP), small outline (SOIC), shrink small outline package (SSOP), thin small outline (TSOP), thin quad flatpack (TQFP), system in package (SIP), multi chip package (MCP), wafer-level fabricated package (WFP) and wafer-level processed stack package (WSP).
[0085] Because the above described nonvolatile memory devices are managed by page unit, their lifetime and accuracy can be improved.
[0086] The foregoing is illustrative of embodiments and is not to be construed as limiting thereof. Although a few embodiments have been described, those skilled in the art will readily appreciate that many modifications are possible in the embodiments without materially departing from the scope of the inventive concept. Accordingly, all such modifications are intended to be included within the scope of the inventive concept as defined in the claims.
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A memory system comprises a nonvolatile memory comprising a memory block having multiple pages, and a controller configured to control the nonvolatile memory to store data in the memory block according to a command and logical address received from an external source. The controller is configured to determine whether the logical address is currently mapped to a bad page of the memory block by referring to a bad page map, and as a consequence of determining that the logical address corresponds to the bad page, remaps the logical address to a different page and stores dummy data in the bad page.
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This invention relates to pressure rollers for roofing machines.
In the construction or maintenance of decks or generally flat-roofed buildings, it is customary to build up a moisture barrier by laying down alternate layers of liquid asphalt and roofing felt or similar material. The felt may advantageously be laid by a roofing machine which consists basically of a wheeled frame which is pulled across the roof by an operator. The frame carries a roll of felt mounted on a storage roller, and a pressure roller which rolls along the roof surface and presses the felt web dispensed from the storage roller against the asphalt layer previously laid down beneath it. A machine of this general type is shown in my U.S. Pat. No. 4,243,468.
It is important, in order to maintain a uniform quality and structure of the moisture barrier, that the pressure roller apply uniform pressure to the felt web throughout the width of the roller, and that the roller be straight when seen from above so as to lay down the web in a straight line. Inasmuch as the roof or deck surface is frequently irregular or uneven, these two requirements call for an inconsistent behavior of the pressure roller: it must be easily flexible in a vertical direction so as to follow the contour of the surface and press against it with uniform force, yet it must be totally rigid in a direction parallel to the roof surface so as to maintain the straight positioning of the web.
SUMMARY OF THE INVENTION
The present invention solves the problem of the above-mentioned inconsistent requirements for the pressure roller by constructing the outer shell of the pressure roller so as to form a flexible cylinder, and mounting that cylinder by means of spaced bearings on a flat axial support member generally in the nature of a leaf spring which is deformable in a direction perpendicular to the roof but not in any other direction.
In order to achieve a generally uniform pressure along the entire width of the roller, the leaf spring of this invention is originally formed, in its unloaded condition, in the shape of a curve defined approximately by a formula discussed in detail in this specification. When a roller mounted on a leaf spring of that curvature is placed against a more or less flat surface, the curvature is flattened out and an approximately constant force is exerted by the roller against the surface throughout its entire width.
In accordance with another aspect of the invention, the entire roller assembly, including its leaf spring support, is resiliently suspended from the frame of the roofing machine so that the axis of the pressure roller need not necessarily be parallel to the axis of the roofing machine's wheels. This enables the pressure roller to maintain a uniform pressure even when the machine is traversing an irregular surface.
It is therefore the object of this invention to provide a pressure roller which is easily deformable in a direction generally perpendicular to the surface on which it rolls while being essentially nondeformable in any direction parallel to the surface on which it rolls.
It is another object of the invention to provide a pressure roller construction which enables the pressure roller to follow contour variations in the surface while maintaining a uniform pressure against the surface throughout its width.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation, partly schematic, of the pressure roller of this invention showing its relation to a roofing machine;
FIG. 2 is a front elevation of the pressure roller assembly of this invention as positioned on a flat surface, including its leaf spring-type supporting means and its suspension from the frame of the roofing machine;
FIG. 3 is a front elevation similar to FIG. 2 but showing the roller adapting to a depression in the surface;
FIG. 4 is a perspective view of the leaf spring-type roller supporting means of this invention;
FIG. 5 is a vertical section of the roller of this invention along its axis; and
FIG. 6 is a vertical section of the roller along line 6--6 of FIG. 5.
DESCRIPTION OF THE PREFERRED EMBODIMENT
FIG. 1 shows, in somewhat schematic form, a roofing machine 10 whose essential elements are a frame 12 supporting a roll 14 of roofing felt and having a handle 16 by which it can be pulled along a roof in the direction of arrow A. The machine rests on wheels 18 and, in operation, on the pressure roller 20 which is the object of this invention. The web 22 of roofing felt is dispensed from the roll 14 and is guided around the pressure roller 20 which presses it against a surface on which a liquid asphalt or adhesive layer 24 has previously been spread. Alternatively, the asphalt or adhesive may be coated on the web itself. As the machine is drawn forward, a small bead 28 of asphalt or adhesive forms in front of the pressure roller 20. The existence of this bead indicates to the operator that the asphalt layer 24 is sufficiently liquid to produce satisfactory adhesion to the web 22. The uniformity of the bead 28 is also an indication to the operator that the web 22 is being pressed against the asphalt layer 24 with uniform force throughout its width.
Referring now to FIG. 2, it will be seen that the pressure roller 20 is mounted on a support member 30 which preferably takes the form of a leaf spring as best illustrated in FIG. 4. The leaf spring 30 is suspended from the frame 12 by a pivot bracket 32 on one end, and a spring-loaded sliding bracket 34 on the other end. The compression spring 36 allows the axis of roller 20 as defined by support member 30 to tilt with respect to the frame of the machine 10, so as to allow the roller to follow the contour of a roof of varying pitch.
A comparison of FIG. 4 (which shows the leaf spring 30 in its unstressed condition) with FIGS. 2 and 3 (which show the leaf spring and roller as they would look when placed onto a flat surface and an uneven surface, respectively, will show that the leaf spring 30 as well as the roller 20 are deformed vertically in use so as to follow the contour of the roof surface 26 over which the roller 20 is being drawn.
The operation of the roller 20 will be more apparent from an examination of FIGS. 5 and 6, which illustrate the internal structure of the roller 20. The outer surface of roller 20 is formed by a suitable covering 40 made of a resilient material such as rubber. The covering 40 is maintained in a generally cylindrical shape by a helical spring 42 which extends throughout the entire width of the roller 20. The support member or leaf spring 30 extends through the center of the roller 20 and defines its axis. Bearing blocks 44a through 44g are fixedly mounted on the leaf spring 30 by a pin 45. The bearing blocks support ball bearings 46a through 46g whose inner and outer races are connected, respectively, to the bearing blocks 44 and the helical spring 42. The number of bearings 46 is dictated by a suitable compromise between economics and effectiveness. The greater the number of bearings, the more uniform the force distribution will be along the width of the roller 20, but at a greater cost and greater weight.
The shape of the leaf spring 30 is best seen in FIGS. 3 and 6. It will be clear from an examination of those figures that the leaf spring 30 can be deformed relatively easily in a vertical direction in FIG. 5 but is quite stiff in the horizontal plane. For this reason, the roller 20 can readily adapt itself to large or small contour variations in the roof surface but will always present a perfectly straight line from viewed from above.
One of the requirements for effective operation of the roller is that it should press the web 22 against the asphalt layer 24 (FIG. 1) with as uniform a force as possible throughout its width. The pressure (in pounds per linear inch) can be expressed as ##EQU1## where W is the weight of the pressure roller 20 in pounds, L is the length of the roller in inches, and F is the downward force applied to the brackets 32, 34.
It has been found that, in order to distribute this pressure as evenly as possible throughout the width of the roller 20, the initial curvature of the leaf spring 30, in its unstressed condition of FIG. 4, should be ##EQU2## where y is the deflection (in inches) of leaf spring 30 at any given point; F is the downward force (in pounds) applied by the frame 12 against the bracket 34; L is the length (in inches) of the roller; I is the moment of inertia of the cross-section of the leaf spring 30; E is the modulus of elasticity of the leaf spring material; and x is the distance (in inches) of the given point from the bracket 34.
It should be understood that equation (2) is an approximation and is generally valid only if the loads F are applied close to the ends of the roller 20, and the maximum deflection of leaf spring 30 is small in comparison to the length of roller 20. Variations in the pressure applied to the web 22 will of course arise to some degree due to the fact that the bearings 46 are discrete rather than continuous, and from the size and severity of any contour variations in the roof surface. However, a leaf spring 30 shaped in accordance with formula (2) above will normally produce a sufficient approximation of a uniform force distribution to be suitable for most practical applications.
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A pressure roller for roofing machines is disclosed which is capable of following dips, rises, and pitch variations in the roof surface along its width while remaining stiff and straight in the directions parallel to the roof surface. A uniform force distribution along the width of the roller is achieved by mounting the roller for rotation about a leaf spring which, in its unstressed condition, has the shape of a curve.
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BACKGROUND OF THE INVENTION
[0001] The present invention relates to a clamping device for various objects and, in particular, to a cable tie for constraining plural objects.
[0002] A number of fastening or clamping devices have been devised for a variety of purposes. For example, clamps are used with electrical systems to connect electric shielding or insulation about electric wires, especially about electrical connectors that receive current carrying conductors. Clamps used in such applications are typically referred to as cable ties.
[0003] Cable ties generally are of one-piece construction, consisting of a metal or plastic band with a buckle or head attached rigidly to one end of the band. The free end of the band feeds through the buckle to form a loop enclosing the electrical wires. The buckle typically contains locking teeth or tabs which interlock with slots or teeth in the band during band adjustment to retain a desired periphery of the band.
[0004] Disadvantages associated with prior cable ties result from the bulky, irregularly contained buckles typically used. Such buckles, in addition to being aesthetically displeasing, frequently inflict damage or injury when inadvertently contacted by objects or persons.
[0005] The object of this invention, therefore, is to provide a cable tie with an improved low profile and smoothly contoured head.
SUMMARY OF THE INVENTION
[0006] The invention is a latchable tie for tieing together plural objects and including a flexible strap with an elongated section defining a longitudinal axis and having a substantially uniform transverse width, a head end, a tail end, an upper surface and a lower surface; the lower surface defining a plurality of longitudinally spaced apart first teeth extending transversely to the axis; and a head defining an outer end portion, an inner end portion joined to the strap, an outer opening in the outer end portion, an inner opening in the inner end portion, a channel extending between the outer opening and the inner opening and adapted to receive the tail end of the strap, a bottom surface for contacting a portion of the objects being tied, an upwardly opening cavity disposed between the inner opening and the strap, and a cavity opening in the bottom surface and communicating vertically with the cavity; and the cavity and cavity opening each having a transverse width greater than the uniform transverse width of the strap. Also included is a latch mechanism disposed in the channel and defining upwardly projecting longitudinally spaced apart second teeth for engaging the first teeth. After insertion of the tail end of the strap through the channel in the head and severing an excess portion of the tail end, the cavity and cavity opening retain a remaining portion of the tail end.
[0007] According to one feature of the invention, the strap further includes a transition section joining the elongated section and the inner end portion of the head, the cavity and cavity opening are straddled by transversely spaced apart connection portions of the head, the connector portions extend between the inner opening and the transition section, and the transition section defines an inclined ramp surface partially defining the cavity and sloping upwardly from the cavity opening toward the strap. The ramp surface upwardly directs the tail end of the strap to facilitate severing thereof.
[0008] According to another feature of the invention, the elongated section has a uniform transverse cross-sectional area, and the connecting portions together define between the inner opening and an inner end of the cavity opening a combined minimum aligned transverse cross-sectional area substantially equal to or larger than the uniform cross-sectional area. The minimum cross-sectional area prevents the existence of a rupturable weak point in the strap.
[0009] According to an additional feature of the invention, the connector portions are tapered downwardly from the inner opening to the transition section. The tapered connector portions desirably enhance the flexibility of the head.
[0010] According to further features of the invention, the transition section has transverse cross-sectional areas diminishing between the head and the elongated section, and also defines transversely spaced apart side surfaces and upper and lower connecting surface portions extending therebetween with at least one of the connecting surface portions defining transverse recesses. The transition section provides a structurally sound connection between the head and strap and the recesses facilitate bending of the transition section to accommodate the curvature of a bundle being secured.
[0011] According to still other features of the invention, the head further defines a bottom opening in the bottom surface and communicating with the channel; and the latch consists of a pawl defining the second teeth, one end portion disposed in the bottom opening and projecting below the bottom surface, and an opposite end portion movably joined to the head so as to allow movement of said one end portion into the channel. In response to forces produced by contact of the one end portion with a portion of the objects being tied, the second teeth on the pawl are forced into tighter engagement with the first teeth on the strap.
[0012] According to yet another feature of the invention, the tie includes a guide joined to the outer end portion and defining an uncovered, guide surface aligned with the longitudinal axis and terminating at the outer opening; the guide surface having a length l at least {fraction (1/4)} a length L of the channel. The guide surface is arranged to guide the tail end of the strap through the outer opening during use of the tie.
[0013] According to another feature of the invention, the guide also includes wall portions straddling the guide surface and having inner surfaces joined to the guide surface by concave joint portions. The wall portions further facilitate insertion of the strap into the head and the joint portions enhance the structural strength of the guide to prevent rupture thereof.
DESCRIPTION OF THE DRAWINGS
[0014] These and other objects and features of the invention will become more apparent upon a perusal of the following description taken in conjunction with the accompanying drawings wherein:
[0015] [0015]FIG. 1 is a top perspective view of a cable tie according to the invention;
[0016] [0016]FIG. 2 is a bottom perspective view of the cable tie;
[0017] [0017]FIG. 3 is a bottom perspective view of a head portion of the cable tie;
[0018] [0018]FIG. 4 is a top view of the head;
[0019] [0019]FIG. 5 is a longitudinal cross-section taken along lines 5 - 5 of FIG. 4;
[0020] [0020]FIG. 6 is a transverse cross-sectional view taken along lines 6 - 6 of FIG. 4;
[0021] [0021]FIG. 7 is a transverse cross-sectional view taken along lines 7 - 7 of FIG. 4;
[0022] [0022]FIG. 8 is a partial longitudinal sectional view of the tie after insertion of the strap into the head;
[0023] [0023]FIG. 9 is a partial top perspective view of the tie after insertion and termination of the excess strap portion; and
[0024] [0024]FIG. 10 is a sectional view taken longitudinally in FIG. 9.
DESCRIPTION OF THE PREFERRED EMBODIMENT
[0025] A tie II for securing together multiple articles such as cables is illustrated in FIGS. 1 - 10 . Forming the tie 11 is an insertion guide portion 12 , a flexible strap 13 , a head 14 joining the guide portion 12 and the strap 13 , and a latch 15 attached to the head 14 . The head 14 includes an outer end portion 18 joined to the guide portion 12 and an inner end portion 19 joined to the strap 13 . Defined by the head 14 is a channel 21 for receiving the strap 13 (FIGS. 8 - 10 ) during use of the tie 11 . The channel 21 extends between an outer opening 22 defined by the outer end portion 18 of the head 14 and an inner opening 23 defined by the inner end portion 19 . Also formed by the inner end portion 19 forming the channel 21 are top wall 28 and side wall 29 portions (FIG. 5) of the head 14 which wall portions retain the strap 13 within the channel as shown in FIG. 8, of the head 14 is an upwardly opening cavity 26 extending between the inner opening 23 and the strap 13 . Communicating vertically with the cavity 26 and overlain thereby is another opening 27 also extending between the inner opening 23 and the strap 13 .
[0026] The strap 13 includes an elongated section 31 with a longitudinal axis X and a transition section 32 joining the head 14 to the elongated section 31 . Defined by the elongated section 31 is a head end 35 joined to the transition section 32 and a tail end 36 for insertion into the channel 21 through the outer opening 22 of the head 14 . Also defined by the elongated section 31 are an upper surface 37 and a lower surface 38 , a major length of which defines a plurality of longitudinally spaced apart first teeth 39 extending transversely to the axis X. The elongated section 31 has a uniform cross-section and corresponding uniform width. Defined by the transition section 32 are side surfaces 41 and 42 joined by an upper and lower connecting surfaces 43 , 44 extending between the side surfaces 41 , 42 . A plurality of transversely extending groove recesses 46 are formed in the upper connecting surface 43 and a plurality of similar transversely extending groove recesses 47 are formed in the lower connecting surface 44 . As shown in FIGS. 4 and 5 the transition section 32 has diminishing transverse cross-sections extending between the head 14 and the elongated section 31 .
[0027] The cavity 26 is partially formed by an inclined ramp surface 51 at an inner end of the transition section 32 . As shown in FIG. 5, the ramp surface 51 slopes upwardly from an inner edge 52 of the cavity opening 27 to the upper connecting surface 43 of the transition section 32 . Further defining the cavity 26 are inner surfaces 53 , 54 of, respectively, connector portions 56 , 57 of the head 14 which connector portions extend between the inner opening 23 and the transition section 32 . Preferably, both the cavity 26 and the another opening 27 have transverse widths substantially equal to the uniform width of the elongated strap section 31 so as to accommodate its passage after exiting the channel 21 of the head 14 . As shown in FIG. 5, the connector portions 56 , 57 taper downwardly from the inner end portion 19 of the head 14 to the ramp surface 51 so as to have therebetween diminishing transversely aligned cross-sectional areas. Preferably however, a minimum combined aligned transverse cross-sectional area of the connector portions 56 , 57 anywhere between the inner opening 23 and the inner end of the another opening 27 is substantially equal to the uniform cross-sectional area of the elongated strap section 31 so as to conserve material and not establish a structural weakness subject to rupture by tensile forces applied to the tie 11 . The combined transverse cross-sectional area at the inner end of the another opening 27 is shown in FIG. 6.
[0028] The latch 15 is a flexible pawl 61 located in a bottom opening 62 in the bottom surface 25 of the head 14 . One end portion 64 of the pawl 61 is disposed in the bottom opening 62 and projects below the bottom surface 25 while an opposite end 65 thereof is movably secured to the outer end portion 18 of the head 14 . Defined in an upper surface of the pawl 61 are a plurality of longitudinally spaced, transversely extending second teeth 68 arranged to engage the first teeth 39 in response to insertion of the elongated section 31 of the strap 13 into the channel 21 through the outer opening 22 . The pawl 61 is separated from the bottom surface 25 by longitudinally extending slots 69 each having an open outer end and an inner end closed by a radius joint 70 with the head 14 .
[0029] Defined by the guide portion 12 is an uncovered guide surface 71 aligned with the axis X and terminating at the outer opening 22 of the head 14 . Straddling the guide surface 71 are upwardly directed wall portions 73 , 74 . Inner surfaces 75 , 76 , respectively, of the wall portions 73 , 74 are joined to the guide surface 71 by concave radius joint portions 77 , 78 which strengthen the guide portion 12 . The guide surface 71 and wall portions 73 , 74 direct movement of the tail end 36 of the elongated strap 31 through the outer opening 22 of the head during insertion of the strap 13 into the channel 21 . To facilitate that function, the guide surface 71 has a longitudinal length l at least {fraction (1/4)} the longitudinal length L of the channel 21 and preferably at least {fraction (1/2)} thereof as shown in FIG. 4. The minimum length of the guide portion 12 also provides strength to prevent rupture during application of tensile stress to the tie 11 . Also, as shown in FIG. 8, the maximum thickness of the head 14 is less than three times the uniform thickness of the strap 13 to provide the tie 11 with a low profile.
[0030] In use, the tie 11 is secured, for example, around a bundle of objects such as cables. During the securement process, the tail end 36 of the elongated strap 31 is passed, as shown in FIG. 8, sequentially through the outer opening 22 , the channel 21 , the inner opening 23 and the cavity 26 . The tail end 36 then is pulled to tightly tension the tie 11 around the bundle (not shown). Insertion of the strap 13 through the channel 21 of the head 14 is facilitated by guidance of the tail end 36 along the guide surface 71 . In a final tightened position of the tie 11 , the second teeth 68 on the pawl 61 engaged adjacent first teeth 39 on the lower surface 38 of the elongated strap section 31 so as to prevent reverse loosening movement of the strap 13 within the head 14 . As the tie is tightened on the bundle, engagement of portions thereof with the pawl 61 exerts an upwardly directed force on a lower surface of the pawl 61 so as to more tightly engage the first and second teeth 39 , 68 . As the tail end 36 of the strap exits the inner opening 23 , engagement with the ramp surface 51 produces upward movement of the exiting strap as shown in FIG. 8 to facilitate severing of the exited excess strap portion. After the excess strap portion is severed, the remaining terminal portion 80 of the flexible strap flexes downwardly into the cavity 26 (FIGS. 9 and 10 ) so as to eliminate undesirable projections from the head 14 . Full reception of the terminal end 80 into the head is facilitated by the vertical communication between the cavity 26 and the cavity opening 27 .
[0031] Obviously, many modifications and variations of the present invention are possible in light of the above teachings. It is to be understood, therefore, that the invention can be practiced otherwise than as specifically described.
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A latchable tie including a flexible strap with an elongated section having spaced apart first teeth, a head end, a tail end, an upper surface and a lower surface; and a head defining an outer end portion, an inner end portion joined to the strap, an outer opening in the outer end portion, an inner opening in the inner end portion, a channel extending between the outer opening and the inner opening and adapted to receive the tail end of the strap, a latch mechanism disposed in the channel and defining upwardly projecting longitudinally spaced apart second teeth for engaging the first teeth.
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This is a continuation of copending application Ser. No. 07/258,003 filed on 10/14/88, now abandoned.
BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention is related to specific types of pigment compositions which are especially suited to both oil-based and water-based systems, as well as processes for flexographic printing using these pigment compositions. More particularly, the pigment composition of the present invention comprises an alkali blue pigment. The pigment composition of the present invention exhibits a high strength and soft texture in comparison with prior art pigment compositions made from similar ingredients.
2. The Related Art
The closest related art of which applicants are aware includes the following U.S. Pat. Nos.: 4,456,485; 4,383,865; 4,032,357.
U.S. Pat. No. 4,383,865, to Iyengar, discloses a process for preparing a soft textured, high strength Alkali Blue pigment composition which comprises insolubilized amines. This composition is made by mixing a solution of alkali blue crude first with an alkaline solution of an alkyl aryl sulfonic acid, then with an acidic solution having from 3 to 36 carbon atoms, following which the pigment composition is recovered. In the '865 patent the preferred group of alkyl aryl sulfonic acids has from 1 to 14 carbon atoms. The most preferred alkyl aryl sulfonic acid appears to be dodecylbenzene sulfonic acid.
U.S. Pat. No. 4,456,485, also to Iyengar, discloses a process for preparing easily dispersible high color strength powdered alkali blue pigments by precipitating the pigment in the presence of various acids and/or amines, and/or esters, and/or alcohols, etc., as well as the product of these processes.
U.S. Pat. No. 4,032,357, assigned to Sherwin-Williams Company, discloses a substantially anhydrous, free-flowing alkali blue pigment composition having an organic anionic dispersant coprecipitated therewith. Furthermore, the pigment and dispersant are admixed with an oil phase in order to reduce the hydrophilic aggregation of the coprecipitated pigment and dispersant. The specific organic dispersants used in the '357 patent are Gafac® RS-710 and Gafac® RS-610.
As can be seen in the appended claims, the scope of the present invention is limited to pigment compositions comprising alkali blue pigment in combination with:
(1) di- and tri- decyl phosphate esters of free acids; and
(2) dehydroabietyl amine.
In contrast, none of the related patents listed above recites this specific combination of elements. Furthermore, none of these related patents refers to flexographic printing.
BRIEF SUMMARY OF THE INVENTION
The present invention relates to both a product and a process. The product is a dry toner useful in both water-based and oil-based printing inks. The product comprises:
(a) between 60 percent, by weight, and 98 percent, by weight, alkali blue pigment particles;
(b) between 1 percent by weight and 20 percent by weight of a surfactant selected from the group consisting of di- and tri- decyl phosphate esters of free acids;
(c) between 1 percent by weight and 20 percent, by weight, of dehydroabietyl amine, said weights based on the total composition.
The process of the present invention is a flexographic printing process in which an ink is applied to a flexible plate in a flexographic printing machine. The ink used in this process comprises the toner which is the product of the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
It has been unexpectedly found that a particular combination of surfactants, when incorporated with an Alkali Blue pigment, produce a pigment product having the desirable characteristic of exhibiting high strength when used in either water flexo or oil ink end uses. The surfactants utilized are (1) di- and tri- decyl phosphate esters of free acids, together with (2) dehydroabietyl amine.
The di- and tri- decyl phosphate esters which have been found to be advantageous in the product and process of the present invention comprise:
TABLE I______________________________________Manufacturer Trade Name Class and Formula______________________________________GAF Chemi- Gafac ® BG-510 free acid of a complexcals Corp. organic phosphate esterGAF Chemi- Gafac ® RA-600 free acid of a complexcals Corp. organic phosphate esterGAF Chemi- Gafac ® RD-510 free acid of a complexcals Corp. organic phosphate esterGAF Chemi- Gafac ® RS-410 free acid of a complexcals Corp. organic phosphate esterGAF Chemi- Gafac ® RS-610 free acid of a complexcals Corp. organic phosphate esterGAF Chemi- Gafac ® RS-710 free acid of a complexcals Corp. organic phosphate esterSybron Chemi- Tanaterge PE-37 sodium salt of complexcals, Inc. organic phosphate esterCyclo Corpora- Cyclophos ® PL6A free acid of organiction phosphate esterCyclo Corpora- Cyclophos ® TD6 free acid of a complextion organic phosphate esterDexter Chemi- Strodex ® SEK-50 potassium salt of complexcal Corp. organic phosphoric acid ester anhydride______________________________________
Additional di- and tri- decyl phosphate esters of free acids are useful in the product and process of the present invention.
The second surfactant used in dehydroabietyl amine. Although the product and process both utilize between 1 weight percent and 20 weight percent of both (1) dehydroabietyl amine and (2) the di- and tri-decyl phosphate ester/free acid surfactant, it is most preferred to utilize approximately 5 weight percent of the phosphate ester surfactant and approximately 5 weight percent of dehydroabietyl amine.
Example 1 (below) illustrates a most preferred process for making a most preferred product of the present invention. Example 2 illustrates a comparative product. Following the Examples are comparative results of pigment strength. These results indicate that the pigment composition of the invention is superior to the toner made in the comparative example. The superiority of the toner of the invention extends to both water flexo and oil ink end uses. The comparative composition was weaker in strength than the toner of the invention. This is very significant, as less of a toner is required where the toner has a higher strength. As can be seen in Table II, the toner of the present invention (i.e. Toner #1) was "stronger" than a comparative toner of the prior art (i.e. Toner #2). By the phrase "11 parts weaker" it is meant that 11 more parts of the weaker toner were required in order to achieve the strength of the standard.
EXAMPLE 1
This example illustrates how to make a preferred embodiment of the product of the present invention.
826 Grams of a 2 percent by weight aqueous sodium hydroxide solution containing 90 grams of Alkali Blue pigment was poured into a one liter beaker. [The alkali blue pigment had been produced by phenylation of parafuchsine with aniline, sulfonation with sulfuric acid, and was finally drowned in water.] 5.0 Grams of an alkyl phosphate ester (Gafac RS®-610) was then added to the beaker. The resulting mixture was then heated to and maintained at 60° C.
In a separate 3 liter beaker, 10.0 grams of a 50% solution of dehydroabietyl amine (e.g. Amine D Acetate) was dissolved in 1600 grams of a 2.4% by weight aqueous hydrochloric acid solution, at 60° C. The alkaline solution of pigment was slowly added to the HCl solution. The pH of the resulting mixture was adjusted to 0.85 and the slurry was heated to 95° C., and held at this temperature for 10 minutes. The resulting pigment dispersed very easily and was strong in tint in both oleoresinous and acrylic flexographic vehicles.
EXAMPLE 2 (COMPARATIVE)
795 Grams of a 2 percent by weight aqueous sodium hydroxide solution containing 88 grams of alkali blue pigment was poured into a 1-liter beaker. The alkali blue pigment was made as described in Example 1. 6.0 Grams of dodecyl benzene sulfonic acid was added to the beaker, and the resulting mixture was heated to, and maintained at, a temperature of 60° C.
In a separate 3-liter beaker, 6.0 grams of dimethyloctadecylamine were dissolved in 1300 grams of a 2 percent by weight aqueous hydrochloric acid solution at 60° C. The alkaline solution of pigment was slowly added to the HCl solution. The pH of the resulting mixture was adjusted to 0.85. The mixture was then heated to a boil. After 3 minutes, the slurry was flooded with cold water to a temperature of 60° C.
PIGMENT STRENGTH COMPARISON FOR EXAMPLES 1 and 2
The toners produced in Examples 1 and 2 (above) were compared for strength in an acrylic water flexo system and in a conventional oil ink. The following procedures were utilized in order to compare the toner of the invention with the toner made via Comparative Example 2. The results of these tests are shown in Table II.
WATER FLEXO TEST METHOD
The acrylic water flexo test method was carried, out as follows: a 42.0 gram portion of the alkali blue toner was added to 238.0 grams of an acrylic vehicle system. The dry pigment was wetted into the vehicle system, and 800 grams of 0.125 inch diameter steel shot was added. The container was sealed and placed on a shaker for 25 minutes. The resulting ink was discharged and reduced with water to a specific print viscosity. The printone strength was measured by comparing the toner of the present invention to the comparative toner described in Example 2. A 2.00 gram portion of the finished ink was then added to 40.00 grams of a white tint base. This mixture was then placed on a shaker for 15 minutes. The tint strength was then comparatively measured from this sample.
OIL INK TEST METHOD
The oil ink test method was carried out as follows: A 0.500 gram portion of alkali blue dry toner was added to 1.000 gram of conventional vehicle system. This mixture was then ground on a Hoover muller for 3 passes; each pass consists of 50 revolutions. The resulting ink paste was then removed from the muller and a 0.100 gram portion was mixed into 5.000 grams of a conventional tinting white. The ultimate strength was obtained from this sample.
TABLE II______________________________________ Water Flexo Oil InkToner from Printone Tint UltimateExample Strength Strength Strength______________________________________1 (standard) (standard) (standard)2 9 parts weak 11 parts weak 14 parts weak______________________________________
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The alkali blue dry toner comprises 60 to 98 weight percent alkali blue pigment particles, 1 to 20 weight percent of di- and tri-decyl phosphate esters of free acids, and 1-20 weight percent of dehydroabietyl amine. The toner exhibits a high strength and soft texture in comparison with prior art pigment compositions made from similar ingredients.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention in general relates to bubble detection, and particularly to the detection of bubbles in the drilling mud of offshore drilling operations.
2. Description of the Prior Art
In the drilling of an oil or gas well, drilling fluid referred to in the industry as "mud," is pumped into the drill pipe where it proceeds out through the drill bit and up the annular space between the drill pipe and the walls of the hole. The purpose of the circulating mud is to clean, cool and lubricate the bit, flush to the surface the cuttings from the bore hole and to protect the walls of the hole until casing is inserted. The density of the mud is carefully controlled at the surface so as to contain various pressures encountered in the hole.
As a well is drilled into the vicinity of an oil deposit, gases may be released form porous rock and find their way into the circulating mud. The presence of such gas in the mud may modify the buoyancy of the drilling string and can cause extensive damage if it goes undetected. Instances have been recorded where drill pipe has been thrown straight up from the well with consequent extensive damage to the drill rig and other equipment when falling back to earth.
Blowouts have been known to cause disastrous fires, and in many instances the gases released may be noxious, such as hydrogen sulfide.
In offshore drilling, without proper controls, emerging gases may disrupt footings of rigs, causing capsizing, and in other instances floating vessels may actually sink since they cannot float on a layer of bubbles.
Presently, detection of down hole conditions is made by an examination of the circulating mud, at the surface. What is needed, however, is the detection of bubbles at a relatively early stage so as to allow corrective action to be immediately taken.
Several acoustic methods have been proposed for the detection of bubbles; however, not in the field of oil well drilling. For example, one system has been proposed for detecting bubbles from leaking containers having pressurized gas therein. The arrangement immerses the containers to be tested in a liquid and an acoustic doppler system is utilized for projecting acoustic energy into the liquid. The appearance of any bubbles from a leaking container causes a doppler frequency shift, indicative of the leak. Such a system, however, for use in conjunction with an oil well would not operate satisfactorily since the presence of solid particulate matter being carried by the drilling mud would cause a doppler readout, even without the presence of gas bubbles.
SUMMARY OF THE INVENTION
The present invention detects bubbles in a liquid subject to inclusion of solid particles which can scatter acoustic energy and includes a relatively low frequency acoustic generation system which is operable to project acoustic energy into a region of the liquid to insonify it with standing waves. A second system in the form of a relatively higher frequency acoustic motion detection system is operable to detect motion of the bubbles in the region, displaced due to the low frequency insonification.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a block diagram of the basic concept of the present invention;
FIG. 2 is a view of an offshore drilling operation;
FIG. 3 is a block diagram of one embodiment of the present invention;
FIG. 4 illustrates the movement of bubbles and particulate matter under the influence of a sound field;
FIG. 5 is the trigger waveform for the transmitter of FIG. 3;
FIGS. 6A and 6B are frequency spectrums of the doppler system of FIG. 3 for off and on conditions of the transmitter;
FIGS. 7A and 7B are plan views of two positioning arrangements for the transducers utilized in FIG. 3; and
FIG. 8 is a view of an alternate transducer placement for a fluid conducting pipe.
DESCRIPTION OF THE PREFERRED EMBODIMENT
In FIG. 1 a low frequency acoustic generation system 10 provides repetitive tone bursts of acoustic energy to insonify a region 12 under investigation. Passing through the region 12 in the direction of arrow 13 is a fluid containing both solid particles 14 shown in black and gas bubbles 15 shown as circles.
By way of example, the frequency of the acoustic wave provided by system 10 may be in the order of 20 kilohertz and when the bubbles 15 are insonified with this tone burst, the many small bubbles agglomerate into fewer large bubbles, and these large bubbles are rapidly displaced to a new location in the field. It is believed that the displacement is due to density gradients in the liquid produced by the 20 kilohertz standing wave field. The low density gas bubbles are especially responsive to such gradient, while the solid particles are not.
A high frequency acoustic motion detection system 20 is provided to detect motion of the bubbles displaced by the low frequency insonification. An analyzer 22 coupled to the motion detection system 20 will then provide an indication of bubble movement toward and away from the detection system 20.
The principles of the present invention can be utilized in various systems where bubbles are to be detected in the presence of other acoustic scatterers. It will, however, be particularly described with respect to an offshore drilling operation, such as illustrated in FIG. 2. A surface vessel 23 confined on station, such as by anchors and/or acoustic means, has a marine riser 25 extending therefrom to a blowout preventer (BOP) 28 on the bed 30 of a body of water and at the top of a well being drilled.
In order to give advance warning of bubble formation, it would be desirable to place the apparatus of the present invention as close to the drill bit as is possible and practical. One possible location would be at the end of the casing normally used in the drilling operations; however, this would necessitate a plurality of systems, one for each casing. Another might be on the marine riser, just at the top of BOP 28 and coupled to the riser by and any one of a number of well-known techniques to transmit acoustic energy into, and receive reflected energy from, the fluid.
FIG. 3 illustrates, by way of example, a transmitter-transducer 34 of the low frequency system and a transmitter/receiver transducer 36 of the high frequency system positioned opposite one another on the marine riser 25 at a position which would be close to the BOP.
By means of a multiconductor cable 38 extending from the transducer location to the surface vessel, signals may be provided to, and conducted from the transducers. The transmitting apparatus which may be aboard the surface vessel includes a low frequency transmitter 40, for example 20 kilohertz, operable to supply transducer 34 with a predetermined number of cycles of 20 kilohertz tone, as governed by the trigger circuit 42. The transmitting transducer 34 may be of a conventional Tonpilz construction which includes a head mass 44, a tail mass 45 and a central motor/generator section 46.
The high frequency motion detection system is conveniently of the doppler type and includes a high frequency, for example 1 megahertz, transmitter 50 operable to supply a signal to transducer 36 by way of transmit/receive (T/R) switch 52. Doppler return signals are conducted from transducer 36 through T/R switch 52 to an amplifier 54 and then through an analog gate circuit 56 which is operable to pass the received signal only when provided with the trigger signal from trigger circuit 42 so that gate 56 is opened to pass signals only when the region under investigation is being insonified. In this manner, the appearance of any doppler shift frequencies is correlated with the repetition rate of the low frequency tone burst to achieve high immunity to background noises.
Various types of detection circuits and readouts could be provided, and FIG. 3 illustrates by way of example the inclusion of filter networks 58 of a predetermined design to just pass certain bands of frequency where doppler shift, due to bubble movement, may be expected.
Various operations may be performed on the filtered signals, such as thresholding and display, recording, or as illustrated in FIG. 3, merely displaying by means of a frequency analyzer 60.
FIG. 4 again illustrates on a larger scale the solid particle 14 and bubbles 15 entrapped in the drilling mud flowing in the direction of arrow 13. The low frequency sound burst is directed toward the region along acoustic axis 70 and, as a result thereof, it is believed that pressure and density gradients are established in the mud. These gradients have no effect on the solid particulate matter; however, the bubbles are especially responsive to such gradient and are displaced from a region of higher pressure and density to one of lower pressure and density. Accordingly, and as illustrated by the arrows on the bubbles, depending upon where the bubbles are in the gradient field, some will move away from the transducer 34 while others will move toward it.
Any relative bubble movement toward and away from doppler transducer 36 will cause a doppler frequency shift output signal indicative, not only of the bubble movement, but also of the relative velocity of the bubble.
In operation, movement of the mud with solid particulate matter, past the doppler transducer 36 will provide some doppler shift output frequencies as normal background output. In addition, contributing to this background doppler shift, will be the drill string moving and banging around within the marine riser. The frequency of the insonifying acoustic wave is chosen so as to impart to the bubbles a certain velocity, or range of velocities, which will produce a doppler shift frequency or range of frequencies, and with a relatively high amplitude so as to be distinguishable from the normal background doppler shifts. For example, FIG. 5 illustrates the off and on times of the low frequency transmitter 40 and corresponds to the output signal of trigger circuit 42. FIG. 6A is a curve of spectral level versus frequency and represents the output of doppler transducer 36 when transmitter 40 is in an off condition. It is seen that the waveform includes a relatively high output level at frequency f o , and a statistical distribution 71 of doppler shifted frequency components backscattered from turbulent fluid elements in the acoustic path.
FIG. 6B illustrates the spectral level versus frequency of the doppler transducer 36 for the on period of transmitter 40 and it is seen that in addition to the background signal at f o , there are two other prominent signals appearing at f o + f d and f o - f d , f d representing the doppler shift due to the previously explained bubble movement toward and away from the doppler transducer. In FIG. 3, the filter networks 58 are designed so as to pass a small range of frequencies centered about f o - f d and f o + f d , as indicated by dotted lines 72 and 73.
FIG. 7A is a plan view of the apparatus on the marine riser 25 for the situation depicted in FIG. 3. It is seen that transmitter-transducer 34 and transmitter/receiver transducer 36 are diametrically opposed. Various other arrangements are possible, including that illustrated in FIG. 7B wherein the acoustic axes of the two transducers are at a relative angle θ with respect to one another, where θ is less than the 180° orientation of FIG. 7A. Other arrangements, such as concentric arrangement of the two transducers or a cordal arrangement of the two transducers are likewise possible.
FIG. 3 illustrates the transducers as being on a horizontal plane; however, it is obvious that other orientations are possible. For example, FIG. 8 illustrates the two transducers 34 and 36 at an angle θ relative to the riser central axis, in which instance suitable couplers or extending bosses 75 and 76 would be provided on the marine riser. With such arrangement a doppler signal due to mud flow would also appear in the frequency distribution curves of FIGS. 6A and 6B and an indication of mud velocity may be obtained.
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Apparatus for detecting bubbles in drilling mud so that appropriate corrective action may take place prior to a possible blowout. A low frequency acoustic field is transmitted through the drilling mud which causes the displacement of any bubbles rising through the mud. A high frequency acoustic doppler detection circuit then detects movement of the bubbles in accordance with their displacement by the low frequency field.
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CROSS REFERENCE TO RELATED APPLICATIONS
This application is a continuation-in-part of Ser. No. 736,003 filed May 20, 1985, now abandoned.
BACKGROUND OF THE INVENTION
This invention relates to novel triphos and tetraphos gold compounds which have tumor cell growth-inhibiting activity, pharmaceutical compositions containing an effective tumor cell growth-inhibiting amount of such a novel compound, and a method for treating tumor cells sensitive to such a compound by administering tumor cell growth-inhibiting amounts of such a novel compound to a host animal afflicted by such tumor cells. This invention also relates to novel pharmaceutical compositions comprising an effective, tumor cell growth-inhibiting amount of a triphos or tetraphos ligand, and a method for treating tumor cells sensitive to such ligands by administering tumor cell growth-inhibiting amounts of such ligands to a host animal afflicted by such tumor cells.
Various references including Clark et al., U.S. Pat. No. 3,364,273, issued Jan. 16, 1968; King et al., J. Am. Chem. Soc., 91, (18), 5191-2 (1969); King et al, J. Am. Chem. Soc., 93 (17), 4158-66 (1971); King et al., Inorg. Chem., 10(9), 1851-67 (1971); King, Acc. Chem. Res., 5, 177-85 (1972) and King et al., U.S. Pat. No. 3,657,298, issued Apr. 18, 1982 disclose 1,1,4,7,10,10-hexaphenyl-1,4,7,10-tetraphosphodecane.
Various references including Bartish, U.S. Pat. No. 4,102,920, issued July 25, 1978, and Antberg et al. Inorg. Chem., 23(5), 4170-4174 (1984), disclose bis(2-diphenylphosphinoethyl)phenyl phosphine and/or bis(2-diphenylphosphinopropyl)phenyl phosphine.
Various references including Hebb et al., U.S. Pat. No. 4,361,707 issued Aug. 3, 1981, disclose tris(diphenylphosphinoethyl)phosphine. Deutsch et al., U.S. Pat. No. 4,387,087, issued June 7, 1983, disclose the use of tris(diphenylphosphinoethyl)phosphine in a method of imaging organs with technetium radiopharmaceuticals.
Cooper et al., Inorg. Chim. Acta, 65(5), L185-186 (1982), disclose the synthesis and X-ray structure of trichloro-1,1,1-(diphenylphosphinomethyl)ethane[trigold(I)].
Several references including Hewertson et al., J. Chem. Soc., 1490-1495 (1962) and Safridis et al., U.S. Pat. No. 3,445,540, issued May 20, 1969, disclose μ-[1,1,1-tris(diphenylphosphinomethyl)ethane].
None of the aforementioned references disclose or suggest the compounds, pharmaceutical compositions and/or methods of treatment of subject invention.
SUMMARY OF THE INVENTION
This invention relates to triphos and tetraphos gold(I) compounds of the formula: ##STR1## wherein: R is the same and is phenyl;
A is the same and is a straight or branched alkanediyl chain of from one to six carbon atoms; and
X is the same and is halo or thiosugar.
When X is thiosugar, the attachment of X to the gold atom is through the sulfur atom of the thiosugar.
This invention also relates to a pharmaceutical composition which comprises an effective, tumor cell growth-inhibiting amount of an active ingredient and an inert, pharmaceutically acceptable carrier or diluent, wherein said composition is useful for inhibiting the growth of animal tumor cells sensitive to the active ingredient, and wherein the active ingredient is a compound of Formula (I), Formula (II), Formula (III), or a compound of the formula: ##STR2## wherein R, X and A are as defined above.
Another aspect of this invention relates to a method of inhibiting the growth of animal tumor cells sensitive to a compound of Formula (I), Formula (II), Formula (III), Formula (IV), Formula (IA), Formula (IIA), Formula (IIIA) or Formula (IVA) which comprises administering to an animal afflicted with said tumor cells, an effective, tumor cell growth-inhibiting amount of a compound of Formula (I), Formula (II), Formula (III), Formula (IV), Formula (IA), Formula (IIA), Formula (IIIA) or Formula (IVA).
DETAILED DESCRIPTION OF THE INVENTION
By the term "thiosugar" is meant any 1-thioaldose. Examples of such thiosugars include 1-thioglucose, 1-thiogalactose, 1-thiomannose, 1-thioribose, 1-thiomaltose, 1-thiofucose, tetra-O-acetyl-1-thioglucose, tetra-O-acetyl-1-thiomannose, tetra-O-acetyl-1-thiogalactose, tri-O-acetyl-1-thioribose, hepta-O-acetyl-1-thiomaltose and tri-O-acetyl-1-thiofucose.
All the compounds of Formula (I), Formula (II), Formula (III), Formula (IV), Formula (IA), Formula (IIA), Formula (IIIA) and Formula (IVA) are either available commercially or can be prepared by methods available to one skilled in the art.
Generally, the compounds of Formula (I), Formula (II), Formula (III) and Formula (IV) wherein X is chloro can be prepared by reacting the appropriate compound of Formula (IA), Formula (IIA), Formula (IIIA) or Formula (IVA) with chloroauric acid tetrahydrate reduced by treatment with thiodiglycol.
The compounds of Formula (I), (II), (III) and (IV) wherein X is bromo are prepared by reacting the appropriate compounds of Formula (IA), Formula (IIA), Formula (IIIA) or Formula (IVA) with bromoauric acid hydrate, which is commercially available, for example from Strem Chemicals, Inc., Newburyport, Mass., reduced by treatment with thiodiglycol. Alternatively, compounds of Formula (I), (II), (III), and (IV) wherein X is bromo are prepared by treatment of the corresponding compounds of Formula (I), (II), (III) and (IV) wherein X is chloro with sodium bromide in an appropriate non-reactive organic solvent, such as aqueous ethanol or DMF.
The compounds of Formula (I), (II), (III) and (IV) wherein X is iodo are prepared by treatment of the corresponding compounds of Formula (I), (II), (III) and (IV) wherein X is chloro or bromo with sodium iodide in an appropriate non-reactive organic solvent, such as acetone.
All the necessary compounds of Formula (IA), Formula (IIA), Formula (IIIA) or Formula (IVA) are available from commercial sources, for example, Strem Chemicals, Inc., Newburyport, Mass.
To prepare the Formula (I), Formula (II), Formula (III) or Formula (IV) compounds wherein X is thiosugar, the corresponding Formula (I), Formula (II), Formula (III) or Formula (IV) compound wherein X is chloro is reacted with a thiosugar source, for example, sodium thioglucose. The necessary thiosugar source is available from commercial sources, for example, from Sigma Chemicals Co., St. Louis, Mo.
As stated above, the compounds of Formula (I), Formula (II), Formula (III), Formula (IV), Formula (IA), Formula (IIA), Formula (IIIA) and Formula (IVA) have tumor cell growth-inhibiting activity which has been demonstrated in at least one animal tumor model.
P388 lymphocytic leukemia is currently the most widely used animal tumor model for screening for antitumor agents and for detailed evaluation of active compounds. This tumor system is widely accepted as an antitumor agent screening tool because it is sensitive to virtually all of the clinically active antineoplastic agents; quantitative and reproducible; amenable for large-scale screening; and predictive for activity in other animal tumor models. Drugs that are highly active in intraperitoneal (ip) P388 leukemia are generally active in other tumor models as well. The antitumor activity of the compounds of Formula (I), Formula (II), Formula (III), Formula (IV), Formula (IA), Formula (IIA), Formula (IIIA), and Formula (IVA) is demonstrated in the P388 leukemia mouse model employing the following protocol:
10 6 P388 leukemia cells are inoculated ip in B6D2F 1 mice. Twenty-four hours later, if the tumor inoculum proves to be free of bacterial contamination (as determined by 24 hours incubation in thioglycollate broth), animals are randomized into groups of 6 and housed in shoebox cages. The compound to be evaluated is dissolved in a minimal volume of either N,N-dimethylacetamide (DMA) or 95% ethanol (depending upon solubility). An equal volume of saline is added; if the drug comes out of solution an equal volume of polyethoxylated castor oil is added and then saline qs to a concentration such that the desired dose is delivered in 0.5 ml. The final concentration of DMA, ethanol and polyethoxylated castor oil is ≧10 percent. Dilutions for lower doses are made with saline so there is a decreasing proportion of organic solvents in the vehicle with decreasing dosage. These vehicles provide soluble formulations (or suspensions). Fomulations are prepared immediately prior to injection. The compound is administered ip on Days 1 through 5 (i.e. treatment is initiated 24 hrs after tumor inoculation). Each experiment includes three groups of 6 animals as untreated controls and animals treated with a positive control, cisplatin, at two dose levels. Animals are weighed as a group on Days 1, 5 and 9 and average weight change (Δwt.) is used as a reflection of toxicity. Each experiment also includes an inoculum titration--groups of 8 mice inoculated ip with 10 5 to 10 o P388 leukemia cells. The titration is used to calculate cell kill achieved by treatment with drugs. Animals are monitored daily for mortality and experiments are terminated after 45 days. The endpoint is median survival time (MST) and increase in lifespan (ILS) which is the percentage of increase in MST relative to untreated controls. Untreated controls inoculated ip with 10 6 P388 leukemia cells generally survive for a median of 9 to 11 days. A drug is considered active if it produces ≧25 percent ILS.
A summary of the evaluation of several compounds of Formula (I), Formula (II), Formula (III), Formula (IV), Formula (IA), Formula (IIA), Formula (IIIA), and Formula (IVA) in the in vivo ip P388 model is shown in the following Table A.
TABLE A______________________________________ ##STR3## FORMULA (I) ##STR4## FORMULA (II) ##STR5## FORMULA (III) ##STR6## FORMULA (IV)RP[AP(R).sub.2 ].sub.2 ; FORMULA (IA)P[AP(R).sub.2 ].sub.3 ; FORMULA (IIA) ##STR7## FORMULA (III)[(R).sub.2PCH.sub.2 ].sub.3CCH.sub.3 ;______________________________________
______________________________________Com-poundNum- Formula MTD.sup.(a) ILS (max).sup. (b)ber Number A X (mg/kg) (%)______________________________________1 I (CH.sub.2).sub.2 Cl 8 30/402 II (CH.sub.2).sub.2 Cl 8 45/453 III (CH.sub.2).sub.2 Cl 12 85/105/ 50/60/604 III (CH.sub.2).sub.2 thio- 8 100/55 glucose5 IV N/A Cl 20 40/306 IA (CH.sub.2).sub.2 N/A 32 80/507 IIA (CH.sub.2).sub.2 N/A 64 35/308 IIIA (CH.sub.2).sub.2 N/A 64 25/409 IVA N/A N/A 128 45/25______________________________________ .sup.(a) maximally tolerated dose for B6D2F female mice on an ipqDxs regimen. .sup.(b) maximum increase in lifespan produced in mice bearing ip P388 leukemia (figures separated by slashes indicate data generated in separat experiments).
Another chemosensitive tumor model is intraperitoneally (ip) implanted M5076 reticulum cell sarcoma in mice. In this system B6D2F female mice are inoculated with 0.5 ml of a 10 percent (w:v) brei of M5076 prepared from pooled subcutaneous (sc) tumors excised at about 21 days from C57B1/6 donors. Drugs are administered ip. Daily treatment is begun 24 hours after implantation and is continued for ten days. The treatment regimen for M5076 is more prolonged than for P388 because of the slower growth rate and longer control survival time of the M5076 tumor. A drug is considered active in this tumor model if it produces ≧25% ILS. The antitumor activity of Compound No. 3 of Table A in the M5076 reticulum cell sarcoma tumore model is set forth in Table B.
TABLE B______________________________________Compound No. .sup.(a) MTD (mg/kg) .sup.(b) ILS (MAX) (%) .sup.(c)______________________________________3 8 96______________________________________ .sup.(a) see Table A for structure. .sup.(b) maximally tolerated dose for B6D2F female mice on an ip qD × 10 regimen. .sup.(c) maximum increase in lifespan produced in mice bearing ip M5076 reticulum cell sarcoma
The cytotoxic activity of Compound No. 3 of Table A was evaluated in vivo using B16 melanoma cells. In this system, groups of eight B6D2F 1 mice are inoculated ip with 0.5 ml of a 10% (w:v) brei of B15 melanoma prepared from pooled sc tumors excised at 14-21 days from C67B 1 /6 donor mice. Daily treatment is begun 24 hours after tumor implantation and is continued daily for ten (10) days. The route of drug administration is ip. The mice are monitored daily for survival for sixty (60) days. Antitumor activity is assessed by prolongation of median survival time. An ILS of ≧25% indicates activity in this tumor model.
A summary of the results of the in vivo ip B16 melanoma assay is shown in Table C.
TABLE C______________________________________Compound No. .sup.(a) MTD (mg/kg) .sup.(b) ILS (%) .sup.(c)______________________________________3 6 30/51______________________________________ .sup.(a) see Table A for structure. .sup.(b) maximally tolerated dose for B6D2F.sub.1 mice on an ip qD .times 10 regimen. .sup.(c) maximum increase in lifespan produced in mice bearing ip B16 melanoma (figures separated by a slash were generated in separate experiments).
The pharmaceutical compositions of this invention comprise an effective tumor cell growth-inhibiting amount of a compound of Formula (I), Formula (II), Formula (III), Formula (IV), Formula (IA), Formula (IIA), Formula (IIIA) or Formula (IVA) and an inert pharmaceutically acceptable carrier or diluent. These compositions are prepared in dosage unit form appropriate for parenteral administration.
Compositions according to the invention for parenteral administration include sterile aqueous or non-aqueous solutions, suspensions or emulsions. The composition may be in the form of a solution of the active ingredient in a minimal volume of dimethylacetamide or ethanol, for example 5% v/v, brought up to volume with peanut oil or normal saline solution. Polyethoxylated castor oil, for example 2 to 5% v/v, may also be used to solubilize the active ingredient. In addition, the composition may be in the form of a slurry with, for example, hydroxypropyl cellulose or other suitable suspending agent. As an emulsifying agent, lecithin for example may be used. The composition may also be provided in the form of a sterile solid which can be dissolved in a sterile injectable medium immediately before use.
Freireich et al., Cancer Chemo. Rept., 50, 219-244 (1966), compared the quantitative toxicity of 18 anticancer drugs in six species after correcting the data to a uniform schedule of treatment for five consecutive days. This analysis demonstrated that mouse, rat, dog, human, monkey and man have essentially the same maximum tolerated dose (MTD) when compared on a basis of mg/m 2 of body surface area. The study suggested that Phase I clinical trials could be safely initiated at a dose one-third the animal MTD. The mouse was as useful as any other species in this regard on which to base the calculation. The appropriate therapeutically effective dose for any compound of the invention can therefore be determined readily by those skilled in the art from simple experimentation with laboratory animals, perferably mice.
It will be appreciated that the actual preferred dosages of the compounds of Formula (I), Formula (II), Formula (III), Formula (IV), Formula (IA), Formula (IIA), Formula (IIIA) or Formula (IVA) used in the compositions of this invention will vary according to the particular compound being used, the particular composition formulated, the mode of administration and the particular site, host and disease being treated. The route of internal administration should be selected to ensure that an effective tumor cell growth-inhibiting amount of the compound of Formula (I), Formula (II), Formula l(III), Formula (IV), Formula (IA), Formula (IIA), Formula (IIIA) or Formula (IVA) contacts the tumor. Optimal dosages for a given set of conditions can be ascertained by those skilled in the art using conventional dosage determination tests in view of the above experimental data. For parenteral administration the dose preferably employed is from about 5 to about 1200 mg/m 2 of body surface per day for five days, repeated about every fourth week for four courses of treatment.
The method for inhibiting the growth of animal tumor cells sensitive to a compound of Formula (I), Formula (II), Formula (III), Formula (IV), Formula (IA), Formula (IIA), Formula (IIIA) or Formula (IVA) in accordance with this invention comprises administering to a host animal afflicted with said tumor cells, an effective tumor cell growth-inhibiting amount of a compound of Formula (I), Formula (II), Formula (III), Formula (IV), Formula (IA), Formula (IIA), Formula (IIIA) or Formula (IVA).
EXAMPLES
The following examples illustrate the chemical preparation of several compounds of Formula (I), Formula (II), Formula (III), Formula (IV), Formula (IA), Formula (IIA), Formula (IIIA) and Formula (IVA) which are used in the compositions and methods of this invention and as such are not be be construed as limiting the scope thereof. All temperatures are in degrees Centigrade.
EXAMPLE 1
μ-[Bis(2-diphenylphosphinoethyl)phenylphosphine]tris(chlorogold)
Chloroauric acid tetrahydrate (2.5 g, 6.07 mmole) in water (10 ml) was reduced upon addition of thiodiglycol (3.0 g, 24.6 mmoles) in water (10 ml)/methanol (60 ml) at 0°. A solution of bis(2-diphenylphosphinoethyl)phenylphosphine (1.08 g, 2.02 mmole), a Formula (IA) compound obtained from Strem Chemicals Inc., Newburyport, Mass., in chloroform (50 ml)/methanol (30 ml) was added and the mixture was stirred for several hours, and allowed to come to room temperature. Water was added and the product extracted with chloroform/methylene chloride, dried (MgSO 4 ), filtered and the solvent was removed in vacuo. The residue was slurried with chloroform, diluted with ethanol and the precipitate collected and dried to give 1.75 g (70%) of product, melting point (m.p.) 173°-177°.
EXAMPLE 2
μ-[Tris(2-diphenylphosphinoethyl)phosphine]tetrakis(chlorogold)
Chloroauric acid tetrahydrate (2.5 g, 6.06 mmole) in water (20 ml) was reduced upon addition of thiodiglycol (3.0 g, 24.6 mmole) in water (20 ml)/methanol (60 ml) at 0°. A solution of tris(diphenylphosphinoethyl)phosphine (1.02 g, 1.5 mmole), a Formula (IIA) compound obtained from Strem Chemicals Inc., Newburyport, Mass., in chloroform (30 ml)/methanol (20 ml) was added, and the mixture was stirred for several hours. Water (200 ml) was added, and the mixture was extracted with chdloroform. The chloroform extracts were dried (MgSO 4 ), filtered and the solvent was removed in vacuo. Methanol was added to the residue and the solution was cooled. The crystals were collected, dissolved in methylene chloride, and treated with activated carbon. Then methanol was added and the mixture was cooled. The resulting crystals were collected to give 2.1 g (86%), of the named Formula (II) product, m.p. 181°-3°.
EXAMPLE 3
μ-[1,1,4,7,10,10-Hexaphenyl-1,4,7,10-tetraphosphodecane]tetrakis(chlorogold)
Chloroauric acid tetrahydrate (1.87 g, 4.54 mmol) in water (20 ml) was reduced upon addition of thiodiglycol (3.0 g, 24.6 mmole) in methanol (60 ml)/water (20 ml) at 0°. 1,1,4,7,10,10-hexaphenyl-1,4,7,10-tetraphosphodecane (0.76 g, 1.13 mmole), a Formula (IIIA) compound obtained from Strem Chemicals, Inc. Newburyport, Mass., in chloroform (60 ml)/methanol (20 ml) was added and the mixture was stirred for several hours. The resulting precipitate was collected and dissolved in methylene chloride. Then hexane was added and the mixture was cooled. Collection of successive crops gave 1.35 g (94%) of the named Formula (III) product, m.p. 184°-186°.
EXAMPLE 4
μ-[1,1,4,7,10,10-Hexaphenyl-1,4,7,10-tetraphosphodecane]tetrakis(1-thio-β-D-glucopyranosato-S)gold
A mixture of sodium β-D-thioglucose (0.97 g, 4.4 mmoles), obtained from Sigma Chemical Co., St. Louis, Mo., and μ-[1,1,4,7,10,10-Hexaphenyl-1,4,7,10,-tetraphosphodecane]tetrakis(chlorogold) (1.6 g, 1 mmole), prepared as described in Example 3, in methanol (150 ml)/chloroform (150 ml)/water (20 ml) was stirred for 18 hours at ambient temperature, and the solvent was evaporated. The residue was washed with water, and then with acetone. The residue was then treated with boiling methanol and filtered, and the methanol was evaporated. Crystallization of the residue from acetone gave 1.5 g (67%) of the named Formula (III) product, m.p. 267°-272°.
EXAMPLE 5
μ-[1,1,1-Tris(diphenylphosphinomethyl)ethane]tris(chlorogold)
Thiodiglycol (2.0 g, 16.4 mmole) in ethanol (10 ml) was added to chloroauric acid tetrahydrate (1.97 g, 4.8 mmoles) in water (20 ml) kept at 0°. An acetone (8 ml) solution of μ-[1,1,1-Tris(diphenylphosphinomethyl)ethane] (1.0 g, 1.6 mmoles), a Formula (IVA) compound obtained from Strem Chemicals, Inc., Newburyport, Mass., was added and the mixture was stirred overnight. The product was collected, washed with water and recrystallized from dimethylformamide to give 1.1 g of the named Formula (V) product, m.p. 197°-202°. Recrystallization from methylene chloride/ether gave 0.7 g of the named Formula (IV) product, m.p. 205°-210° (dec.).
EXAMPLE 6
Using the procedure of Example 1, by reacting the appropriate Formula (IA) compound and the appropriate haloauric acid tetrahydrate, reduced by treatment with thiodiglycol, the following compounds of Formula (I) wherein X is chloro or bromo are prepared, or by reacting the appropriate Formula (I) compound wherein X is chloro with sodium bromide in an appropriate organic solvent, such as aqueous ethanol or DMF, the following compounds of Formula (I) wherein X is bromo are prepared, and by reacting the appropriate compound of Formula (I) wherein X is chloro or bromo with sodium iodide in an appropriate organic solvent, such as acetone, the following compounds of Formula (I) wherein X is iodo are prepared:
a. μ-[bis(2-diphenylphosphinomethyl)phenylphosphine]tris(chlorogold)
b. μ-[bis(2-diphenylphosphinopropyl)phenylphosphine]tris(chlorogold)
c. μ-[bis(2-diphenylphosphinobutyl)phenylphosphine]tris(chlorogold)
d. μ-[bis(2-diphenylphosphinopentyl)phenylphosphine]tris(chlorogold)
e. μ-[bis(2-diphenylphosphinohexyl)phenylphosphine]tris(chlorogold)
f. μ-[bis(2-diphenylphosphinoethyl)phenylphosphine]tris(bromogold
g. μ-[bis(2-diphenylphosphinoethyl)phenylphosphine]tris(iodogold)
EXAMPLE 7
Using the procedure of Example 4, by reacting the appropriate thioglucose source with the appropriate Formula (I) compound wherein X is chloro, prepared according to the procedure of Example 1 or 6, the following Formula (I) compounds wherein X is thioglucose are prepared:
a. μ-[bis(2-diphenylphosphinomethyl)phenylphosphine]tris(1-thio-β-D-glucopyranosato-S)gold
b. μ-[bis(2-diphenylphosphinoethyl)phenylphosphine]tris(1-thio-β-D-glucopyranosato-S)gold
c. μ-[bis(2-diphenylphosphinopropyl)phenylphosphine]tris(1-thio-β-D-glucopyranosato-S)gold
d. μ-[bis(2-diphenylphosphinobutyl)phenylphosphine]tris(1-thio-β-D-glucopyranosato-S)gold
e. μ-[bis(2-diphenylphosphinopentyl)phenylphosphine]tris(1-thio-β-D-glucopyranosato-S)gold
f. μ-[bis(2-diphenylphosphinohexyl)phenylphosphine]tris(1-thio-β-D-glucopyranosato-S)gold
g. μ-[bis(2-diphenylphosphinoethyl)phenylphosphine]tris(1-thio-α-D-mannopyranosato-S)gold
h. μ-[bis(2-disphenylphosphinoethyl)phenylphosphine]tris(1-thio-β-D-galactopyranosato-S)gold
i. μ-[bis(2-diphenylphosphinoethyl)phenylphosphine]tris(1-thio-D-ribofuranosato-S)gold
EXAMPLE 8
Using the procedure of Example 2, by reacting the appropriate Formula (IIA) compound with the appropriate haloauric aicd tetrahydrate, reduced by treatment with thiodiglycol, the following compounds of Formula (II) wherein X is chloro or bromo are prepared; or by reacting the appropriate Formula (II) compound wherein X is chloro with sodium bromide in an appropriate organic solvent such as aqueous ethanol or DMF, the following compounds of Formula (II) wherein X is bromo are prepared; and by reacting the appropriate Formula (II) compound wherein X is chloro or bromo with sodium iodide in an appropriate organic solvent such as acetone, the following compound of Formula (II) wherein X is iodo are prepared:
a. μ-[Tris(2-diphenylphosphinomethyl)phosphino]tetrakis(chlorogold)
b. μ-[Tris(2-diphenylphosphinopropyl)phosphino]tetrakis(chlorogold)
c. μ-[Tris(2-diphenylphosphinobutyl)phosphino]tetrakis(chlorogold)
d. μ-[Tris(2-diphenylphosphinopentyl)phosphino]tetrakis(chlorogold)
e. μ-[Tris(2-diphenylphosphinohexyl)phosphino]tetrakis(chlorogold)
f. μ-]Tris(2-diphenylphosphinoethyl)phosphino]tetrakis(bromogold)
g. μ-[Tris(2-diphenylphosphinoethyl)phosphino]tetrakis(iodogold)
EXAMPLE 9
Using the procedure of Example 4, by reacting the appropriate thioglucose source with the appropriate Formula (II) compound wherein X is chloro, prepared according to the procedure of Example 2 or 8, the following formula (II) compounds wherein X is thioglucose are prepared:
a. μ-[Tris(2-diphenylphosphinomethyl)phosphine]tetrakis(1-thio-β-D-glucopyranosato-S)gold
b. μ-[Tris(2-diphenylphosphinoethyl)phosphine]tetrakis(1-thio-β-D-glucopyranosato-S)gold
c. μ-[Tris(2-diphenylphosphinopropyl)phosphine]tetrakis(1-thio-β-D-glucopyranosato-S)gold
d. μ-[Tris(2-diphenylphosphinobutyl)phosphine]tetrakis(1-thio-β-D-glucopyranosato-S)gold
e. μ-[Tris(2-diphenylphosphinopentyl)phosphine]tetrakis(1-thio-β-D-glucopyranosato-S)gold
f. μ-[Tris(2-diphenylphosphinohexyl)phosphine]tetrakis(1-thio-β-D-glucopyranosato-S)gold
g. μ-[Tris-(2-diphenylphosphinoethyl)phosphine]tetrakis(1-thio-α-D-mannopyranosato-S)gold
h. μ-[Tris(2-diphenylphosphinoethyl)phosphine]tetrakis(1-thio-β-D-galactopyranosato-S)gold
i. μ-[Tris(2-diphenylphosphinoethyl)phosphine]tetrakis(1-thio-D-ribofuranosato-S)gold
EXAMPLE 10
Using the procedure of Example 3, by reacting the approriate Formula (IIA) compound and the appropriate haloauric acid tetrahydrate, reduced by treatment with thiodiglycol, the following compounds of Formula (III) wherein X is chloro or bromo are prepared; or by reacting the apporpriate compound of Formula (III) wherein X is chloro with sodium bromide in an appropriate organic solvent, such as aqueous ethanol or DMF, the following compounds of Formula (III) wherein X is bromo are prepared; and by reacting the appropriate compound of Formula (III) wherein X is chloro or bromo with sodium iodide in an appropriate organic solvent such as acetone, the following compounds of Formula (III) wherein X is iodo are prepared:
a. μ-[1,1,3,5,7,7-hexaphenyl-1,3,5,7-tetraphosphoheptane]tetrakis(chlorogold)
b. μ-[1,1,5,9,13,13,-hexaphenyl-1,5,9,13-tetraphosphotridecane]tetrakis(chlorogold)
c. μ-[1,1,6,11,16,16-hexaphenyl-1,6,11,16-tetraphosphohexadecane]tetrakis(chlorogold)
d. μ-[1,1,7,13,19,19-hexaphenyl-1,7,13,19-tetraphosphononadecane]tetrakis(chlorogold)
e. μ-[1,1,8,15,22,22-hexaphenyl-1,8,15,22-tetraphosphodocosane]tetrakis(chlorogold)
f. μ-[1,1,4,7,10,10-hexaphenyl-1,4,7,10-tetraphosphodecane]tetrakis(bromogold)
g. μ-[1,1,4,7,10,10-hexaphenyl-1,4,7,10-tetraphosphodecane]tetrakis(iodogold)
EXAMPLE 11
Using the procedure of Example 4, by reacting the appropriate thioglucose source with the appropriate Formula (III) compound wherein X is chloro, prepared according to the procedure of Example 3 or 10, the following Formula (III) compounds wherein X is thioglucose are prepared:
a. μ-[1,1,3,5,7,7-hexaphenyl-1,3,5,7-tetraphosphoheptane]tetrakis(1-thio-.beta.-D-glucopyranosato-S)gold
b. μ-[1,1,5,9,13,13-hexaphenyl-1,5,9,13-tetraphosphotridecane]tetrakis(1-thio-β-D-glucopyranosato-S)gold
c. μ-[1,1,6,11,16,16-hexaphenyl-1,6,11,16-tetraphosphohexadecane]tetrakis(1-thio-β-D-glucopyranosato-S)gold
d. μ-[1,1,7,13,19,19-hexaphenyl-1,7,13,19-tetraphosphononadecane]tetrakis(1-thio-β-D-glucopyranosato-S)gold
e. μ-[1,1,8,15,22,22-hexaphenyl-1,8,15,22-tetraphosphodocosane]tetrakis(1-thio-β-D-glucopyranosato-S)gold
f. μ-[1,1,4,7,10,10-hexaphenyl-1,4,7,10-tetraphosphodecane]tetrakis(1-thio-β-D-galactopyranosato-S)gold
g. μ-[1,1,4,7,10,10-hexaphenyl-1,4,7,10-tetraphosphodecane]tetrakis(1-thio-D-mannopyranosato-S)gold
h. μ-[1,1,4,7,10,10-hexaphenyl-1,4,7,10-tetraphosphodecane]tetrakis(1-thio-D-ribofuranosato-S)gold
EXAMPLE 12
Using the procedure of Example 5, by reacting the appropriate Formula (IVA) compound with the appropriate haloauric acid tetrahydrate, reduced by treatment with thiodiglycol, the following compounds of Formula (IV) wherein X is bromo or chloro are prepared; or by reacting the apporpriate compound of Formula (IV) wherein X is chloro with sodium bromide in an appropriate organic solvent, such as aqueous ethanol or DMF, the following compounds of Formula (IV) wherein X is bromo are prepared; and by reacting the appropriate compound of Formula (IV) wherein X is chloro or bromo with sodium iodide in an appropriate organic solvent such as acetone, the following compounds of Formula (IV) wherein X is iodo are prepared:
a. μ-[1,1,1-tris(diphenylphosphinomethyl)ethane]tris(bromogold)
b. μ-[1,1,1-tris(diphenylphosphinomethyl)ethane]tris(iodogold)
EXAMPLE 13
Using the procedure of Example 4, by reacting the appropriate thioglucose source with the named compound of Example 5, the following Formula (IV) compounds wherein X is thioglucose are prepared:
a. μ-[1,1,1-tris(diphenylphosphinomethyl)ethane]tris(1-thio-β-D-glucopyranosato-S)gold
b. μ-[1,1,1-tris(diphenylphosphinomethyl)ethane]tris(1-thio-β-D-galactopyranosato-S)gold
c. μ-[1,1,1-tris-diphenylphosphinomethyl)ethane]tris(1-thio-α-D-mannopyranosato-S)gold
d. μ-[1,1,1-tris(diphenylphosphinomethyl)ethane]tris(1-thio-D-ribofuranosato-S)gold
EXAMPLE 14
As a specific embodiment of a composition of this invention, an active ingredient, such as one part of the compound of Example 3, is dissolved in 5 parts of dimethylacetamide and 5 parts of polyethoxylated castor oil and then normal saline solution qs, and is administered parenterally in one dose of 15 mg/m 2 to a host animal afflicted with tumor cells sensitive to that compound.
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Triphos and tetraphos gold compounds which have tumor cell growth-inhibiting activity, pharmaceutical compositions containing an effective, tumor cell growth-inhibiting amount of such a compound or its corresponding triphos or tetraphos ligand, and a method for treating tumor cells sensitive to such a compound or its corresponding triphos or tetraphos ligand.
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CROSS REFERENCE TO RELATED APPLICATIONS
This invention is related to, and claims priority from, European patent application EP 00200304.4, filed Jan. 31, 2000, entitled “AWNING ASSEMBLY AND CONTROL SYSTEM”, and incorporates the prior application in its entirety herein by reference.
BACKGROUND OF THE INVENTION
This invention relates to a retractable and extendable awning and a control system for automatically extending and retracting the awning.
Retractable and extendable awnings are generally known from U.S. Pat. Nos. 1,075,385, 1,804,550, GB 1 175 723, GB 2 042 058, EP 0 084 076, EP 0 125 727, EP 0 489 186 and EP 0 795 660.
BRIEF SUMMARY OF THE INVENTION
The present invention has as an object to eliminate inconveniences of the prior art by providing such an awning with improved features.
In accordance with this invention, a retractable and extendable awning, includes at least one arm support bracket, at least one arm having first and second pivoting arm sections, a front bar, a roller adapted to be mounted for rotation, a fabric cloth for winding about and unwinding from the roller, wherein the first arm section has a first end pivotally linked to the bearing support and a second end, the second arm section having a first end pivotally linked to the second end of the first arm section and a second end pivotally linked to the front bar.
According to another aspect of the invention, the front bar of the awning is provided with a weather sensor unit comprising a sensor which can detect movement of the front bar as a result of wind. Advantageously, the sensor unit is also provided with a light sensor, a rain sensor and a wind sensor. The additional wind sensor may be provided in addition to the movement sensor as this can only detect the presence of wind with the awning in an extended position. With the danger of wind removed it would be desirable if the awning can be extended automatically rather than manually. Hence the additional wind sensor which makes this possible. The movement sensor detects all vertical movements or shocks of the extended awning. If such movements occur outside of a predefined range a signal can be produced to effect retraction of the awning to prevent it from being damaged. The movement sensor can be based on the principle using a conductive fluid and two electrical contacts. If the fluid as a result of movement contacts both contacts an electrical connection is made. The number of electrical contacts within a given time frame can be used to detect movement. The viscosity of the conductive fluid determines the sensitivity of this type of movement sensor. Preferably the wind sensor is selected to be highly sensitive, whereas the movement or shock sensor can be of a much lower sensitivity. The wind sensor can be included in a wind catching body which is movably mounted with respect to the sensor unit. Such a wind catching body is preferably shaped to catch wind from all possible directions. Known wind detecting devices do only detect wind in a horizontal direction and are mostly mounted at a location remote from the awning which also does not help in recognising the actual danger level to which an individual awning may at times be exposed. Often gusts of wind blow vertically upward with respect to a facade of a building which carries the awning and this can be particularly dangerous if undetected. The present invention will cope with this situation more adequately. The sensor unit preferably communicates by means of wireless transmission with a control unit, which advantageously can be positioned indoor, and preferably the sensor unit is also programmed in a manner to save power. The sensor unit further comprises circuitry which at idle is in a sleep mode and consumes only 10 microamperes. An IRQ-pin is used to force a processor out of this sleep mode. This can be made to happen once for every 10 seconds or so. Upon awakening the unit will read the measurements of its sensors and compare these with threshold values stored in an internal table. Only when one of the values exceeds the specified threshold the unit will establish communication with either an indoor or outdoor control unit. Additionally the sensor unit will also establish communication with the control unit every one to five minutes, or so, to send a ‘live’ signal even without having to report a surpassing of a threshold value. The circuitry thereby enables the control unit to detect proper operation and communication of the sensor unit. During such predefined periodic communications the control unit can also transmit any new settings of threshold values to the sensor unit. Power supply for the sensor unit circuitry is provided by a rechargeable battery or accumulator which is charged by a solar cell. To economise on the investment for solar cells the solar cell is preferably composed of four individual cells. To allow charging of the battery with a relatively low voltage of 2 V, a step-up converter is used. This enables charging under even very low light levels, while under excessive light conditions the charging current will be limited to prevent damage to the battery.
According to yet another aspect of the invention an awning is, further provided with an indoor control unit. Upon installation particular settings for the outdoor weather sensor unit, such as sun and wind can be downloaded from the control unit to the sensor unit and stored at both ends in a programmable memory, such as an EEPROM, which memorises these settings. Only if the sensor unit detects a value outside of these settings it will establish communication with the control unit, so as to minimise transmissions between the two devices and the power consumption required thereby. If however the control unit does not receive the standard periodic “live”-signal transmission it will retract the awning and switch itself into manual mode. A suitable message may be displayed on a display device of the control unit to indicate this. The indoor control unit preferably is connected to mains supply and includes a transformer and a triac control for an electric motor incorporated in the awning or like sun protective device. Conveniently a high frequency circuit for wireless transmission of signals can be combined with the high voltage circuit board in the control unit. Another circuit board can be provided for the low voltage section of the control unit. The low voltage circuit board thereby contains the logical controls which can be fed by a low voltage, such as 5 V DC. These include a processor, a liquid crystal display, switches and optionally a temperature sensor. The processor comprises a control algorithm, a routine for decoding switch actuations and a display driver. To obtain an as adaptable as possible arrangement, the display driver and decoder for the switch matrix are included in a timer. An internal serial port is used for communication with a transceiver module. To control an electric motor for moving the awning from a retracted into an extended position and vice-versa a revolution counter and a power surge detection may be employed to detect the appropriate end positions of the awning. Such end position controls are usually incorporated in the electric motor units. An IRQ input and routine are however reserved in the control unit for the possible inclusion of an optional motor control in the control unit if so desired. It then also becomes possible to program the power surge (measured by a triac), which should result in the motor to cut out, with the help of the control unit. A main program algorithm has only a reduced number of tasks, which improves clarity and reliability. The main program thus includes two programming modes and decision sequences for intellectual control.
According to a still further aspect of the invention an awning is provided that further includes a hand-held remote control transmitter.
The invention also provides a control system in particular for an awning as referred to above, which includes at least one of a weather sensor, an indoor control unit and optionally a hand-held remote control transmitter, all preferably as referred to above.
BRIEF DESCRIPTION OF THE DRAWINGS
Further aspects of the invention will be apparent from the detailed description below of particular embodiments and the drawings thereof, in which:
FIG. 1 is a general perspective view of a retractable arm awning of this invention in an extended position;
FIG. 2 is a schematic side view of a first embodiment of support bracket for the awning of FIG. 1;
FIG. 3 is a schematic side view of a slightly modified, second embodiment of support bracket for the awning of FIG. 1;
FIG. 4 is a schematic side view of a further, third embodiment of support bracket for the awning of FIG. 1;
FIG. 5 is a schematic side view of a fourth embodiment of support bracket for the awning of FIG. 1;
FIG. 6 is a detailed top perspective view of the first embodiment of support bracket of FIG. 2;
FIG. 7 is a detailed side elevation view of the support bracket of FIG. 6;
FIG. 8 is a detailed side elevation view of the second embodiment of support bracket of FIG. 3;
FIG. 9 is a detailed bottom perspective view of the second embodiment of support bracket of FIG. 8;
FIG. 10 is a cross-sectional view of the first embodiment of support bracket, taken along line X—X in FIG. 7;
FIG. 11 is a is a front elevation view of an optional alternative embodiment of the bushing of the support bracket of FIGS. 7 and 10;
FIG. 12 is a vertical cross- sectional view of the bushing of FIG. 11;
FIGS. 13 and 14 are perspective view from opposite sides of the bushing of FIG. 11;
FIG. 15 is a vertical cross-sectional view of the awning of FIG. 1 in a retracted position;
FIG. 16 is a top elevation view of one of the articulated arms of the awning of FIG. 1 in a retracted position;
FIG. 17 is an elevation view of the arm of FIG. 16;
FIGS. 18 and 19 are perspective view from opposite sides of the arm of FIG. 16;
FIGS. 20 and 21 are perspective view from opposite sides of a first, rear end plug element of a rear section of the arm of FIG. 16;
FIG. 22 is a perspective view of a second, front-end plug element of a rear section of the arm of FIG. 16, forming part of the central pivot swivel;
FIG. 23 is a perspective view of a third, rear end plug of a front section of the arm of FIG. 16, forming part of the central pivot swivel;
FIG. 24 is a perspective view of a fourth, front-end plug of a front section of the arm of FIG. 16;
FIG. 25 is a vertical cross-sectional view, taken along line XXV—XXV in FIG. 26, of the front-end plug of the front arm section of FIG. 24;
FIG. 26 is an enlarged fragmentary elevation view of the front-end plug of the front arm section of FIG. 24;
FIG. 27 is a perspective fragmentary view of the rear section of the arm of FIG. 16, with the rear section partly broken away to show its connection to the rear end plug of FIGS. 20 and 21, inserted into it;
FIG. 28 is a front perspective view of an outdoor weather sensor unit which can be mounted on the front of the front bar of the awning of FIG. 1;
FIG. 29 is a front perspective view of an indoor control unit which can be in communication with the weather sensor unit of FIG. 28;
FIG. 30 is a schematic representation of the circuitry of the outdoor weather sensor unit of FIG. 28;
FIGS. 30 a and 30 b are schematic representations of the circuitry of an alternative embodiment outdoor weather sensor unit;
FIG. 31 a is a schematic representation of the circuitry of an alternative embodiment low voltage section of the indoor control unit;
FIG. 32 is a schematic reprensentation of the high voltage section of the circuitry of the indoor control unit of FIG. 29;
FIG. 32 a is a schematic representation of the circuitry of an alternative embodiment high voltage section of the indoor control unit;
FIG. 33 is a flow chart of the operation of the processor of the outdoor weather sensor unit of FIG. 28;
FIG. 34 is a flow chart of the main program operation of the indoor control unit of FIG. 29;
FIG. 35 is a flow chart of the programming mode operation sub-routine of the indoor control unit of FIG. 29;
FIG. 36 is a flow chart of the installation mode operation sub-routine of the indoor control unit of FIG. 29;
FIG. 37 is a flow chart of the manual mode operation sub-routine of the indoor control unit of FIG. 29;
FIG. 38 is a flow chart of the auto mode operation sub-routine of the indoor control unit of FIG. 29;
FIG. 39 is a top perspective view of an optional hand-held wireless remote control transmitter which can be used to operate the indoor control unit of FIG. 29;
FIG. 40 is a flow chart of the operation of the remote control transmitter of FIG. 39; and
FIG. 41 is a schematic representation of the circuitry of the hand-held remote control transmitter of FIG. 39;
FIG. 41 a is a schematic representation of the circuitry of an alternative embodiment hand-held remote control transmitter;
FIG. 42 is a schematic representation of the arrangement of the devices used with the awning control system;
FIG. 43 is a schematic representation of an alternative arrangement of the devices used with the awning control system;
FIG. 44 is a schematic representation of another alternative arrangement of the devices used with the awning control system.
In these Figures, corresponding parts in different embodiments are referred to by corresponding names and by the same last two reference numerals.
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 shows a retractable arm awning 1 of the general type with which the present invention is concerned. The awning 1 of FIG. 1 has a wall mount cassette 3 housing a roller 5 from which a fabric cloth 7 in the extended position of the awning is extending and supported by a collapsible support system comprising a front bar 9 connected to a front edge of the fabric cloth 7 and two collapsible arms 11 , 13 . Each of the collapsible arms 11 , 13 is hingeably mounted from a corresponding arm support bracket 15 and 17 respectively and comprises first and second pivoting arm sections 19 , 23 and 21 , 25 respectively. Each of the first and second arm sections are joined by a central pivot swivel 27 , 29 respectively and the second arm sections 21 , 25 are hingeably joined to the rear side of the front bar 9 . The front bar 9 preferably, but not necessarily, is shaped as a lid to close the opening 31 in the cassette 3 from which the fabric cloth and collapsible frame extend, when the awning is in a retracted position.
The awning of FIG. 1 preferably includes some mechanism for adjusting the angle 33 at which the awning extends from a building wall (not shown).
FIGS. 2 through 5 schematically show different forms of arm support brackets as referred to by numerals 15 , 17 in FIG. 1 .
FIG. 2 represents a first embodiment of arm support bracket 115 having a base part 35 and a link 37 pivotally attached thereto by means of pivot pin 39 . The link 37 has means for pivotally attaching a first arm section 19 or 23 as will be discussed below but for clarity such means are deleted from FIGS. 2 through 5. A screw spindle 41 , upon rotation by a suitable tool in either of two opposite rotational directions, adjusts the angle 47 between the vertical and the link 37 and thereby the angle of extension 33 as indicated in FIG. 1 . The base part 35 has a square recess 49 at its rear end which can be attached over a square section bar extending along the width of the awning (not shown, but conventional in awnings).
FIG. 3 shows a slightly modified second embodiment of support bracket 215 which is generally identical to that of FIG. 2, but for the addition of a gear box 51 with an eyelet coupler 53 to be driven by an extension crank rod (not shown, but conventional in the operation of awnings). Driving the screw spindle 41 through gearbox 51 will allow ready angular adjustments by a conventional crank rod from a remote position that is convenient to the operator, rather than having to revert to tools.
FIG. 4 shows a further third embodiment of arm support bracket 315 , which is generally very similar to the basic bracket 115 of FIG. 2 . Support bracket 315 uses a different form of base part 55 , which attaches directly to a building wall or to the structure of a wall mount cassette (numeral 3 in FIG. 1) without using any square section bar, such as in the previously described embodiments. In all other respects the angular adjustment through a screw spindle 41 is similar to that of FIGS. 2 and 3. Likewise the support bracket 315 of FIG. 4 could be modified with a gearbox 51 such as shown in FIG. 3 for the second embodiment 215 .
Finally FIG. 5 shows as a fourth embodiment yet another form of support bracket 415 , which does not use a screw spindle for angular adjustment. Support bracket 415 shown with a similar base part 55 as the bracket of FIG. 4 could alternatively also be provided with a base part 35 such as the bracket of FIGS. 2 and 3. The angular adjustment of the link 37 of bracket 415 is effected by means of a lockable gas spring 57 , which has one end attached to the bushing 45 and another end pivotally attached to a suitable fixed structure such as the building wall or to the base part 55 . Locking gas springs of a suitable type are obtainable under the trade designation KALLER from Strömsholmen AB of Sweden or under the trade designation BLOC-O-LIFT from Stabilus of Germany. Such lockable gas springs not only provide the appropriate angular adjustment of the link 37 but also provide for cushioning of any forces acting on the awning in its extended position. Means for cushioning can also be incorporated in the bushing 45 , but this will be described in reference to FIG. 10 .
FIGS. 6 and 7 are a perspective top view and a side elevation respectively of the support bracket 115 of FIG. 2 . The same reference numerals are used to denote the same parts. It is seen from FIG. 6 that the screw spindle 41 has a polygonal driving head 42 at a forward end protruding or reachably exposed through the bushing 45 . Such a polygonal driving head 42 can be a hexagonal cavity which can be driven by a regular allen key wrench, but clearly other driving ends for other convenient tools known to the skilled person can be selected.
The bushing 45 is further shown to have a body 59 and a pivot pin 61 , which conveniently can be screw threaded in the body 59 to be removable and hence be provided with a polygonal driving head or cavity. The link 37 is provided with a bearing section 63 with a through bore 65 for receiving a pivot pin for hingeably connecting the first pivoting arm sections ( 19 or 23 in FIG. 1) of a collapsible awing arm ( 11 or 13 in FIG. 1 ).
The link 37 of an awning can be made in right-hand and left-hand versions with the through bore 65 on different sides depending in the arc of movement of the awning arm, but it is also conceivable to use a single type of link with a through bore such as 65 ) on each opposite side.
FIG. 7 shows a side elevation of support bracket 115 generally similar to the embodiment of the schematic view of FIG. 2 . Here it is seen that the screw spindle 41 can effectively define two sections 67 and 69 . The first section 67 can be provided with a male screw thread and engage a female screw thread in the bushing 45 . The second section 69 can have a non-circular cross section for driving engagement by either a tool or other driving means. It is further seen from FIGS. 6 and 7 that the rear end of the base part 35 is provided with screw fasteners 71 , 73 spanning across the open ended square recess 49 for clampingly forcing the opposite legs 75 , 77 together on a square bar or the like (not shown, but conventional) to attach the support bracket.
FIGS. 8 and 9 show a side view and a perspective bottom view, respectively, of the second embodiment of support bracket 215 , also shown schematically in FIG. 3 . Basically the embodiment of FIGS. 8 and 9 is identical to that of FIGS. 6 and 7, except for the addition of the gear box 51 engaging the screw spindle 41 and allowing adjustment thereof by driving the eyelet coupler 53 . The reference numerals in FIGS. 8 and 9 are otherwise used identically to those in FIGS. 2, 6 and 7 . It should be noticed in this regard that an existing embodiment according to FIGS. 6 and 7 can be modified by the addition of a gearbox 51 to the embodiment of FIGS. 8 and 9.
FIG. 10 is a cross section of the support bracket 115 of the embodiment of FIG. 7 in the direction of arrows X—X and serves to illustrate a first optional form of bushing 145 suitable to replace any of the bushings 45 as described with respect to FIGS. 2 through 9. The bushing 145 comprises in a concentric arrangement a rigid inner bushing 147 , a resilient intermediate bushing 149 and a rigid outer bushing 151 . The outer bushing 151 carries female screw thread for engaging the male screw thread 67 of the screw spindle 41 . The male screw threaded portion 67 of the screw is however freely movable through the inner bushing 147 , which is pivotally retained in the link 37 by opposite screwed-in pivot pins 61 , 62 .
Any forces that act on the link 37 in the axial direction of the screw spindle 41 will be cushioned by the resilient intermediate bushing 149 and thereby would prevent damage to the screw spindle or its mounting in the base part 35 . With respect to the mounting of the screw spindle 41 in the base part 35 , FIG. 10 also serves to illustrate a feature shared in common with the other embodiments but not yet visible in any of the previous illustrations. The second section 69 of the screw spindle 41 , having a hexagonal cross-section for engagement by the gearbox 51 or the like drive means, is further provided with a ball shaped head 79 which is engaged in an axial cavity of the transverse pin 43 . An intermediate neck portion 81 can extend from the cavity and be position therein through an axial slot coextending with the axial cavity in the transverse pin 43 . Once engaged in the cavity of the transverse pin 43 , the ball shaped head 79 is retained therein by a locking screw 83 .
FIGS. 11 through 14 show yet another second optional embodiment 245 for the bushing (generally numbered 45 in FIGS. 2 through 9 ). It is sometimes desirable that a particular adjusted angle of extension (angle 33 in FIG. 1) and hence the angle of link 37 (angle 47 in FIGS. 7 and 8) is cancelled when the collapsible arms ( 11 , 13 in FIG. 1) reach the retracted position, so that the front bar ( 9 in FIG. 1) may abut against and close the cassette opening ( 31 in FIG. 1) in a predefined angular orientation. One such mechanism is described in GB 2042058 and uses a transversely movable locking bolt which is moved by the awning arm through a linking rod. It has been found that transverse movement of such a locking bolt can be somewhat difficult if this is at the same time also forced against the screw spindle element. The bushing arrangement 245 of FIGS. 11 through 14 can overcome this drawback and would also result in a very compact arrangement. To this end the bushing 245 has an inner bushing 247 and a concentric hollow outer bushing 251 . Accommodated in a cavity of the inner bushing is threaded nut 249 adapted to engage the screw-threaded section 67 of the screw spindle 41 . The nut 249 as best shown in FIG. 12 is also contoured to allow accommodation within the hollow interior of the hollow outer bushing 251 . The inner bushing 247 is provided with an opening 253 large enough to allow unhindered axial movement of the screw spindle 41 , but small enough to prevent passage of the nut 249 . The outer bushing 251 is provided with a first perimeter opening 255 of a size large enough to allow passage of the nut 249 . The outer bushing 251 is also provided with a second perimeter opening 257 on an opposite side and aligned with the first perimeter opening 255 . The second perimeter opening 257 is of a size large enough to allow certain relative rotational movement of the outer bushing 251 in respect of the inner bushing 247 with the screw spindle 41 in position and extending through the second perimeter opening 257 . All of FIGS. 11 through 14 show the bushing element 247 and the outer bushing 251 . If upon retraction of the awning the outer bushing 251 were rotated from the position shown in FIG. 12 to a position in which the nut 249 could escape through the first perimeter opening 255 , then the locked position of the link ( 37 in FIGS. 2 through 10) would be cancelled for the purpose described herein above. To this end the outer bushing 251 may be provided with a flange portion 259 in one of its axial ends, from which flange portion a lever arm 261 may extend (see in particular FIGS. 13 and 14 ). The lever arm 261 may have an opening for engagement by a linking rod or the like (not shown, but known to the skilled person from GB 2042058) operatively connecting it to a confronting awning arm. Although the angular rotational movement of the outer bushing 251 may optionally be limited by the size of the second perimeter opening 257 and the screw spindle 41 extending therethrough it may also be convenient to have a separate indexing means for this. As shown in FIGS. 11, 13 and 14 such indexing means may comprise one or more radially extending pins 265 , 267 on the inner bushing 27 and one or more corresponding annular recesses 269 , 271 on the outer bushing 251 .
FIG. 15 shows a cross section through one form of awning according to the present invention, which is shown in a retracted position. In this position the front bar 9 acts as a lid to close the forward opening of cassette box 3 , which houses the entire awning mechanism in its retracted position. It is seen that the cassette 3 houses a roller 5 on which the awning cloth is wound. A square section bar or rod 85 is used in this embodiment to mount the various awning components, notably the arm support brackets.
A wall mount bracket 87 is used to fix the square section bar 85 in position with respect to a vertical building surface (not shown, but conventional and known to the skilled person). The square bar 85 further receives at least two base parts 35 of the appropriate arm support brackets ( 15 and 17 in FIG. 1 ). FIG. 15 also illustrates a version of awning incorporating a lockable gas spring 57 such as schematically shown in the embodiment of FIG. 5 . This gas spring 57 is of an appropriate type as supplied by the firms of Stabilus or of Strömsholmen AB is of a variety that can be locked in any desired position of telescopic adjustment in a manner commonly found in adjustable office seats and typing chairs. Further FIG. 15 shows the attachment of the front bar 9 to the second section 25 of the collapsible awning arm. To this end the second section 25 carries a front pivot pin 89 onto which an arcuate mounting plate 91 is hingeably mounted. The mounting plate is affixed by suitable fasteners (not shown but conventional) to a correspondingly inwardly arcuate rear surface of the front bar 9 . The abutting arcuate surfaces of the mounting plate 91 and the front bar 9 allow for accurate angular adjustment of the front bar 9 , so that it closes the cassette 3 in the correct orientation.
Also shown in FIG. 15 is another eyelet coupler 92 through which the awning can be driven into an extended position or from an extended position to a retracted position by means of a conventional crank rod (not shown). The eyelet coupler 92 through a shaft and an appropriate gear transmission drives the roller 5 in a conventional manner to wind or unwind the awning cloth. Extension of the awning cloth will further be promoted in that the collapsible awning arms are resiliently biased towards the extended position as will be further explained herein below. The skilled person will also instantly recognise that the roller 5 can be driven by any electric motor, such as through a tube-type motor or the like. Suitable motors are widely available for this purpose from amongst others the firms of: ELERO Antriebs-und Sonnenschutztechnik GmbH, Becker-Antriebe GmbH or SOMFY.
For a description of a suitable collapsible arm for use in a collapsible frame according to the invention reference will now be made to FIGS. 16 though 27 . FIG. 16 shows a top plan view of a collapsible awning arm corresponding to awning arm 13 of FIG. 1 .
Arm 13 has a first pivoting section 23 and a second pivoting section 25 . The first and second pivoting sections are joined to one another by a central pivot swivel 29 and the front pivot pin 89 connects mounting plate 91 to an opposite end of the second pivoting section 25 .
An end of the first arm section 23 opposite of the central pivot swivel 29 carries a forked end 93 for hingeably attaching to the bearing section 63 of any of the arm support brackets of FIGS. 2 through 9. In this regard a hinge pin (not shown, but conventional) will be inserted through respective openings 95 , 96 in an aligned arrangement with the through bore 65 of one of the arm support brackets 115 , 215 , 315 or 415 . The first and second arm sections 23 , 25 each comprise a length of tubular profile 97 , 99 respectively, which can each be of an appropriate length in relation to the desired drop of the awning and the extended length of the awning cloth ( 7 in FIGS. 1 and 15 ). The variability of the arm length is indicated by interruptions of the tubular profiles 97 and 99 in FIGS. 16 through 19.
The forked end 97 is in the form of a first end plug element 101 , which partly engages into the hollow interior of the tubular profile 97 . The central pivot swivel 29 is an assembly of second and third plug elements 103 , 105 . The front pivot pin 89 and mounting plate 91 are hingeably mounted on yet another, fourth plug element 107 . FIG. 17 shows a front elevation of the awning arm of FIG. 16 and FIGS. 18 and 19 show perspective views of the same awning arm from opposite directions. FIG. 17 allows the recognition of spring tensioned flexible fourth plug element 109 which extends around the central pivot swivel and which biases the first and second arm sections 23 , 25 towards a straightened longitudinally aligned position. The flexible fourth plug element 107 can be spring tensioned by one or more tension springs housed in one or each of the tubular profiles 97 and/or 99 in a conventional manner. Suitable arrangements for biasing awning arms into an extended position are described, for example, in GB 1.175.723; EP 0.125.727; EP 0.489.186 and EP 0.795.660. In particular these documents show the arrangement of tension springs and the use of different forms of flexible elements, such as cables; chains and flexible belts or strips. The skilled person may additionally be aware of still further suitable constructions and further description is considered therefore to be redundant.
FIGS. 17 and 19 in particular show that the arcuate mounting plate 91 is provided with vertically extending arcuate slots 111 , 113 . The slots 111 , 113 can receive fasteners for adjustably attaching the front bar 9 (FIGS. 1 and 15) to the mounting plate 91 .
FIGS. 20 and 21 show perspective views from opposite directions of the first end plug element 101 , before it is mounted in the tubular profiles ( 97 in FIGS. 16 through 19 ). Such a component can be conveniently formed as a moulding in metal or optionally plastic. The first end plug 101 includes a plug-in end 121 , which can additionally be provided with anchoring openings 123 for attachment of an arm biasing tension spring (not shown, but described in GB 1.175.723; EP 0.125.727; EP 0.489.186 and EP 0.795.660). Also provided on the plug in end 121 is a generally T-shaped channel arrangement 125 which is in communication with an opening 127 . The opening 127 will be in an exposed position after mounting of the first end plug 101 in the tubular profile 97 . The T-shaped channel arrangement 125 can be extended along the edges of the plug-in end at 129 and 131 . The opening 127 and channel arrangement are for a purpose to be explained in reference to FIG. 27 below.
FIG. 22 shows the second plug element 103 which forms part of the central pivot swivel 29 . The second end plug element 103 is provided with a T-shaped channel arrangement 133 similar to that of the first plug element described in reference to FIGS. 20 and 21. The channel arrangement 133 is on a similar plug-in end 135 and communicates with an exposed opening (similar to 127 of FIGS. 20 , 21 but not visible in the view according to FIG. 22 ). It is further apparent from FIG. 22 that the second plug element 103 is provided with a hinge body 137 having a central hinge bore 139 for co-operation with the third plug element 105 illustrated in FIG. 23 .
The third plug element 105 illustrated in FIG. 23 is provided with a plug in end 161 which is generally similar to the plug-in end 135 of FIG. 22, but shown from an opposite side. A similar T-shaped channel arrangement 163 is provided on the plug-in end 135 , but most of it is positioned on the reverse side, which is not visible in the view of FIG. 23 Also, in the third plug element 105 the channel arrangement will be communicating with an opening similar to opening 127 of FIGS. 20 and 21 but this again is hidden from view in FIG. 23 . Since these features are generally identical to those already described in reference to FIGS. 20 through 22, and will be further explained in reference to FIG. 27, further description at this point is considered unnecessary. FIG. 23 also shows that element 105 is further provided with hinge ears 165 , 167 for receiving the hinge body 137 therebetween. Further, the hinge ears 165 , 167 are each provided with a relevant opening 169 , 176 for alignment with the central hinge bore 139 whereupon a conventional hinge pin (not shown) can be inserted to hingeably connect the second and third plug elements 103 , 105 .
FIGS. 24 through 26 show an assembly of the fourth plug element 107 and mounting plate 91 . FIG. 24 generally also shows the front pivot pin 89 which can have an additional angular compensation feature that will be explained in reference to FIG. 25 . FIG. 24 further shows that the fourth plug element 107 also has a plug-in end 173 by which it can be inserted into the tubular profile 99 , which is partly broken away to show this. The plug-in end 173 is again substantially similar to those described in reference to the structures of FIGS. 20 though 23 and further features thereof will be explained in reference to FIG. 27 . The exposed portion of the fourth plug element 107 as shown in FIG. 24 also has a pivot pin receiving protrusion 175 received between upper and lower hinge ears 177 , 179 extending from the rear side of the mounting plate 91 and held together by the front pivot pin 89 .
FIG. 26 shows an enlarged fragmentary front elevation of the fourth plug element 107 and mounting plate 91 assembly as represented in FIG. 17 and FIG. 25 shows a cross section through the same assembly in accordance with the line XXV—XXV in FIG. 26 . FIG. 25 in particular shows the angular compensation feature for the front pivot pin 89 . The front pivot pin 89 in this regard includes a central axle 181 which has a screwdriver slot 183 at its bottom end. The axle 181 is engaged in a collar 185 by means of a male screw thread on the axle 181 and female screw thread on the inner bore of the collar 185 . The collar 185 is both rotatably and axially pivotally held by its upper outer circumference with which it is engaged in a bore of the lower hinge ear 179 . It is possible to retract (or engage) the central axle 181 from (or into) engagement with the upper hinge ear 177 by unscrewing (or screwing home) the axle 181 with respect to the collar 185 . In the upper hinge ear 177 there is engaged a transverse angle compensating bearing element 187 which has a bearing cavity for rotatably receiving the upper end of the central axle 181 . The bearing element 187 is generally formed as a cylindrical body with its outer circumference mated to a horizontal bore in the upper hinge ear 177 . The bearing element 187 is horizontally slidable in respect of the upper hinge ear 177 . This results in some limited angular lost motion between the mounting plate 91 and the front awning arm section 25 . Conveniently the amount of lost motion is about 7 degrees, which would enable to cope with most of the misalignments encountered with the front bar 9 and the cassette 3 upon full retraction of the awning. The skilled person can devise alternative angle adjustment means for adjusting the angle of the mounting plate 91 in respect of the front pivot 89 and the previously described arrangement is nothing more than one possible solution.
FIG. 27 illustrates a novel technique for affixing the plug-in ends of the plug elements to the ends of the tubular profiles. Although FIG. 27 shows this in particular for the first end plug element 101 and the first tubular profile 97 a similar arrangement will be used for the second, third and fourth plug elements 103 , 105 , 107 as well as for the second tubular profile 99 . It has been known for awnings to affix such plug element by means of glue or adhesives but it has so far always been necessary to apply the glue before assembly of the plug and profile parts. This has made control over the glue connection very difficult in that too small an amount of glue was bound to be scraped off and removed from the critical areas. An excessive amount of glue has likewise resulted in ineffective connections and in an uneconomic use of usually expensive adhesive compositions. According to the present invention the plug element 101 is first inserted into an end of the tubular profile 97 as shown in FIG. 27, but yet without adhesive material. Only after assembly a suitable glue or adhesive is injected through opening 127 (see FIGS. 20 and 21) and a bead of glue or adhesive 189 is formed in the T-shaped channel formation 125 . This has resulted in a much improved distribution of the adhesive material as well as in a more economic use thereof.
FIGS. 28 through 38 illustrate a novel arrangement for the automatic control of electrically operated awnings. FIG. 28 shows a weather sensor unit 421 for mounting onto the front bar of awning (front bar 9 in FIGS. 1 and 15 ). The sensor unit 421 on its front face carries a wind sensor 423 in the form of a resiliently movably mounted wind catching body, shaped as a hollow housing. A first electronic movement sensor such as a motion switch sold by Assemtech Europe Ltd under part number MS 24 is incorporated into the hollow wind catching body 423 . The sensor unit 421 further houses a solar panel 425 which can extend to both sides of a central housing 427 . The solar panel charges an accumulator or battery ( 477 in FIG. 30 ), which forms the power supply for the entire sensor unit. Further, the sensor unit 421 houses a water sensor 429 for sensing rain, a light sensor and a temperature sensor which will be further identified in reference to FIG. 30 which shows the electronic circuit of the sensor unit 421 . Optionally, a shock sensor may additionally be included in the sensor unit 421 .
Further the sensor unit 421 includes an antenna or the like for wireless transmission of parameter values to an indoor control unit.
FIG. 29 shows an indoor control unit 431 having a display device 433 for displaying parameter values, which may in part have been transmitted to it from the outdoor weather sensor unit 421 . The control unit 431 also has a number of buttons for selecting different functions and for making adjustments. The programming buttons for adjustments of threshold values are normally covered by a pivotable lid 435 . With the pivotable lid 435 closed, only a limited number of buttons is exposed and these include a button 437 for selecting the mode of the display device 433 , and an auto/manual mode selection button 439 , a stop button 441 for interrupting the operation of the control unit and preferably somewhat larger buttons for manually selecting deployment or extension 443 and for manually selecting retraction of the sun protection device 445 . Adjustments of various settings can be obtained by a number of buttons behind the pivotable lid 435 . These include selector buttons for setting the sensitivity by changing a threshold value of the wind sensor 447 , the sun sensor 449 , the optional shock sensor 451 and a programming enter button 453 . After selection each of these switches combines with a tumbler switch 455 for either increasing or decreasing the sensitivity of the selected sensor. By subsequently actuating the enter button 453 any change in sensitivity threshold can be stored. The adjusted settings are subsequently transmitted from the control unit 431 to the outdoor sensor unit 421 . The wireless transmission between the units 421 and 431 effectively eliminates any requirement for cabling between these units and hence significantly promotes an efficient installation of the awning as well as an improved reliability.
The control unit 431 additionally controls the power supply to an electric motor for operating the awning as will be discussed in reference to FIG. 32 . Further details of the weather sensor unit 421 will become apparent from a discussion of its circuitry shown in FIG. 30 and those of the control unit 431 from a discussion of its circuitry shown in FIGS. 31 and 32.
FIG. 30 shows the circuitry of the outdoor weather sensor unit 421 which includes a shock sensor 461 . The shock sensor determines movement of a front bar ( 3 in FIGS. 1 and 15) which may go beyond the notice of a motion sensor 463 (for wind sensor 423 ). Also included in the circuit of FIG. 30 are a light sensor 465 , a water sensor 467 for detecting rain and a temperature sensor 469 for assisting the light sensor in determining sunshine levels. Each of these sensors feeds a processor 471 which decides, on the basis of stored threshold values, whether or not the awning will be operated to extend or to retract. The processor 471 to this end communicates with a memory device 472 and a transceiver 473 , which is connected to an antenna 475 for radio frequency signals. Other forms of wireless transmissions are conceivable and these would include infra-red or ultra-sound, but in the environment of an outdoor awning some preference is given to radio frequency waves and hence the presence of an antenna 475 , which can conveniently be incorporated on a printed circuit board and as such may be positioned behind the solar panel 425 of the sensor unit 421 . The memory device 472 preferably is an EEPROM (electronically erasable programmable read-only memory) for storing threshold values for the sensor readings.
The solar panel 425 will continuously charge, depending on the ambient light conditions, an accumulator 477 which will also take care of the temporary power requirements of the sensor unit 421 . The accumulator 477 preferably is a Nickel Metal Hydride (NiMH)-type battery. NiMH battery chemistry stores up to 40% more power than conventional Nickel Cadmium (NiCd) rechargeable batteries and can deliver this power much more quickly. NiMH batteries unlike NiCd have no memory effects, they will store almost the same amount of power for their entire lifetime. NiMH rechargeable batteries last through 500-1000 recharge/discharge cycles and are considered perfect for high drain electronics. Temporary power requirements thereby may exceed the instantaneous capacity of the solar panel. Preferably a charging circuit between the solar panel 425 and the accumulator 477 includes a DC to DC step-up converter. A preferred form of step-up converter for use with solar panels and NiMH-type accumulators uses one or two MOSFET semiconductor elements in combination with a Schottky diode. As discussed above the motion sensor 463 incorporated in wind sensor 423 can be an omni-directional motion switch MS 24 from Assemtech Europe Ltd. Alternatively the wind sensor 423 can be in the form of a piezo element, which can be regarded as a voltage source with a large capacity. An appropriate amplifier circuit ensures that strongly varying signals, such as noise of air moving past the piezo-sensor, cause pulses which lower the voltage on an exit capacitor. The higher the speed of wind, the lower the voltage of the capacitor. This output is connected to the processor 471 . The shock sensor 461 conveniently can be a lesser sensitive motion switch and preferably is a device sold by the Comus Group of companies as their part number CM 4400-1.
FIGS. 30 a and 30 b show a circuit arrangement alternative to that of FIG. 30 . Like components have been indicated by similar reference numerals with a suffix “a”. Shock sensor 461 a is connected to the “SHOCK” terminal of central processing unit 471 a . Wind and motion sensor 463 a ( 423 in FIG. 28) is a piezo sensor and connects to the “WIND” terminal of central processor 471 . Light sensor 465 a , water (or rain) sensor 467 a ( 429 in FIG. 28) and temperature sensor 469 a are positioned conveniently on a separate sensor circuit board, the circuit of which is illustrated in FIG. 30 b . The circuit of FIG. 30 b connects to the circuit of FIG. 30 a through a 12-pins male and female connectors “HDR — 12”.
Also shown in FIG. 30 b is a further connector “HDR — 6”, which connects to the connector “HDR — 12”. This further connector “HDR — 6” is a Flash program connector for the externally writable data memory integrated in processor unit 471 a . This memory replaces the external memory device 472 of the FIG. 30 embodiment. A transceiver unit 473 a connects to antenna 475 a . Particularly advantageous is the “Low Voltage Solar Converter Unit”, which connects the solar panel 425 a to a battery assembly 477 a . The “Low Voltage Solar Converter” includes a step-up DC-to-DC converter (sometimes also called a voltage increasing chopper). The main components of the step-up converter are: inductor/inductance L 4 ; semiconductor switch T 4 and supplemental N-channel MOSFET T 2 ; diode D 1 (Schottky ZHCS 750) and capacitor/capacitance in the form of high capacity elco C 23 compensated for low resistance by additional capacitors C 19 and C 20 .
Semiconductor switch T 4 operates the step-up converter at those times when the voltage is too low to operate the MOSFET switch T 2 . Switch T 4 is operated by an oscillator circuit as indicated in FIG. 30 a by a dash-dotted box. The output of the oscillator connects to the “STARTUP_OSC>>” connector of the step-up converter where Schottky diode D 3 (ZHCS750) adds the output voltage of the solar panel 425 a to the pulsed voltage generated by the oscillator. The resulting voltage is offered to the base of T 4 .
As soon as the voltage offered to the step-up converter is high enough for the MOSFET switch T 2 to operate, the oscillator output is grounded through semiconductor T 3 of the oscillator circuit. Then the MOSFET T 2 is controlled from the “N_GATE>>” output of the central micro processor 471 a and a further P-channel MOSFET T 1 is controlled from the “P_GATE>>” output of the processor 471 a to take over from the Schottky diode D 1 . The P and N gates of the processor 471 a are software driven.
In this manner a particularly advantageous step-up converter has been obtained. The alternative use of semi-conductor switches T 4 and T 2 provides for a register or compound step-up converter that has optimal characteristics for each of a low voltage and a higher voltage range.
The provision of Schottky diode D 3 enables to offer an as high as possible voltage to the base of the low voltage semiconductor switch T 4 . The additional MOSFET switch T 1 , which is positioned in parallel to diode D 1 , allows to eliminate the losses which normally occur in diodes such as D 1 .
FIG. 31 shows the low voltage circuitry of the indoor control unit 431 which includes a processor 481 connected to an oscillator 483 . Further the processor 481 is connected to the display device 433 through a data bus 482 and 8-bits latches 484 and also to an EEPROM (Electronically Erasable Programmable Read-Only-Memory) 485 . Optionally but not necessarily the circuitry of FIG. 31 can be provided with test and/or programming connectors such as 487 , 489 and 491 . Further an array of light emitting diodes (LED's) 493 may be provided for illumination of the display 433 . For connection to the high voltage circuitry there is an 8-pins male connector 495 .
FIG. 31 a shows an alternative circuit arrangement to the low voltage circuitry of FIG. 31 . Similar components have been indicated by like reference numerals carrying a suffix “a”. Switches SW 1 through SW 12 w are similar to those in FIG. 31 and generally correspond to the buttons and switches shown in FIG. 29 on the control unit 431 as follows:
SW 1 = 447 (wind)
SW 2 = 437 (display)
SW 3 = 446 (installers programming switch)
SW 4 = 449 (sun)
SW 5 = 439 (auto/manual)
SW 6 and SW 7 = 455 (sensitivity +and −)
SW 8 = 451 (shock)
SW 9 = 453 (enter)
SW 10 = 443 (extension/roll out)
SW 11 = 441 (stop/interrupt)
SW 12 = 445 (retraction/roll in)
A processor 481 a is responsive to software including steps according to any one of the flow charts according to FIGS. 34-37 and through a data bus 482 a is connected to an EEPROM device 485 a and a LCD-display 433 a . The LCD display 433 a is controlled through six 8-bits latches 484 a . The circuit of FIG. 31 a further includes a number of optional test or programming connectors 487 a , 489 a , 491 a , of which the latter is intended for the display device 433 a.
Also shown in FIG. 31 a is an additional BUZZER, which signals the execution of a programming or adjusting step to a user. The component “U3” in FIG. 31 a and “NEWSHAPE” in FIG. 31 represents a temperature sensor for measuring the indoor temperature.
FIG. 32 shows the high voltage section of the circuitry of the control unit 431 with a corresponding 8-pins female connector 496 for connection to the low voltage section. The high voltage or power section has a 220V mains supply 501 , an earth connector 503 , a motor current connector for retraction 505 and a motor current connector for extension 507 .
Additional motor control circuitry is normally integrated in the conventional drive motor units but could alternatively also be integrated on the circuit board of FIG. 32 beyond the connectors 505 and 507 . This is optional and depends on the type of motor unit used.
Further the high voltage circuitry of FIG. 32 includes a transformer 509 and a transceiver 511 and antenna 513 for communication with the sensor unit 421 .
FIG. 32 a is generally similar to the previously disclosed high voltage power section circuit of FIG. 32 . Again an 8-pins connector 496 a connects to the printed circuit board of the low voltage circuitry of FIG. 31 a at 495 a . Like components have been designated by like reference numerals provided with the suffix “a”.
FIG. 33 shows a flow chart for the processor 471 of the sensor unit 421 of FIGS. 28 and 30. In step 601 a wake-up signal is produced which initializes the processor 471 in step 603 . In step 605 the processor 471 determines whether or not the sensor unit 421 is in a programming mode. If it is not, step 607 measures the amount of light, step 609 measures the temperature, step 611 determines the presence of wind, step 613 determines the presence of shocks and step 615 determines the presence of rain by use of the various sensors described hereinabove. Subsequently, step 617 compares the measurements with the predefined thresholds.
Since it is conceivable that an awning or the like window covering with a wireless transmitting sensor unit as disclosed is going to be used in the vicinity of another similar device, it is desirable that each of such devices would only respond to its associated control unit and not to any other transmitters or control units in its neighborhood. Therefore each control unit 431 will be given an individual one of a number of different channels. Upon installation it will then be necessary for the transmitter of the sensor unit to identify itself to its respective control unit. This is why step 605 checks for the presence of a programming instruction. If this is detected, step 619 requests transmission of address information from the control unit and with step 621 is set to receive channel information from the control unit 431 . Such programming instructions can be given by short-circuiting the conductive contacts of the water/rain sensor ( 429 in FIG. 28; 467 in FIG. 30 ), which can be recognised by the processor 471 as a programming instruction. If step 623 determines that transmission channel information is not received within a specified delay, step 625 will return the sensor unit 421 to its sleep mode. If the specified delay is not found to have lapsed by step 623 , then step 627 will continue to look for transmission channel settings until step 629 continues with a confirmation of such setting or until step 623 determines the lapse of the predefined delay for receiving such settings. Step 627 thus checks the receipt of channel settings and repeats steps 621 and 623 for as long as the programming instruction is valid. Once channel information has been received, step 629 confirms such receipt to the control unit 431 and step 631 takes the address information from the received channel settings transmission. Step 632 then stores the channel address in the memory device (EEPROM) 472 of the sensor unit 421 . After this step 633 returns the sensor unit 421 to its sleep mode. Returning now to step 617 , which compares the sensor values with the stored thresholds in the memory device ( EEPROM) 472 , if this determination does not indicate any necessary activity (that would result from exceeding of any of the thresholds) steps 635 and 637 will return the sensor unit 421 to its sleep mode as long as a predefined period of time (i.e. 1 to 5 minutes) has not passed. As soon as step 635 determines the lapse of the predefined time interval it communicates with the control unit 431 through steps 639 , 641 and 643 . Also if the determination at step 617 indicates measurements surpassing the pre-set threshold; then also the sensor unit 421 communicates with the control unit 431 through steps 639 , 641 and 643 . Upon such communication, step 645 checks whether a response from the control unit 431 is received within a pre-set time frame and if not it will return the sensor unit 421 to its sleeping mode. If step 645 and 649 have determined that a message has been received from the control unit then step 651 saves the new settings and step 653 returns the sensor unit 421 to its sleep mode. Within the present time frame steps 643 , 645 and 649 will repeatedly be cycled so that the receipt of new settings from the control unit 431 may be intercepted.
FIG. 34 shows the basic flow chart for the control unit 431 and its processor 481 . After connecting the unit to a power supply, represented by step 655 , the unit will be initialised at step 657 . Then a continuous cycle starts which continuously checks the selected mode of operation. In step 659 it is determined whether a programming mode has been selected and if so step 661 will revert to the program mode sub-routine shown in FIG. 35 .
If no programming mode is detected in step 659 then step 663 determines whether an installation mode has been selected. If this is found to be the case step 665 refers to the installation sub-routine of FIG. 36 . Otherwise the cycle will continue at step 667 to check whether the manual mode has been selected by switch 439 . If such proves to be the case step 669 will enter the manual mode subroutine of FIG. 37 . Otherwise the cycle continuous to step 671 to find out whether the automatic mode is selected by switch 439 to refer to the subroutine of FIG. 38 through step 673 or to repeat the above described cycle from step 659 .
FIG. 35 shows the programming mode sub-routine for the control unit 431 , which starts at step 661 . The processor 481 at step 675 selects a relevant sensor settings from its table stored in EEPROM 485 in response one of the selector buttons 447 , 449 or 451 having been actuated and step 677 displays this sensor setting on the display 433 . Step 679 thereupon determines whether another actuation of a program button has been effected to select a different setting for display. If this is positive, step 681 will select the relevant value from the table setting and display this. Once the operator does not depress a program button for another selection step 683 determines whether the tumbler switch 455 is depressed to increase the current value and if so to add in step 685 one value increment and in step 687 to display the increased value. If however step 683 does not recognise actuation of the switch 455 towards increasing, step 689 will determine actuation of switch 455 in the decreasing direction and if positive through steps 691 and 693 lowers and displays the adjusted value.
Irrespective of the determination at step 689 the subroutine will be continued with step 695 which determines whether the stop button 441 may have been depressed and if so step 697 returns to step 663 in the main program. Otherwise the subroutine will continue and check as step 699 whether the enter button 453 has been depressed. If the enter button 453 has not been depressed the sub-routine repeats from step 677 . When the enter button has been depressed the subroutine continues with step 701 . Step 701 awaits the receipt of an information package from the outdoor sensor unit 421 . After 20 seconds, step 703 , through step 705 will display an error in display device 433 whereupon step 707 returns to the main program to continue at step 663 .
Until such time step 709 will determine whether any information package is received in full and return to step 701 or continue at step 711 . In step 711 a modified information package is prepared, containing any new limits, which subsequently in step 713 are sent to the outdoor sensor unit 421 . Step 715 awaits a confirmation of receipt by the sensor unit 421 and if this is not obtained within a predefined time span step 719 indicates an error in display device 433 , after which step 721 returns to the main program to continue at step 663 (FIG. 34 ). During the predefined time span step 723 will determine the presence of a recognisable receipt confirmation of the information package or return to step 715 for another cycle. If a correct confirmation is received step 725 will store the new settings also in its EEPROM 485 . Step 727 will thereafter return to the main program and continue with step 663 .
FIG. 36 illustrates the installation sub-routine, which allows fine adjustments upon installation in contrast to the course adjustments permitted by the user and described with respect to FIG. 35 .
Step 663 in the main program (FIG. 34) detects whether the installation program switch ( 446 in FIG. 29) has been actuated and continues at step 665 with the sub-routine of FIG. 36 . Conveniently the program switch is only reachable for operation by inserting a pin or a needle through a restricted opening. This prevents accidental actuation by the intended user. Step 729 then selects a first one of either an address, light sensor setting; a shock sensor setting or a wind sensor setting from a memory table and continues in step 731 with displaying the relevant value on the display device 433 . Switch 733 detects whether the installers switch 446 has been additionally actuated and if so at step 735 selects the next value from the memory table and repeat the cycle with displaying this next value at step 731 . If step 733 does not detect any further actuation of the installers switch 446 it continues with step 737 with determining the actuation of the sensitivity switch 455 for an increase. If so steps 739 and 741 adjust to the table value and the adjusted value is displayed in the display 433 . If no actuation of the sensitivity switch 455 towards an increased value can be determined the program continues at step 743 , which determines the actuation of switch 455 towards any decrease of the displayed table value. If so the value is decreased accordingly and stored in the table at step 745 and displayed at step 747 . If no actuation of sensitivity switch 455 can be determined at all the program continues at step 749 and determines whether perhaps the stop button 441 has been depressed. If so step 751 returns to the main program (FIG. 34) to continue with step 667 . If the stop button 441 has not been actuated step 753 checks whether perhaps the enter button 453 has been actuated to give an enter instruction. If this is not the case the same cycle is repeated from step 731 . If an enter instruction is received through actuation of the enter button 453 the program will continue with step 755 to receive an information package with current settings from the outdoor unit 421 (FIGS. 28, 30 and 33 ). If step 757 determines a receipt failure after 20 seconds step 759 will display an error message on the display 433 and step 761 will return to the main program to continue with step 667 . Otherwise step 763 will repeat the cycle from step 755 until a complete information package has been received. After this step 765 will add any new limits and address to prepare a new information package for sending to the outdoor unit 421 . Step 767 will subsequently send the modified information package and step 769 will await a confirmation transmittal from the outdoor unit 421 . Step 771 will check whether the predefined time frame for the receipt of a confirmation has lapsed and if so will display and error message in the display 433 and return with step 775 to the main program to continue at step 667 . Step 777 will repeat the previous cycle from step 769 until a full confirmation has been received, in which case optionally step 779 may check the confirmation of an optional remote control unit (to be described in reference to FIGS. 39 and 40) has also confirmed receipt of the new set of information. If not, step 779 recycles from step 767 by resending the information package. If steps 777 and 779 have been positively concluded then step 781 will store the values in EEPROM 485 and step 783 will return to the main program to continue with step 667 .
FIG. 37 depicts the flow-chart of the manual mode sub-routine reverted to from step 669 of the main program of FIG. 34 . Step 669 in FIG. 37 starts the manual mode selected by button 439 of the control unit. Step 785 determines whether the sensor unit has transmitted any exceeding of the shock sensor threshold value. If so step 787 activates the retraction control. Thereafter step 789 returns to the main program to continue at step 671 . If no excess shock has been reported step 791 checks whether the water (or rain) sensor ( 429 in FIG. 28; 467 in FIG. 30) has been activated or not. Activation of the rain sensor results in step 793 to instruct retraction of the awning and step 795 to return to the main program to proceed with step 671 . If no rain has been reported step 797 checks whether retraction button 445 has been depressed. If not the subroutine continues at step 801 and also after instructing the retraction of the awning upon a positive signal in step 797 . Step 801 determines whether perhaps the extension button 443 has been actuated, in which case step 807 instructs the extension of the awning. Either directly from step 801 or via step 807 the next step 805 checks activation of the stop button 441 to interrupt at step 807 any extension or retraction under progress. If no interruption has occurred or after interruption has been effected the sub-routine of FIG. 37 at step 809 returns to the main program of FIG. 34 to continue with step 671 .
FIG. 38 shows the auto mode sub-routine which follows step 673 of the main program. Step 673 activates the auto mode and step 811 checks the transmitted measurement values of the shock sensor 461 . Step 813 corresponds to step 787 of the manual sub-routine of FIG. 37 and step 815 continues the main program at step 659 . Steps 817 through step 821 also result in a similar sequence to that of steps 791 through 793 of the manual sub-routine of FIG. 37 except that step 821 continues the main program with step 659 . Step 823 , with which the sub-routine of FIG. 38 continues if no excessive shock or the presence of rain is reported, is an additional step specific for the auto mode operation of FIG. 38 . Step 823 checks exceeding of a predefined level of light from the light sensor 465 . If positive this will result in step 825 to instruct extension of the awning. If not or following step 825 a further additional auto-mode step 827 checks whether a predefined value of the wind sensor 423 has been exceeded. If positive step 829 will instruct retraction of the awning and continue with step 831 . If step 827 results in a negative determination the sub-routine will also continue with step 831 . Steps 831 through 843 are identical to steps 797 through 809 of the manual sub-routine of FIG. 37 except that the return step 843 continues the main program (FIG. 34) with step 659 rather than step 671 . For a further explanation of these steps reference is therefore made to the preceding description of FIG. 37 .
FIG. 39 illustrates an optional wireless remote control transmitter 901 . The transmitter 901 is conveniently shaped reminiscent to the right hand portion of the indoor control unit 431 and carries the operational buttons in an identical lay-out. Button 903 operates the retraction of the awning and corresponds to button 445 of the control unit 431 . Button 905 operates the extension of the awning and corresponds to button 443 of the control unit 431 . Button 907 is a stop button to interrupt previously given instructions and is similar in function to button 441 of the control unit 431 . Button 909 is the auto or manual mode selector button and corresponds to button 439 of the control unit 431 . Using this arrangement of similarly positioned buttons on the remote control transmitter 901 makes for a user-friendly operation. Also the replicated exterior design enhances easy recognition of the present remote transmitter amongst several remote control transmitters as these may be encountered in modern households. In a forward end 911 of the transmitter 901 a window may be provided through which either infrared light or ultra-sound emitted for wireless transmission of any instructions.
Also the transmitter 901 may be arranged with a suitable antenna and use radio frequency signals. As such transmitters usually fed by one or more batteries are conventional and the skilled person will readily recognise a suitable arrangement for such a device. A detailed discussion of the necessary circuitry is thereby largely redundant. It is however useful to duplicate some of the programmable features from the control unit 431 also in the remote control transmitter 901 .
As shown in FIG. 40 the remote control transmitter may be arranged to carry out a number of program steps. Step 915 comes into operation as soon as one of the buttons on the transmitter is depressed. This connects the power source in the form of one or more batteries (not shown) to the circuitry of the transmitter. Step 917 initializes and step 919 recognises which of the buttons has been depressed. At step 921 it is determined whether also at the same time a programming switch is activated. Such a programming switch can be hidden from normal use in the battery compartment.
The function of such a programming is to identify the remote control to the control unit upon installation, as will be described separately hereinbelow. Under normal consumer operation the programming switch will not be operated and step 923 will download the address information previously programmed from an EEPROM. Subsequently steps 925 will combine this address information with instructions relating to the relevant depressed actuation button 903 , 905 , 907 or 909 and assemble this into an instruction package to be sent to the control unit 431 .
Step 927 will transmit this package and step 929 will pause for a while before restarting the cycles at step 927 . This cycles is endless and will be continued for as long as the operating person depresses one of the button on the remote control transmitter 901 . After the button is released the cycles stops because the power source is disconnected. Reapplying any of the buttons will result in the program to restart at step 915 .
Since it is conceivable that an awning or the like window covering with a remote control as disclosed is going to be used in the vicinity of another one it is desirable that each of such devices would only respond to its associated remote control transmitter and not another transmitter in its neighbourhood. Therefore each control unit 431 will be given an individual one of 256 different addresses. Upon installation it will then be necessary for the transmitter to introduce itself to its respective control unit. This is why step 921 checks for the simultaneous actuation of a programming switch. If this is detected, step 931 requests transmission of address information from the control unit and with step 933 is set to receive address information from the control unit. Step 935 checks the receipt of such address information and repeats steps 933 and 935 as long as the same buttons are depressed and until address information is received. Once address information has been received step 937 confirms such receipt to the control unit 431 and step 939 takes the address information from the received transmission. Step 941 then stores the address information in the EEPROM of the transmitter 901 . As long as the buttons and programming switch are not released the cycle is repeated from step 933 onward. After release of the buttons, which disconnects the power source any subsequent actuation of any of the buttons 903 , 905 , 907 or 909 will again start the program from step 915 .
FIG. 41 shows one possible form of circuitry for the hand-held transmitter 901 , which incorporates a controller 951 , a transceiver 953 and a radio frequency antenna 955 . Actuation of one of the buttons 903 , 905 , 907 , or 909 results in a power supply to be connected to the controller 951 via the transistor 957 . The controller 951 using the programmed sequence of FIG. 40 thereupon will establish wireless communication with the control unit 431 .
FIG. 41 a is a further embodiment of the transmitter circuit of FIG. 41 and part of a remote control transmitter as shown in FIG. 39 . Like reference numerals are provided again with suffix “a”. The feed supply stabilisation shown separate from the circuit is actually connected thereto at its “VDD”, “VCC” and “GND” terminals. The controller or processor 95 a is responsive to the programmed sequence of FIG. 40 .
In addition to the components already disclosed and discussed with respect to FIG. 41 there are now additional switches/buttons SW 5 , SW 6 and SW 7 for remote programming and adjustment of the control unit 431 . The switches SW 5 through SW 7 can be hidden on the transmitter 901 behind a lid or may be positioned on the bottom side thereof (not visible in FIG. 39 ).
Switch SW 5 enables one to generate a random address and to communicate this address to the nearest control unit. For this purpose a 22K resistor has been included in the connection between terminal “PA6” of processor 951 a and terminal “RF_PWR” of transceiver 953 a . This 22K resistor limits the power of the transmitter in only its program mode to ensure that only the nearest control unit 431 responds to the transmitted signals and thereby the transmission does not alter the setting of any nearby further control unit. Switch SW 6 depending on a combined use with switch SW 5 has the functions of either changing the direction of retraction or extension or programs the end “switch” for the extension or outward movement.
Switch SW 7 in a similar way has the function of programming an end “switch” for the retraction or inward movement while alternatively it has the function of setting an amount of reverse rotation after operation of an inward end “switch” to release the tension in a wound fabric. The latter feature is particularly advantageous if the control system is applied to an awning of roller blind. It is further recognised in FIG. 41 a , that headers “J1” and “J4” are optional test connectors, while header “J2” is a jumper, which can be used to select the control of a motor unit 431 in the manner described above. This further use of the remote controller 901 will be described in reference to FIGS. 42, 43 and 44 .
FIG. 42 is a schematic representation of the arrangement of devices used with the above described embodiments. Shown in FIG. 42 is that each of a sensor unit 421 and a remote control 901 may be in wireless communication with a control/operation unit 431 . The control unit 431 as shown in FIG. 42 is wired between a mains power supply 975 and a motor 977 for driving a sun protective device, such as an awning or a blind.
FIG. 43 shows an alternative arrangement in which the control unit 431 has been split in a control section 431 A and a power section 431 B, each with its own respective power supply 975 A and 975 B respectively. The control section 431 A is now also in wireless communication with the power section 431 B. The power supply 975 A to the control section 431 A may optionally be from batteries or the like, while the power supply 975 B to the power section 431 B and ultimately to motor 977 may be a regular 220 Volts main supply. The arrangement according to FIG. 43 would allow the shortest possible wiring, while the power section 431 B may conveniently be enclosed in the motor housing or be accommodated close to it in the housing of a sun protection device.
FIG. 44 illustrates a simplified arrangement in which the sensor unit 421 and the control section 431 A with its power supply 975 A have been deleted.
If now as described with respect to FIG. 41 a the Jumper is set for direct control of a motor unit the remote control transmitter 901 may be readily adapted for control of an elaborate version according to FIG. 43 or a simplified version in accordance with FIG. 44 .
It is thus believed that the operation and construction of the present invention will be apparent from the foregoing description. The term comprising when used in this description or the appended claims should not be construed in an exclusive or exhaustive sense but rather in an inclusive sense. Features which are not specifically or explicitly described or claimed may be additionally included in the structure according to the present invention without deviating from its scope.
The invention is further not limited to any embodiment herein described and, within the purview of the skilled person, modifications are possible which should be considered within the scope of the appended claims. Equally all kinematic inversions are to be considered within the scope of the present invention.
Reference to either axially, radially or tangentially if used in the above is generally in relation to rotatable or cylindrical bodies of elements described.
Where in the above reference is made to longitudinal or lateral this is in reference to the length or width directions respectively of elements which have an oblong or otherwise elongate appearance in the accompanying drawings. This interpretation however has only been used for ease of reference and should not be construed as a limitation of the shape of such elements. Expressions, such as right, left, horizontal, vertical, above, below, upper, lower, top, bottom or the like if used in reference to the construction as illustrated in the accompanying drawings are relevant only to the relative positions and in a different orientation of the construction should be interpreted in accordance with comparable relative positions.
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This invention relates to a retractable and extendable awning and a control system for automatically extending and retracting the awning. In a retractable fabric awning a front of the awning fabric is attached to a movable front bar, movably mounted at the wall of a building by retractable arms. The rear of the fabric is unrolled from a roll of the fabric on the building wall when the arms move the front bar away from the building. The awning features a weather sensor unit on its front bar. The weather sensor unit can detect excessive wind and mechanical shocks and also sunlight and rain. The sensor is in wireless (via radio frequency) communication with an indoor control unit which can automatically retract the front bar during windy, rainy and/or low sunlight conditions and extend the front bar during calm and sunny conditions.
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INCORPORATION BY REFERENCE TO ANY PRIORITY APPLICATIONS
[0001] Any and all applications for which a foreign or domestic priority claim is identified in the Application Data Sheet as filed with the present application are hereby incorporated by reference under 37 CFR 1.57.
BACKGROUND
[0002] 1. Field
[0003] The present disclosure generally relates to ring protection devices which can be used to at least partially encase a user's ring.
[0004] 2. Description of the Related Art
[0005] For a large number of people, a ring carries a high amount of sentimental and/or monetary value. In many cases, rings are worn with a high frequency over a long period of time. It can be nearly impossible to consistently wear a ring while also preventing the ring's exposure to severe damage (via direct contact by liquid, solid, and gases) or loss. These sometimes daily activities include showering, cleaning dishes, and exercise, amongst many others. Given the value of a ring, owners often times either decide to keep the ring on, exposing the ring to further damage. In the alternative, if the user decides to frequently remove the ring from their hand in order to avoid damage, the ring is then exposed to a higher likelihood of loss. In fact, there are at least hundreds of thousands of individuals that purchase insurance policies to protect against damage and/or loss to their rings for this exact reason.
SUMMARY
[0006] Disclosed herein in certain embodiments is a ring protection device. In some embodiments, the ring protection device can comprise a shell configured to at least partially encase a ring, and a hinge mechanism configured to move the shell between an open position and closed position.
[0007] In some embodiments, the shell can be formed of a rigid material. In some embodiments, the shell can include a clasp mechanism to strengthen the shell when in the closed position. In some embodiments, the ring protection device can further comprise a tracking device mechanism. In some embodiments, the shell can completely engulf the entire ring.
[0008] Also disclosed herein is a ring protection device for protecting a ring worn on a human finger which can comprise a shell configured to at least partially encircle the ring when the ring is being worn, and a sealing layer connected to the shell, wherein said sealing layer is configured to contact human skin in order to reduce liquid access to the ring when the ring is being worn.
[0009] In some embodiments, the shell can be formed of a rigid material. In some embodiments, the shell can be configured to not contact the ring.
[0010] In some embodiments, the ring protection device can further comprise a hinge mechanism configured to move the shell between an open position and closed position. In some embodiments, the ring protection device can further comprise a clasp mechanism to strengthen the shell when in the closed position.
[0011] In some embodiments, said shell can comprise a housing compartment which can be configured to protect a portion of the ring that houses one or more primary stones of the ring. In some embodiments, said housing compartment can be removable from a rest of the shell. In some embodiments, the housing compartment can be a first housing compartment, and the first housing compartment can be replaceable with a second housing compartment. In some embodiments, the first housing compartment can have a size or a material that is different from a size or a material of the second housing compartment.
[0012] Also disclosed herein is a ring protection device for protecting a ring worn on a human finger which can comprise a shell configured to at least partially encircle the ring while it is being worn, the shell comprising a housing compartment configured to protect a portion of the ring that houses one or more primary stones of the ring, and a sealing layer connected to the shell, wherein said sealing layer is configured to contact human skin in order to reduce liquid access to the ring.
[0013] In some embodiments, said sealing layer can be further configured to prevent movement of the ring protection device on the user's finger due to activity or outside contact.
BRIEF DESCRIPTION OF THE DRAWINGS
[0014] FIGS. 1A-C illustrate perspective views of an embodiment of a ring protection device.
[0015] FIGS. 2A-E illustrate an embodiment of a ring protection device in different positions and from different points of view.
[0016] FIGS. 3A-D illustrate components of an embodiment of a ring protection device in different positions and from different points of view.
DETAILED DESCRIPTION
[0017] Some embodiments described herein relate to a ring protection device for protecting a person's ring during active or passive conduct or activities. Some embodiments allow the user to protect people and/or fragile material from the sharp edges of the user's ring. Some embodiments relate to a ring protection device that allows a ring owner to protect and/or track his or her ring while not wearing it. Some embodiments allow the ring protection device to be easily put on by one hand of a user.
[0018] Embodiments of a ring protection device that may be worn by an individual in order to protect the ring and gem from being damaged, dinged, scratched, or lost, especially during active conduct, are disclosed herein. Embodiments of the disclosed ring protection device can effectively protect the ring from outside contact while simultaneously limiting liquid, such as grease, water, and other liquid chemicals, from entering its perimeter. In some embodiments, the device can have liquid, air, or powder tight sealing. Embodiments of the ring protection device can also be designed to fit comfortably on the user's finger, even during movement based activities. Further, embodiments of the ring protection device can be configured to generally stick on a user's finger, so it doesn't come off during showering or sweating.
[0019] Embodiments of the disclosed ring protection device can be used to protect and/or track a ring when the user removes it from his or her finger. Embodiments of the ring protection device can prevent the loss of the ring by alarming (e.g. lights, sounds, or vibration) the user when the ring is a specific distance away and can also prevent damage by protecting the rim from undesired contact. This may be advantageous to deter theft of the device, and therefore the ring.
[0020] Described herein are various embodiments of a ring protection device that greatly decreases the risk of damage or loss to a ring, and often times, a valuable ring. The ring can be an annulus. Furthermore, the ring can be a jewelry ring made from various materials such as gold, platinum, silver, jewels, crystals, and stones.
[0021] FIGS. 1A-C show an embodiment of a ring protection device 100 . The ring protection device 100 can include a shell, casing or layer 102 . The shell 102 can be made from a protective material, such as plastic, metal or ceramic, though the type of material is not limiting. In some embodiments, the protective material can be rigid or semi-rigid such that the shell does not substantially deform under a load. In some embodiments, the protective material can have slight give to absorb impacts. For example, protective material can have an elastic modulus of at least 1 GPa, though the elastic modulus is not limiting. Furthermore, the protective material can have a relatively high hardness, though the hardness is not limiting. In some embodiments, the protective material can also be transparent or translucent. In some embodiments, the protective material can be opaque. In some embodiments, the protective material can be transparent/translucent in some portions and opaque in other. In some embodiments, shell 102 can completely, substantially, or at least partially encircle, encase, encapsulate or cover the ring 110 . For example, the shell 102 can be an annulus or generally annular, and the shape of the shell 102 is not limiting. The annulus may be continuous or may not be continuous.
[0022] Some embodiments of the ring protection device 100 include a hinge 104 and/or clasp mechanism 106 that aids the device 100 in moving back and forth from an open to closed position. For example, the annulus may have gaps, breaks or discontinuities. The annulus may have two or more discontinuities to form two or more segments of the annulus. The segments can be separate components. The segments can be coupled together with a hinge 104 and/or clasp mechanism 106 . For example, a hinge 104 can be coupled to a first segment 103 and a second segment 105 at a discontinuity so that the first 103 and second segments 105 can rotate about the discontinuity. A clasp mechanism 106 can be coupled to a first segment 103 adjacent to a discontinuity and the clasp mechanism 106 can be removably coupled to a second segment 105 to lock and unlock the first and second segment 103 / 105 together. The hinges 104 and clasp mechanisms 106 can be used interchangeably on the device 100 , and the position and attachment parts are not limiting.
[0023] The shell 102 can have an opening or slot 108 on an inside of the shell 102 . In some embodiments, the shell 102 can have an annular dome shape. In some embodiments, the shell 102 can have an annular slot 108 on an inside of the annular shell 102 . The slot 108 can be sized to have a ring 110 disposed therein, though the size is not limiting. In some embodiments, the slot 108 can contain at least one lock clip to hold a ring 110 in place.
[0024] The ring protection device 100 can include a sealing layer 112 coupled to the shell 102 . The coupling of the sealing layer 112 to the device 100 is not limiting and mechanical and/or chemical coupling can be used. In some embodiments, the sealing layer 112 can be adjacent to the slot 108 . For example, the sealing layer 112 can be on an inner most surface of the shell 102 . As such, the sealing layer 112 can be sandwiched between the shell 102 and a user's finger and/or can be sandwiched between the shell 102 and the ring 110 . Furthermore, the sealing layer 112 can be adjacent to both sides of the slot 108 . Therefore, the sealing layer 112 can include two separate portions. In some embodiments, the sealing layer 112 can be substantially continuous around the annulus of the shell 102 . Thus, the sealing layer 112 can be an annulus, or generally an annulus. In some embodiments, the sealing layer 112 may not be substantially continuous around the annulus of the shell 102 . The sealing layer 112 can be configured to reduce liquid access to the ring 110 . Thus, in use, the slot 108 can be substantially fluidly (e.g., liquidly) isolated from outside of the shell 102 . The sealing layer 112 can be formed from a material that can elastically deform to provide a good seal between the shell 102 and the user's finger. For example, the sealing layer 112 can be a polymer, rubber, foam, or foam-like material, and the type of material is not limiting. Furthermore, the sealing layer 112 can be adapted to function with the hinge 104 and/or clasp mechanism 106 (e.g., fasteners). For example, the sealing layer 112 can have discontinuities similar to that of the shell 102 .
[0025] The shell 102 can also include a housing compartment 114 configured to encircle, encase, encapsulate or cover a portion of the ring 110 that houses one or more stones. Since the portion of the ring 110 that houses the stone tends to be larger than the rest of the ring 110 , the housing compartment 114 can be larger (e.g. thicker, wider, and/or taller) than the rest of the shell 102 . Furthermore, as described above, the sealing layer 112 can also be attached to the housing compartment 114 of the shell 102 . The housing compartment 114 can be configured to be separated from the rest of the shell 102 .
[0026] The ring protection device 100 can also include a protecting layer configured to contact the ring 110 . For example, the protecting layer can be within the slot 108 and/or the housing compartment 114 . The protecting layer can be or formed from foam, foam-like material, shape-memory foam, or elastic material, though the type of material is not limiting. The protecting layer may deform to form fit to the ring 110 .
[0027] The ring protection device 100 can be symmetrical or asymmetrical. For example, some users may wear the ring 110 adjacent to or near a knuckle. The ring 110 may be configured to be worn adjacent to or near a knuckle of the user's finger. For example, the ring protection device 100 may be asymmetrical such that a side of the ring protection device 100 (e.g., shell 102 , sealing layer 112 ) closest to the user's knuckle may be configured and/or shaped differently than a side of the ring protection device 100 furthest form the user's knuckle. Other portions of the ring protection device 100 may be asymmetrical such as to conform to a finger.
[0028] The ring protection device 100 can also include one or more light bulbs, such as LEDs (light emitting diodes) or fluorescence, in order to help see both the ring protection device 100 and the ring 110 itself. The number and type of light bulbs is not limiting.
[0029] The ring protection device 100 can be used to encase the ring 110 while the user is not wearing the ring 110 . The ring protection device 100 can include one or more tracking devices, such as GPS, to help the user keep track of the location of his or her ring 110 . The type of tracking device is not limiting.
[0030] FIG. 2A shows a front cross-sectional view of an embodiment of a ring protection device 100 in an open position with a hinge mechanism incorporating a single hinge 104 .
[0031] FIG. 2B shows a side cross-sectional view of an embodiment of a ring protection device 100 shown in FIG. 2A in which neither the shell 102 nor the sealing layer 112 contacts the user's ring band.
[0032] FIG. 2C shows the front cross-sectional view of an embodiment of a ring protection device 100 shown in FIG. 2A in which the shell 102 is in a closed position and is configured to contact the ring band for further stability.
[0033] FIG. 2D shows a cross sectional view of an embodiment of a ring protection device 100 that uses one possible type of a clasp mechanism 106 with a male and female end. The female clasp end is shown as 106 on the left, and the male clasp end is shown as 106 on the right. The female clasp end could be located on either the first segment 103 or the second segment 105 , and the male clasp end could be located on the opposite segment as the female clasp end.
[0034] FIG. 2E shows a side cross-sectional view of an embodiment of a ring protection device 100 with a hinge 104 or clasp 106 line when the device is in the closed position. As the cross section segment cuts down the center of device 100 , the lighter gray shade in FIG. 2E indicates an actual cut through of device 100 , while the dark shade indicates a side view of device 100 which is not a cut through.
[0035] FIGS. 3A-D show a further embodiment of a ring protection device 100 . As shown in FIGS. 3A-B , and described above, the ring protection device 100 can have a generally annular shape. FIG. 3A illustrates an embodiment of a ring protection device 100 in a closed configuration. FIG. 3B illustrates an embodiment of the ring protection device 100 of FIG. 3A in an open configuration. As shown, in some embodiments the shell 102 can be split into three segments 302 , 304 , and 307 . In some embodiments, the shell 102 can be split into more than three segments, and the number of segments is not limiting. Each of segments 302 / 304 can attach to housing segment 307 which can be connected to the housing compartment 114 . In some embodiments, the segments 302 / 304 can then attach to one another through a clasp mechanism 106 . In some embodiments, the clasp mechanism 106 can be part of segments 302 / 304 . As shown in FIG. 3B , where the device 100 is opened, both segments 302 / 304 can rotate away from each other. Accordingly, a ring 110 can be inserted through the opened clasp mechanism 106 and inserted into slot 108 . In some embodiments, the segments 302 / 304 can rotate about hinges 104 so that they are generally about 90, 100, 110, 120, 130, 140, 150, 160, 170, or 180° apart, though this angle is not limiting. In some embodiments, each of the segments 302 / 304 / 307 can be generally ¼ of a circle, ½ of a circle, or ¾ of a circle.
[0036] In FIGS. 3A-B , the segments 302 / 304 contain a gap 320 in the shell 102 . The underlying sealing layer 112 can fill the gap 320 in the shell 102 and/or segments 302 / 304 . In some embodiments, the segments 302 / 304 can extend fully around the outside of the sealing layer 112 and eliminate the gap 320 . Accordingly, in some embodiments the sealing layer 112 may not be visible when the ring is in the closed position on a finger. In some embodiments, the sealing layer 112 can extend over the edge of the clasp mechanism 106 . In some embodiments, the sealing layer 112 can be thicker in some portions of the device 100 and thinner in others. For example, the sealing layer 112 can be thinner below the housing compartment 114 than around the segments 302 / 304 approximately 90° away in the closed position.
[0037] FIGS. 3C-D illustrate more detailed viewpoints of different components of embodiments of ring protection device 100 .
[0038] FIG. 3C illustrates an embodiment of a housing segment 307 having a pair of hinges 104 located underneath the housing compartment 114 . In some embodiment, the hinges 104 can be generally snap hinges, configured to remain in certain locations, though the type of hinge 104 is not limiting. In some embodiments, the housing segment 307 can contain a sealing layer 112 . In some embodiments, the housing compartment 114 can be generally centered between hinges 104 . In some embodiments, the housing compartment 114 is not centered between hinges 104 . In some embodiments, other types of rotational connections can be used between segment 307 and segments 302 / 304 , and the type or means of rotation is not limiting. In some embodiments, the sealing layer 112 in the housing segment 307 and segments 302 / 304 can overlap when the hinges 104 are closed, thereby creating a generally seamless 360 degree seal on a user's finger.
[0039] In some embodiments, the housing compartment 114 can be decorated to include colors or patterns. In some embodiments, the housing compartment 114 can be generally rectangular shaped. However, the shape of the housing compartment 114 is not limiting. For example, the housing compartment 114 can be generally round, generally circular shaped, or generally triangular shaped. In some embodiments, the housing compartment 114 can be configured to retain a specific sized stone on a ring 110 . In some embodiments, the housing compartment 114 can have generally smooth corners so as not to injure a user. In some embodiments, the housing compartment 114 can be configured to fit within the hinge 104 , as shown in FIGS. 3A-B . In some embodiments, the inside of the housing compartment 114 can contain the sealing layer 112 to protect a ring 110 . In some embodiments, the housing compartment 114 can be integrally formed with the housing segment 307 . In some embodiments, the housing compartment 114 can be attached, either removably or non-removably, from the housing segment 307 . In some embodiments, the shell 102 can consist of the housing segment 307 only, and can be attached or molded to a sealing layer 112 that can wrap up to 360 degrees around the user's finger. In some embodiments, the shell 102 can be attached (e.g., overmolded) directly to the sealing layer 112 with the use of a hinge 104 or a clasp 106 . The attachment technique is not limiting. In yet other embodiments, the shell 102 can consist of segments 302 / 304 only, and can be attached or molded to a sealing layer 112 that can wrap up to 360 degrees around the user's finger.
[0040] FIG. 3D illustrates an embodiment of a clasp 106 . In some embodiments, the clasp 106 is a portion of a larger segment (see segments 302 / 304 in FIG. 3A ). In some embodiments, the clasp 106 can also be its own segment. As shown, the clasp can contain a button 306 , or other actuating mechanism, which can release the clasp 106 . The clasp 106 can contain a male 314 and female 312 component. The button 306 can be located on either component. In some embodiments, the female component 312 can be configured to receive and retain the male component 314 . However, a person having skill in the art would understand that different configurations of clasps could be used, such as those including hooks, magnetics, or frictional holding, and the type of clasp is not limiting. In some embodiments, the sealing layer 112 in the segments 302 / 304 can extend into the clasp 106 and can overlap when the clasp 106 is closed, thereby creating a generally seamless seal on a user's finger.
[0041] Some embodiments have been described in connection with the accompanying drawings. The figures are drawn to scale, but such scale should not be limiting, since dimensions and proportions other than what are shown are contemplated and are within the scope of the disclosed inventions. Distances, angles, etc. are merely illustrative and do not necessarily bear an exact relationship to actual dimensions and layout of the devices illustrated. Components can be added, removed, and/or rearranged. Further, the disclosure herein of any particular feature, aspect, method, property, characteristic, quality, attribute, element, or the like in connection with various embodiments can be used in all other embodiments set forth herein. Additionally, it will be recognized that any methods described herein may be practiced using any device suitable for performing the recited steps.
[0042] While various embodiments of the innovation have been described, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of the innovation. Accordingly, the innovation is not to be restricted except in light of the attached claims, or claims that may be presented in the future, and their equivalents.
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Embodiments of the present disclosure are directed to a ring protection device. The ring protection device can have a shell layer to at least partially encase a ring. The ring protection device can have a shell layer containing a housing segment. The segments of the shell layer can be connected to other segments via a hinge mechanism. The shell segments and hinge mechanism can be configured to encase a ring and protect it from damage. The shell layer can be connected to a sealing layer to aid the ring protection functionality. The hinge mechanism can be opened and closed to insert and remove a ring into the ring protection device.
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[0001] The present disclosure claims benefit of Chinese patent application CN 201410479934.8, entitled “DISPLAY PANEL, PIXEL STRUCTURES THEREOF AND METHOD FOR DRIVING THE DISPLAY PANEL” and filed on Sep. 18, 2014, which is incorporated herein by reference.
TECHNICAL FIELD
[0002] The present disclosure relates to the image display technology. In particular, it relates to a display panel having both two-dimensional and three-dimensional display functions, a pixel structure thereof, and a method for driving the display panel.
TECHNICAL BACKGROUND
[0003] With the development of display technology, three-dimensional display technology has become one of the most compelling technical trends so far. Film patterned retarder (FPR for short) is one of the mainstream three-dimensional display technologies. In FPR technology, a polarizing film is attached to a liquid crystal display panel and cooperates with polarizing glasses, so that a three-dimensional image is split into a left-eye image and a right-eye image, and then the images obtained are separately transmitted to the left eye and the right eye of a viewer, thereby enabling a three-dimensional display. However, there are certain defects in this technique, that is, crosstalk between the left eye image and the right eye image might occur when the viewer watches from a relatively large viewing angle. Crosstalk causes the images that the viewer is watching to be blurring.
[0004] In addition, a large size liquid crystal display panel using a vertical alignment display mode (VA mode for short) further presents a technical problem of color shift caused by the large viewing angle. In this regard, the manufacturers of the current liquid crystal display panels generally apply a charge-shared technology, in which a pixel electrode of each sub-pixel in a pixel structure is divided into two portions, respectively a main portion and a sub portion. Driven by the same grayscale voltage, different voltages are exerted on the main portion and sub portion, so as to control the liquid crystal molecules corresponding to the main and sub portions to deflect over different deflection angles, thereby realizing the effect of low color shift.
[0005] To avoid crosstalk during a three-dimensional display, the manufacturers of liquid crystal display panel would appropriately enlarge a shielding distance between the pixels located in adjacent lines when designing a three-dimensional FPR pixel structure, which, however, would deteriorate the transmittance under a two-dimensional display. Meanwhile, low color shift of such a liquid crystal display panel cannot be realized under three-dimensional display. Therefore, it is a technical issue that a person skilled in the related industry is committed to solve to equip the LCD panel with both two-dimensional and three-dimensional display functions while enabling an effect of low color shift.
SUMMARY OF THE INVENTION
[0006] In order to solve the above problems, the present disclosure provides a display panel which has both two-dimension and three-dimension display functions and is further capable of a display effect of low color shift, a pixel structure thereof, and a method for driving the display panel.
[0007] The present disclosure provides a pixel structure comprising a plurality of sub-pixels, wherein a pixel electrode of each of the sub-pixels comprises:
a main portion configured to receive a scan signal of a first scan line, and then to receive a data signal of a data line, so that it has a main-portion voltage, a first portion configured to receive the scan signal of the first scan line, and then to receive the data signal of the data line, so that it has a first-portion voltage, and a second portion configured to receive a scan signal of a second scan line, and then to receive the data signal of the data line, so that it has a second-portion voltage, wherein the main-portion voltage, the first-portion voltage, and the second-portion voltage are different from one another.
[0012] According to an embodiment of the present disclosure, the main portion is electrically connected to the data line through a first electrode and a second electrode of a main-portion charging switch, and a control terminal of the main-portion charging switch is electrically connected to the first scan line. Meanwhile, the main portion is further electrically connected. with a main-portion liquid crystal capacitor and a main-portion storage capacitor.
[0013] According to an embodiment of the present disclosure, the first portion is electrically connected to the data line through a first electrode and a second electrode of a first-portion charging switch, and a control terminal of the first-portion charging switch is electrically connected to the first scan line. Meanwhile, the first portion is further electrically connected with a first-portion liquid crystal capacitor and a first-portion storage capacitor, wherein both ends of either the first-portion liquid crystal capacitor or the first-portion storage capacitor are electrically connected to a first electrode and a second electrode of a first-portion discharge switch, and a control terminal of the first-portion discharge switch is electrically connected to the first scan line.
[0014] According to an embodiment of the present disclosure, the second portion is electrically connected to the data line through a first electrode and a second electrode of a second-portion charging switch, and a control terminal of the second-portion charging switch is electrically connected to the second scan line. The second portion is further electrically connected with a second-portion liquid crystal capacitor and a second-portion storage capacitor, wherein both ends of either the second-portion liquid crystal capacitor or the second-portion storage capacitor are electrically connected to a first electrode and a second electrode of a second-portion discharge switch, and a control terminal of the second-portion discharge switch is electrically connected to the second scan line.
[0015] According to an embodiment of the present disclosure, the main-portion liquid crystal capacitor, the first-portion liquid crystal capacitor, and the second-portion liquid crystal capacitor each are formed of common electrodes respectively between each of the main, first, and the second portions and a color filter substrate, and the main-portion storage capacitor, the first-portion storage capacitor, and the second-portion storage capacitor each are formed of common electrodes respectively between each of the main, first, and the second portions and an array substrate where they are located.
[0016] In addition, the present disclosure further provides a display panel, comprising:
a plurality of data lines, a plurality of scan lines in a staggered arrangement with the data lines, forming a plurality of sub-pixel regions, and a plurality of sub-pixels arranged inside the sub-pixel regions, wherein a pixel electrode of each of the sub-pixels comprises:
a main portion configured to receive a scan signal of a first scan line, and then to receive a data signal of a data line, so that it has a main-portion voltage, a first portion configured to receive the scan signal of the first scan line, and then to receive the data signal of the data line, so that it has a first-portion voltage, and a second portion configured to receive a scan signal of a second scan line, and then to receive the data signal of the data line, so that it has a second-portion voltage, wherein the main-portion voltage, the first-portion voltage, and the second-portion voltage are different from one another.
[0024] According to an embodiment of the present disclosure, the main portion is electrically connected to the data line through a first electrode and a second electrode of a main-portion charging switch, and a control terminal of the main-portion charging switch is electrically connected to the first scan line. The main portion is further electrically connected with a main-portion liquid crystal capacitor and a main-portion storage capacitor.
[0025] The first portion is electrically connected to the data line through a first electrode and a second electrode of a first-portion charging switch, and a control terminal of the first-portion charging switch is electrically connected to the first scan line. The first portion is further electrically connected with a first-portion liquid crystal capacitor and a first-portion storage capacitor, wherein both ends of either the first-portion liquid crystal capacitor or the first-portion storage capacitor are electrically connected to a first electrode and a second electrode of a first-portion discharge switch, and a control terminal of the first-portion discharge switch is electrically connected to the first scan line.
[0026] The second portion is electrically connected to the data line through a first electrode and a second electrode of a second-portion charging switch, and a control terminal of the second-portion charging switch is electrically connected to the second scan line. The second portion is further electrically connected with a second-portion liquid crystal capacitor and a second-portion storage capacitor, wherein both ends of either the second-portion liquid crystal capacitor or the second-portion storage capacitor are electrically connected to a first electrode and a second electrode of a second-portion discharge switch, and a control terminal of the second-portion discharge switch is electrically connected to the second scan line.
[0027] Further, the main-portion liquid crystal capacitor, the first-portion liquid crystal capacitor, and the second-portion liquid crystal capacitor each are formed of common electrodes respectively between each of the main, first, and the second portions and a color filter substrate; and the main-portion storage capacitor, the first-portion storage capacitor, and a second-portion storage capacitor each are formed of common electrodes respectively between each of the main, first, and the second portions and an array substrate where they are located.
[0028] In addition, the present disclosure also provides a method for driving a display panel, wherein the display panel comprises a plurality of data lines, a plurality of scan lines, and a plurality of sub-pixels, the data lines and the scan lines are arranged in a staggered manner to form a plurality of sub-pixel regions, the sub-pixels are arranged inside the sub-pixel regions, and a pixel electrode in each of the sub-pixels comprises a main portion, a first portion, and a second portion,
said method comprises steps for driving a two-dimensional display and/or a three-dimensional display: the steps for driving the two-dimensional display include: during a positive/negative polarity reversal period,
transmitting, at a same time point, a data signal respectively to the main portion and the first portion through a data line, so that the main portion and the first portion respectively have a main-portion voltage and a first-portion voltage, and transmitting, at a next time point, a data signal to the second portion through the data line, so that the second portion has a second-portion voltage, wherein the main-portion voltage, the first-portion voltage, and the second-portion voltage are different from one another;
the steps for driving the three-dimensional display include:
turning the second portion into a black area and maintaining its dark state, and transmitting, at a same time point, a data signal respectively to the main portion and the first portion through the data line, so that the main portion and the first portion respectively have a main-portion voltage and a first-portion voltage, wherein there is a predetermined voltage difference between the main-portion voltage and the first-portion voltage.
[0037] Further, in the steps for driving the three-dimensional display, it is preferable to carry out black frame insertion during a vertical retrace period, so as to turn the second portion into a black area.
[0038] As compared with the prior art, one or more embodiments of the present disclosure can have the following advantages.
[0039] The display panel of the present disclosure comprises a pixel structure comprising a 1D2G structure (comprising one data line and two scan lines), three portions (a portion Main, a portion Sub1 and a portion Sub2) and twelve domains, which can not only achieve a lower color shift under the two-dimensional display mode by differing the voltages in said three portions from one another, but also enable a lower color shift under the three-dimensional display mode by applying a voltage difference between the portions Main and Sub1. after forming a wider light shielding area needed for the three-dimensional display in the portion Sub2. In this case, on the premise of guaranteeing the transmittance under the two-dimensional display, a compatibility of two-dimensional display and three-dimensional display is achieved, and better effect of low color shift is further realized in both the two-dimensional display and the three-dimensional display, thereby improving the image display quality.
[0040] Other features and advantages of the present disclosure will be further explained in the following description and partially become apparent therefrom, or be understood through the embodiments of the present disclosure. The objectives and advantages of the present disclosure will be achieved through the structure specifically pointed out in the description, claims, and the accompanying drawings.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS
[0041] The accompanying drawings, which constitute a part of the description, are used to further explain the present disclosure in view of the embodiments. It should be understood that the drawings are only provided to better understand the present disclosure, they should not be construed as limitations thereto. In the accompanying drawings:
[0042] FIG. 1 schematically shows a structure of a display panel according to Example 1 of the present disclosure;
[0043] FIG. 2 schematically shows a structure of a pixel electrode in a sub-pixel according to Example 1 of the present disclosure;
[0044] FIG. 3 shows an equivalent circuit of the sub-pixel of FIG. 2 ; and
[0045] FIG. 4 schematically shows the operating condition of the pixel electrode in the sub-pixel of FIG. 2 under a three-dimensional display mode.
DETAILED DESCRIPTION OF THE EMBODIMENTS
[0046] To clarify the objectives, technical solutions, and the advantages of the present disclosure, the present disclosure will be further described in details with reference to the following specific embodiments and the accompanying drawings.
[0047] FIG. 1 schematically shows a structure of a display panel according to Example 1 of the present disclosure. The display panel comprises an image display area 100 , a scan driving circuit 200 and a data driving circuit 300 . The image display area 100 comprises an array formed by a plurality of scan lines GL 1 to GLM and a plurality of data lines DL 1 to DLN in a staggered arrangement, as well as a plurality of pixel structures 110 serving as elements of the array. In this case, the scan driving circuit 200 transmits scan signals to the pixel structures 110 in the image display area 100 through a plurality of scan lines GL 1 to GLM coupled to the scan driving circuit 200 . The data driving circuit 300 transmits data signals to the pixel structures 110 in the image display area 100 through a plurality of data lines DL 1 to DLN coupled to the data driving circuit 300 .
[0048] Generally, each of the pixel structures 110 of a color display panel contains a red sub-pixel, a green sub-pixel, and a blue sub-pixel. In Example 1, all of the sub-pixels use a 1D2G structure. That is, for one sub-pixel, a sub-pixel region (i.e., a pixel electrode region defining the sub-pixel) is defined by a longitudinal data line together with a horizontal first scan line and a horizontal second scan line.
[0049] FIG. 2 schematically shows a structure of a pixel electrode in the sub-pixel according to Example 1 of the present disclosure. The pixel electrode is divided into three portions, i.e., a main portion Main, a first portion Sub 1 and a second portion Sub2, wherein preferably, each of the portions is divided into four domains.
[0050] The main portion Main is configured to receive a scan signal Gn of the first scan line and then to receive a data signal Data of the data line under the action of the scan signal Gn, so that it has a main-portion voltage V_Main.
[0051] The first portion Sub1 is configured to receive the scan signal Gn of the first scan line, and then to receive a data signal Data of the data line under the action of the scan signal Gn, so that it has a first-portion voltage V_Sub1.
[0052] The second portion Sub2 is configured to receive a scan signal Gn+ 1 of the second scan line, and then to receive a data signal Data of the data line under the action of the scan signal Gn+ 1 , so that it has a second-portion voltage V_Sub2.
[0053] In this case, the main-portion voltage V_Main, the first-portion voltage V_Sub1, and the second-portion voltage V_Sub2 should be different from one another, so that low color shift of the LCD panel under a two-dimensional display mode can be realized. Furthermore, when the LCD panel operates under a three-dimensional display mode, the second portion Sub2 disenables its display function and serves as a light shielding area. Meanwhile, since the main-portion voltage V_Main is different from the first-portion voltage V_Sub1, the effect of low color shift can also be realized.
[0054] It should be noted that, in this example, the first scan line Gn and the second scan line Gn+ 1 can be arranged as two adjacent scan lines, which, however, may not be limited hereto in practical applications.
[0055] FIG. 3 shows an equivalent circuit of the sub-pixel shown in FIG. 2 .
[0056] For the main portion Main, a main-portion charging switch TFT_A electrically connects the data line to the main portion with its first electrode and second electrode, and a control terminal of the charging switch TFT_A is electrically connected to a first scan line to receive a scan signal Gn. Meanwhile, the main portion Main is further electrically connected to a storage capacitor Cst_Main and a liquid crystal capacitor Clc_Main. Under the action of the scan signal Gn, the charging switch TFT_A is enabled, and a data signal Data of the data line is transmitted to the storage capacitor Cst_Main and the liquid crystal capacitor Clc_Main via the charging switch TFT_A. The storage capacitor Cst_Main and the liquid crystal capacitor Clc_Main each are charged based on the data signal Data, and then store the corresponding potentials. As a result, the main portion Main has a corresponding main-portion voltage V_Main, so that the liquid crystal moleculars corresponding to the main portion Main deflect accordingly, thereby displaying the corresponding image data.
[0057] In a specific example, the storage capacitor Cst_Main of the main portion can be formed of a common electrode A_com between the main portion Main and an array substrate where the main portion is positioned, and the liquid crystal capacitor Clc_Main in the main portion may be formed of a common electrode CF_com between the main portion and a color filter substrate.
[0058] For the first portion Sub1, a first-portion charging switch TFT_B electrically connects the data line to the first portion Sub1 with its first and second electrodes, and a control terminal of the charging switch TFT_B is electrically connected to the first scan line to receive the scan signal Gn. Meanwhile, the first portion Sub1 is also electrically connected to a storage capacitor Cst_Sub1 and a liquid crystal capacitor Clc_Sub1, wherein both ends of either the storage capacitor Cst_Sub1 or the liquid crystal capacitor Clc_Sub1 are electrically connected to a first electrode and a second electrode of a discharge switch TFT_C, and a control terminal of the discharge switch TFT_C is electrically connected to the first scan line to receive the scan signal Gn. Under the action of the scan signal Gn, the charging switch TFT_B is enabled, then the data signal Data of the data line is transmitted to the storage capacitor Cst_Sub1 and the liquid crystal capacitor Clc_Sub 1 via the charging switch TFT_B. Then the storage capacitor Cst_Sub1 and the liquid crystal capacitor Clc_Sub1 each are charged based on the data signal Data and then store the corresponding potentials. In the meantime, since the discharge switch TFT_C is also enabled, the potentials of the storage capacitor Cst_Sub1 and the liquid crystal capacitor Clc_Sub1 decline due to the electric leakage through the discharge switch TFT_C. In this case, the first portion Sub1 has a first-portion voltage V_Sub1, a level of which is different from that of the main-portion voltage V_Main, so that the liquid crystal moleculars corresponding to the first portion Sub1 deflect accordingly, thereby displaying the corresponding image data.
[0059] In a specific example, the storage capacitor Cst_Sub1 of the first portion may be formed of a common electrode A_com between the first portion Sub1 and an array substrate where the first portion is positioned, and the liquid crystal capacitor Clc_Sub1 of the first portion may be formed of a common electrode CF_com between the first portion Sub1 and a color filter substrate.
[0060] For the second portion Sub2, a second-portion charging switch TFT_D electrically connects the data line to the second portion Sub2 with its first and second electrodes, and a control terminal of the charging switch TFT_D is electrically connected to a second scan line to receive a scan signal Gn+ 1 . Meanwhile, the second portion Sub2 is also electrically connected to a storage capacitor Cst_Sub2 and a liquid crystal capacitor Clc_Sub2, wherein both ends of either the storage capacitor Cst_Sub2 or the liquid crystal capacitor Clc_Sub2 are electrically connected to a first electrode and a second electrode of a discharge switch TFT_E, and a control terminal of the discharge switch TFT_E is electrically connected to the second scan line to receive the scan signal Gn+ 1 . Under the action of the scan signal Gn+ 1 , the charging switch TFT_D is enabled, the data signal Data of the data line is transmitted to the storage capacitor Cst_Sub2 and the liquid crystal capacitor Clc_Sub2 via the charging switch TFT_D. The storage capacitor Cst_Sub2 and the liquid crystal capacitor Clc_Sub2 each are charged based on the data signal Data, and then store the corresponding potentials. In the meantime, since the discharge switch TFT_E is also enabled, the potentials of the storage capacity Cst_Sub2 and the liquid crystal capacitor Clc_Sub2 decrease due to the electric leakage through the discharge switch TFT_E. As a result, the second portion has a second-portion voltage V_Sub2, a level of which is different from that of the main-portion voltage V_Main, so that the liquid crystal corresponding to the second portion Sub2 deflects accordingly, thereby displaying the corresponding image data.
[0061] In a specific example, the storage capacitor Cst_Sub2 of the second portion can be formed of a common electrode A_com between the second portion Sub2 and an array substrate where the second portion is located, and the liquid crystal capacitor Clc_Sub2 of the second portion can be formed of a common electrode CF_com between the second portion Sub2 and a color filter substrate.
[0062] It should be noted that each of the potentials V_Main, V_Sub1, and V_Sub2 of the pixel electrodes of the sub-pixels as mentioned above or will be mentioned below can refer to a voltage of a pixel electrode per se, or to a voltage difference between the pixel electrode and the common electrode A_com of the array substrate or that between the pixel electrode and the common electrode CF_com of the color filter substrate, which is generally known in the art. Accordingly, the meaning of the potential of a pixel electrode in the present disclosure is not limited to that as defined by the examples of the present disclosure.
[0063] Said charging switches and discharge switches are preferably made of thin film transistors. A first electrode and a second electrode of each of the charging switches and the discharge switches are usually the drain electrode and the source electrode, and a control terminal thereof is the gate electrode.
[0064] Detailed description of the circuit operating condition and the voltage changes in each of the portions of a pixel electrode respectively under a two-dimensional display mode and a three-dimensional display mode will be given below.
[0065] During a positive polarity inversion period under a two-dimensional display mode, a voltage of the data signal is higher than that of the common electrode which refers to the common electrode CF_com of the color filter substrate and/or the common electrode A_com of the array substrate in this example.
[0066] 1) In the case that a scan signal Gn of the first scan line is of high level while a scan signal Gn+ 1 of the second scan line is of low level.
[0067] The charging switch TFT_A in the main portion is enabled, so that a data signal Data of the data line is transmitted to the liquid crystal capacitor Clc_Main and the storage capacitor Cst_Main in the main portion via the charging switch TFT_A. The liquid crystal capacitor Clc_Main and the storage capacitor Cst_Main in the main portion are charged based on the data signal Data, and store the corresponding voltages, i.e., a main-portion voltage V_Main.
[0068] The charging switch TFT_B and the discharge switch TFT_C in the first portion are turned on, so that data signal Data of the data line is transmitted to the liquid crystal capacitor Clc_Sub1 and the storage capacitor Cst_Sub1 in the first portion via the charging switch TFT_B. Then the liquid crystal capacitor Clc_Sub1 and the storage capacitor Cst_Sub1 in the first portion are charged based on the data signal Data and store the corresponding voltages. At the same time, because the discharge switch TFT_C is also turned on, the potentials of the liquid crystal capacitor Clc_Sub1 and the storage capacitor Cst_Sub1 in the first portion decline to a first-portion voltage V_Sub1, a level of which is different from that of the main-portion voltage V_Main, due to the electric leakage from the discharge switch TFT_C.
[0069] The charging switch TFT_D and the discharge switch TFT_E in the second portion are both turned off and thus the second-portion voltage V_Sub2 is zero.
[0070] 2) In the case that the scan signal Gn of the first scan line is of low level while the scan signal Gn+ 1 of the second scan line is of high level.
[0071] The charging switch TFT_A in the main portion, and the charging switch TFT_B and the discharge switch TFT_C in the first portion are turned off, and thus the main-portion voltage V_Main and the first-portion voltage V_Sub1 both remain the same.
[0072] The charging switch TFT_D and the discharge switch TFT_E in the second portion are both enabled, so that the data signal Data of the data line is transmitted to the liquid crystal capacitor Clc_Sub2 and the storage capacitor Cst_Sub2 in the second portion via the charging switch TFT_D. Then, the liquid crystal capacitor Clc_Sub2 and the storage capacitor Cst_Sub2 in the second portion are charged based on the data signal Data and store the corresponding voltages. In the meantime, since the discharge switch TFT_E is enabled, the potentials of the liquid crystal capacitor Clc_Sub2 and the storage capacitor Cst_Sub2 in the second portion may decline to a second-portion voltage V_Sub2, a level of which is different from that of the main-portion voltage V_Main, due to the electric leakage through the discharge switch TFT_E.
[0073] During a negative polarity inversion period under a two-dimensional display mode, a voltage of the data signal is lower than that of the common electrode which refers to the common electrode common CF_com of the color filter substrate and/or the common electrode A_com of the array substrate in this example.
[0074] 1) In the case that a scan signal Gn of the first scan line is of high level while a scan signal Gn+ 1 of the second scan line is of low level.
[0075] The charging switch TFT_A in the main-portion is turned on, so that a data signal Data is transmitted to the liquid crystal capacitor Clc_Main and the storage capacitor Cst_Main in the main portion via the charging switch TFT_A. Then, the liquid crystal capacitor Clc_Main and the storage capacitor Cst_Main in the main portion discharge based on the data signal Data and store the corresponding voltages, i.e., a main-portion voltage V_Main.
[0076] The charging switch TFT_B and the discharge switch TFT_C in the first portion are both enabled, so that the data signal Data of the data line is transmitted to the liquid crystal capacitor Clc_Sub1 and the storage capacitor Cst_Sub1 in the first portion via the charging switch TFT_B. Then, the liquid crystal capacitor Clc_Sub1 and the storage capacitor Cst_Sub1 in the first portion discharge based on the data signal Data and store the corresponding voltages. At the same time, since the discharge switch TFT_C is also turned on, the potentials of the liquid crystal capacitor Clc_Sub1 and the storage capacitor Cst_Sub1 in the first portion increase to a first-portion voltage V_Sub1, a level of which is different from that of the main-portion voltage V_Main, due to the electric leakage from the discharge switch TFT_C.
[0077] The charging switch TFT_D and the discharge switch TFT_E in the second portion are both disenabled, and thus the second-portion voltage V_Sub2 is zero.
[0078] 2) In the case that the scan signal Gn of the first scan line is of low level while the scan signal Gn+ 1 of the second scan line is of high level.
[0079] The charging switch TFT_A in the main portion, and the charging switch TFT_B and the discharge switch TFT_C in the first portion are disenabled, and thus the main-portion voltage V_Main and the first-portion voltage V_Sub1 both remain the same.
[0080] The charging switch TFT_D and the discharge switch TFT_E in the second portion are enabled, so that the data signal Data of the data line is transmitted to the liquid crystal capacitor Clc_Sub2 and the storage capacitor Cst_Sub2 in the second portion via the charging switch TFT_D. Then, the liquid crystal capacitor Clc_Sub2 and the storage capacitor Cst_Sub2 in the second portion discharge based on the data signal Data and store the corresponding voltages. In the meantime, since the discharge switch TFT_E is enabled, the potentials of the liquid crystal capacitor Clc_Sub2 and the storage capacitor Cst_Sub2 in the second portion increase to a second-portion voltage V_Sub2, a level of which is different from that of the main-portion voltage V_Main, due to the electric leakage from the discharge switch TFT_E.
[0081] In a specific example, when the voltage difference between the main-portion voltage V_Main and the first-portion voltage V_Sub 1 differs from that between the main-portion voltage V_Main and the second-portion voltage V_Sub2, the requirement that the main-portion voltage V_Main, the first-portion voltage V_Sub1 and the second-portion voltage V_Sub2 should be different from one another is naturally met.
[0082] In this case, whether it is during the positive polarity inversion period or the negative polarity inversion period, the main-portion voltage, the first-portion voltage and the second-portion voltage in the pixel electrode are different from one another, As a result, images displayed by these three portions are significantly different from one another, thereby achieving a low color shift display under the two-dimensional display mode.
[0083] FIG. 4 schematically shows the operating condition of the pixel electrode in the sub-pixel of FIG. 2 under a three-dimensional display mode. In order to achieve low color shift display under the three-dimensional display mode, the second portion in the pixel electrode is configured to be a light shielding area required for three-dimensional display, so that a sufficient shielding distance between two adjacent lines of a pixel structure can be guaranteed, and also a significant voltage difference between the main portion and the first portion can be obtained. In this example, it is preferred to perform black frame insertion to the second portion during the vertical retrace, so that the second portion becomes a black area. Then, the scan signal Gn+ 1 controlling the operation of the second portion is disenabled so that the second-portion voltage V_Sub2 is zero, thereby keeping the second portion in a dark state to avoid light leakage caused by electric leakage. Similar to that in the two-dimensional display mode, the data signal is transmitted simultaneously to the main portion and the first portion via the data line, and thus the main portion and the first portion. each have a main-portion voltage and a first-portion voltage, and between the two voltages there is a predetermined voltage difference. Due to the voltage difference between the main portion voltage and the first-portion voltage, images displayed by the main portion and the first portion are significantly different, thereby effectively solve the problem of color shift during the three-dimensional display.
[0084] The above are only preferred embodiments of the present disclosure, and the scope of the present invention is not limited thereto. Any changes or replacement within the technical scope of the present disclosure which easily occur to a person skilled in the art should fall within the scope of the present disclosure. Accordingly, the scope of the invention should be subjected to that defined in the claims.
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The present disclosure relates to a display panel, a pixel structure, and a method for driving the display panel. The pixel structure comprises a plurality of sub-pixels, each of which comprises: a main portion configured to receive a scan signal of a first scan line, and then to receive a data signal of a data line, so that it has a main-portion voltage; a first portion configured to receive the scan signal of the first scan line, and then to receive the data signal of the data line, so that it has a first-portion voltage; and a second portion configured to receive a scan signal of a second scan line, and then to receive the data signal of the data line, so that it a second-portion voltage, wherein the main-portion voltage, the first-portion voltage and the second-portion voltage are different from one another. The display panel can not only achieve lower color shift for 2D display, but also enable lower color shift for 3D display by using a voltage difference between the main portion and the first portion after turning the second portion into a light shielding area.
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TECHNICAL FIELD
[0001] The disclosure relates to the technology of resetting an intelligent terminal, and in particular to a method and device for resetting an intelligent terminal.
BACKGROUND
[0002] Due to the complexity of a system and the diversification of application programs in the usage process, an intelligent terminal is getting closer to a daily used personal computer. In the usual usage of an intelligent terminal, people often flash and upgrade the intelligent terminal and install various small application softwares in the intelligent terminal; particularly, game players will frequently install various new mini games, however, due to the problems such as diversification of terminal models, operating systems and platforms of intelligent terminals, diversification of radio access device interfaces, compatibility of games and the like, turning off, turning on, starting and resetting an intelligent terminal are the more common operations. Taking the most commonly used mobile phone in intelligent terminals as example:
[0003] the common resetting methods of a mobile phone are as follows: (1) normally turning on and turning off, that is, pressing the power key for a few seconds to realize the resetting and restarting of the mobile phone; (2) hard resetting, that is, entering into a boot interface in the cooperation of the function key and the power key, and restoring the factory settings by inputting the initial resetting password; (3) soft starting, that is, pressing the resetting hole in the terminal for a few seconds by using a sharp object to start the terminal.
[0004] In case of the non-fatal dead halt of an intelligent terminal in a normal operation, the intelligent terminal can be reset and restarted by the power key; however, if the intelligent terminal encounters dead halt, invalid soft reset, exceptions of a flashing process and the like, it is necessary to restore the intelligent terminal system by hard starting.
[0005] If an intelligent terminal has been configured to a long time, the registry will be damaged due to junk files and some third-party softwares usually installed, which makes the intelligent terminal respond slowly, stop responding or be dead halt. If an intelligent terminal operates much slowly, or some program operates abnormally, even a dead halt of the intelligent terminal occurs, it is generally required to solve these problems by soft resetting. After some programs are installed, soft resetting may also be needed. Meanwhile, in the usual usage, the intelligent terminal further needs to be reset by soft resetting at intervals, so as to clarify the intelligent terminal system and smoothen the operation program.
[0006] At present, there are three soft resetting methods as follows:
[0007] (1) directly disassembling battery to power off to realize soft starting; the defects of this method are as follows: sudden power-off of an intelligent terminal will result in loss of data being edited, and sudden loss of the latest address list and short messages in memory; and an abnormal turn-off and power-off will result in sudden interruption of current, resulting in that the terminal cannot be turned on due to permanent damage of partial devices in the terminal;
[0008] (2) pressing the resetting hole for a few seconds by using a sharp object to realize soft resetting; the defects of this method are as follows: it is inconvenient to perform the operation, and an extremely sharp and thin tool is needed; some resetting holes are arranged in the terminal battery groove, thus it is necessary to pull out the battery before resetting; the setting of a resetting hole in the intelligent terminal not only influences the appearance of intelligent terminal, but also increases cost of opening the resetting hole; and
[0009] (3) realizing soft resetting by pressing a certain function key or an assemblage of two function keys for a long time; the defects of this method are as follows: a single function key is very easy to cause a misoperation; although an assemblage of two function keys may reduce possibility of misoperation, misoperation still be easily caused when a large area of the keyboard is pressed; and it is not as convenient as the soft starting in a normal mode.
SUMMARY
[0010] In view of the problems above, the main object of the disclosure is to provide a method and device for resetting an intelligent terminal, which are greatly convenient for the resetting of the intelligent terminal.
[0011] In order to realize the above object, the technical solution of the disclosure is realized as follows.
[0012] A method for resetting an intelligent terminal includes:
[0013] receiving a reset instruction input by a user after a receiving state of reset instructions is started;
[0014] determining whether the reset instruction is valid, determining a current running state of the intelligent terminal when the received reset instruction is valid, and triggering a reset of the intelligent terminal when the intelligent terminal is in a dead halt state or an abnormal instruction state.
[0015] Preferably, the step of triggering the reset of the intelligent terminal may include:
[0016] triggering a hard reset of the intelligent terminal when the intelligent terminal is in a dead halt state; and
[0017] triggering a soft reset of the intelligent terminal when the intelligent terminal is in an abnormal instruction state.
[0018] Preferably, the reset instruction may be an assemblage sequence of keyboard keys of the intelligent terminal.
[0019] Preferably, the resetting method may further include:
[0020] setting a key of the intelligent terminal as a reset starting key; and
[0021] starting, by the intelligent terminal, the receiving state of reset instructions when a duration of the reset starting key being pressed reaches a set threshold.
[0022] Preferably, the resetting method may further include:
[0023] executing no reset instruction, when the reset instruction is valid and the current running state of the intelligent terminal is a normal instruction state.
[0024] A device for resetting an intelligent terminal, including: a starting unit, a receiving unit, a determining unit, a determination unit and a resetting unit; wherein
[0025] the starting unit is configured to start a receiving state of reset instructions of the intelligent terminal;
[0026] the receiving unit is configured to receive a reset instruction input by a user;
[0027] the determining unit is configured to determining whether the reset instruction is valid, and trigger the determination unit when the reset instruction is valid;
[0028] the determination unit is configured to determine a current running state of the intelligent terminal, and trigger the resetting unit when the intelligent terminal is in a dead halt state or an abnormal instruction state; and
[0029] the resetting unit is configured to reset the intelligent terminal.
[0030] Preferably, the resetting unit may trigger a hard reset of the intelligent terminal when the determination unit determines that the intelligent terminal is in a dead halt state; and
[0031] the resetting unit may trigger a soft reset of the intelligent terminal when the determination unit determines that the intelligent terminal is in an abnormal instruction state.
[0032] Preferably, the reset instruction may be a assemblage sequence of keyboard keys of the intelligent terminal.
[0033] Preferably, the resetting unit may further include:
[0034] a setting unit configured to set a key of the intelligent terminal as a reset starting key;
[0035] wherein when a duration of the reset starting key being pressed reaches a set threshold, the starting unit starts the receiving state of reset instructions of the intelligent terminal.
[0036] Preferably, the resetting unit may execute no reset instruction, when the determining unit determines that the reset instruction is valid and the determination unit determines that the current running state of the intelligent terminal is a normal instruction state.
[0037] In the disclosure, a reset starting key is set on the keyboard of an intelligent terminal; the receiving state of reset instructions of the intelligent terminal is started by pressing the reset starting key for a long time; a determining is performed after a reset instruction input by a user is received; the current state of the intelligent terminal is determined after the reset instruction is determined to be valid, and then a reset operation is performed according to the state of the intelligent terminal. The disclosure can perform a soft reset of the intelligent terminal quickly, conveniently and securely, thereby greatly avoiding the instable work state caused by disassembling battery and avoiding the reset misoperation caused by the resetting of the existing single function key.
BRIEF DESCRIPTION OF THE DRAWINGS
[0038] FIG. 1 shows a schematic diagram illustrating a composition and structure of a device for resetting an intelligent terminal according to the disclosure;
[0039] FIG. 2 shows a schematic diagram illustrating an application structure of an intelligent terminal according to the disclosure; and
[0040] FIG. 3 shows a flowchart illustrating a resetting application of an intelligent terminal according to the disclosure.
DETAILED DESCRIPTION
[0041] The basic principle of the disclosure is that: a reset starting key is set on the keyboard of an intelligent terminal; the receiving state of reset instructions of the intelligent terminal is started by pressing the reset starting key for a long time; a determining is performed after a reset instruction input by a user is received; the current state of the intelligent terminal is determined after the reset instruction is determined to be valid, and then a reset operation is performed according to the state of the intelligent terminal.
[0042] FIG. 1 shows a schematic diagram illustrating a composition and structure of a device for resetting an intelligent terminal according to the disclosure; as shown in FIG. 1 , the device for resetting an intelligent terminal according to the disclosure comprises: a starting unit 100 , a receiving unit 101 , a determining unit 102 , a determination unit 103 and a resetting unit 104 ; wherein the starting unit 100 is configured to start a receiving state of reset instructions of the intelligent terminal; the receiving unit 101 is configured to receive a reset instruction input by a user; the determining unit 102 is configured to determining whether the reset instruction is valid, and trigger the determination unit 103 when determining that the reset instruction is valid; the determination unit 103 is configured to determine the current running state of the intelligent terminal, and trigger the resetting unit 104 when the intelligent terminal is in a dead halt state or an abnormal instruction state; and the resetting unit 104 is configured to reset the intelligent terminal. When the determining unit 102 determines that the reset instruction is valid and the determination unit 103 determines that the current running state of the intelligent terminal is a normal instruction state, the resetting unit 104 does not execute the reset instruction.
[0043] Wherein, when the determination unit 103 determines that the intelligent terminal is in a dead halt state currently, the resetting unit 104 triggers a hard reset of the intelligent terminal; when the determination unit 103 determines that the intelligent terminal is in an abnormal instruction state, the resetting unit 104 triggers a soft reset of the intelligent terminal.
[0044] The reset instruction above is an assemblage sequence of the keyboard keys of the intelligent terminal. The reset instruction can be either a key assemblage of letter keys, such as “adgj”, “ajtwp” and the like, or a key assemblage of number keys, such as “12345”, “101001” and the like; the length and the assemblage mode of the above-mentioned reset instruction can be set arbitrarily.
[0045] As shown in FIG. 1 , the device for resetting the intelligent terminal according to the disclosure may further comprise a setting unit 105 configured to set a key of the intelligent terminal as a reset starting key, when a duration of the reset starting key being pressed reaches a set threshold, the starting unit 100 starts the receiving state of reset instructions of the intelligent terminal.
[0046] FIG. 2 shows a schematic diagram illustrating an application structure of an intelligent terminal according to the disclosure; the intelligent terminal according to the disclosure may comprise a resetting module, a baseband chip 12 , a power management module 13 , a FLASH memory module 14 and a reset display module 15 . Wherein the resetting module in the disclosure may comprise a reset instruction input module 16 , a sequence detector 17 , a mode selecting module 18 , a hard reset output enabling module 19 , a soft reset output enabling module 110 and a reset management module 111 . Wherein:
[0047] the reset instruction input module 16 is connected with the sequence detector 17 , and is configured to complete the input of the reset instruction; here, the reset instruction is realized by an assemblage of corresponding keys on the intelligent terminal keyboard; specifically, the enabling or disabling of the receiving state of reset instructions is realized by pressing a control key for a long time, when the control key is pressed for a set period of time, the receiving state of reset instructions of the intelligent terminal is started, it is indicated that high level is valid and the sequence code input at this moment is valid; when the control key is pressed again for a set period of time, the receiving state of reset instructions of the intelligent terminal is disabled, it is indicated that low level is invalid and the sequence code input at this moment is invalid. Or, the enabling or disabling of the receiving state of reset instructions is realized by pressing-down or non-pressing-down of a control key; when the control key is pressed down to be in a pressing-down state, the receiving state of reset instructions of the intelligent terminal is started, it is indicated that high level is valid and the sequence code input at this moment is valid; when the control key is pressed again to be in a non-pressing-down state, the receiving state of reset instructions of the intelligent terminal is disabled, it is indicated that low level is invalid and the sequence code input at this moment is invalid. The input mode of the reset instruction according to the disclosure can prevent a user from entering into a soft reset program by mistake when the input information and dialed number are coincidentally the same as the reset instruction. The reset instruction is an assemblage sequence of the keyboard keys of the intelligent terminal. The reset instruction may be either a key assemblage of letter keys, such as “adgj”, “ajtwp” and the like, or the reset instruction may be a key assemblage of number keys, such as “12345”, “101001” and the like; the length and the assemblage mode of the above reset instruction can be set arbitrarily.
[0048] The sequence detector 17 is connected with the mode selecting module 18 , and is configured to complete detection of a keyboard sequence code input by a user, that is, detecting whether the sequence code input by a user is a reset instruction. The process of detecting the sequence code is as follows: when the soft reset instruction is set as 1010, the detector first detects the first instruction, and if the first instruction is 1, the detector continues to detect the second sequence, otherwise, the detector outputs a high resistance Z; when detecting that the second sequence is 0, the detector continues to detect the third sequence, otherwise, the detector outputs a high resistance Z; when detecting that the third sequence is 1, the detector continues to detect the is fourth sequence, otherwise, the detector outputs a high resistance Z; when detecting that the fourth sequence is 0, the detector outputs a low level 0 to the mode selecting module 18 and then selects the soft reset. Likewise, when the hard reset instruction is set as 0101, in the condition that the enabling of key is valid, when the sequence detector detects this sequence according to the rules above, the detector outputs a high level 1 to the mode selecting module 18 and then selects the hard reset.
[0049] The soft reset enabling module 110 and the hard reset enabling module 19 are connected with the mode selecting module 18 , and are configured to output different reset valid signals RST 0 _N and RST 1 _N corresponding to different inputting modes. The reset enabling signal is of high level at the beginning, when it is detected that a user needs to perform a reset operation, a low level pulse is generated immediately and lasts for three clock periods, then the reset enabling signal is recovered to high level state.
[0050] The reset management module 111 is configured to manage the reset work mode of the intelligent terminal; when the intelligent terminal works normally, the reset management module detects that other modules are in a sleep state, even if there is a misoperation during inputting, it is unable to activate the soft reset output enabling module 110 to work; when the intelligent terminal is in a dead halt state or an abnormal instruction state, the soft reset output enabling module 110 is activated immediately to enter into the quick soft reset state. In this way, not only faulty reset can be prevented, but also energy consuming caused by soft reset of system can be saved to lengthen the standby time of the system.
[0051] The baseband chip 12 is connected with the reset module and is communicated with the reset module through a General Purpose Input Output (GPIO) interface; when the GPIO_RST pin of the baseband chip receives a reset low level, the baseband chip is reset, the baseband chip restores the kernel ARM and DSP chip to an initial program line, then the system reloads to operate.
[0052] The reset display module 15 is connected with the baseband chip 12 ; when the system is reset successfully, the baseband chip outputs a signal level to a turn-on indictor lamp of the intelligent terminal, and lighting of the indicator lamp indicates that reset is successfully.
[0053] The FLASH memory module 14 is connected with the baseband chip 12 ; when the system receives a hard reset instruction, an Application Programming Interface (API) program is called to clear problematic programs in the intelligent terminal and erase the third-party softwares and problematic programs in the FLASH chip, and then the intelligent terminal restores the security system.
[0054] The power management module 13 is connected with all other modules, and is configured to supply voltage required for the normal operation of the system. Meanwhile, when the intelligent terminal is in an powered-on reset state, the power management module receives a reset low level signal PS_HOLD from the baseband chip and outputs a reset enabling signal to the resetting module, to complete the powering-on and resetting process.
[0055] FIG. 3 shows a flowchart of a resetting application of an intelligent terminal according to the disclosure, and the processing flow as shown in FIG. 3 is a flowchart after the intelligent terminal is currently in a dead halt state or an abnormal instruction state; as shown in FIG. 3 , the resetting application flow of the intelligent terminal according to the disclosure comprises:
[0056] step 1001 : the type of a dead halt is determined in accordance with the response to a user's key pressing, when the intelligent terminal is in an abnormal work state, step 1002 is executed; when the intelligent terminal is in a complete dead halt state with no response, step 1005 is executed; and step 1001 can be executed when the user starts the receiving state of reset instructions of the intelligent terminal, or the current running state of the intelligent terminal can be determined after the user inputs a reset instruction and the reset instruction is confirmed to be correct; those skilled in the art should understand that the above execution result corresponds to the execution mode;
[0057] step 1002 : in the cooperation of valid enabling of the control key, the user inputs a soft reset password sequence sequentially; that is, when being in the reset instruction receiving state, the intelligent terminal receives the reset instruction input by the user;
[0058] step 1003 : in the condition that control key is valid, a sequence detecting module is of the intelligent terminal detects whether the input password sequence is consistent with the originally stored soft reset sequence, if yes, step 1008 is executed; otherwise, step 1004 is executed;
[0059] step 1004 : the intelligent terminal detects that the input sequence is wrong, the reset management module resets each module relating to resetting, to wait for the inputting of the next instruction; the flow is ended;
[0060] step 1005 : in the cooperation of valid enabling of control key, the user inputs a hard reset password sequence sequentially, and then step 1006 is executed;
[0061] step 1006 : in the condition that control key is valid, a sequence detector of the intelligent terminal detects whether the input password sequence is consistent with the original hard reset sequence, if yes, step 1008 is executed; otherwise, step 1007 is executed;
[0062] step 1007 : the intelligent terminal detects that the input sequence is wrong, the reset management module resets each module relating to resetting, to wait for the inputting of the next instruction; the flow is ended;
[0063] step 1008 : the mode selecting module detects the output signal of the sequence detector, if the output signal is a soft reset signal, step 1009 is executed; and, if the output signal is a hard reset signal, step 1011 is executed;
[0064] step 1009 : after receiving an input enabling signal, the soft reset enabling output module generates a low level reset signal RST_N 1 and sends the low level reset signal RST_N 1 to the baseband processor chip, and then step 1010 is executed;
[0065] step 1010 : when the GPIO_RST pin of the baseband chip receives a soft reset low level, the baseband chip is reset, the baseband chip restores the kernel ARM and DSP chip to an initial program line, and the system reloads to operate; and then step 1013 is executed;
[0066] step 1011 : after receiving an input enabling signal, the hard reset enabling output module generates a low level reset signal RST_N 2 and sends the low level reset signal RST_N 2 to the baseband processor chip, and then step 1012 is executed;
[0067] step 1012 : when the system receives a hard reset instruction, an API program is called to clear the problematic programs in the intelligent terminal and erase the third-party softwares and problematic programs in the FLASH chip, and the intelligent terminal restores the security system; and then step 1013 is executed;
[0068] step 1013 : after the reset operation is successful, the reset management module feeds back a signal to the baseband chip, and then the baseband chip outputs a signal to the reset display module to complete this reset process; and then step 1014 is executed; and
[0069] step 1014 : the reset management module resets each module relating to resetting, to restore to the initial work state and wait for the next reset signal; the flow is ended.
[0070] The above are only the preferred embodiments of the disclosure and are not intended to limit the protection scope of the disclosure.
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The disclosure discloses a method for resetting an intelligent terminal, including: receiving a reset instruction input by a user after a receiving state of reset instructions is started; determining whether the reset instruction is valid, determining a current running state of the intelligent terminal when the received reset instruction is valid, and triggering a reset of the intelligent terminal when the intelligent terminal is in a dead halt state or an abnormal instruction state. The disclosure further discloses a device for resetting an intelligent terminal. The disclosure can perform a soft reset of the intelligent terminal quickly, conveniently and securely, thereby greatly avoiding the instable work state caused by disassembling battery and avoiding the reset misoperation caused by the resetting of the existing single function key.
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BACKGROUND AND SUMMARY OF THE INVENTION
This application is a continuation of application Ser. No. 07/866,135 filed Apr. 9, 1992, which is a continuation-in-part of U.S. Ser. No. 07/822,433 filed Jan. 17, 1992, which is a continuation-in-part of U.S. Ser. No. 07/317,626, filed Mar. 1, 1989 (abandoned), which was a continuation-in-part of U.S. Ser. No. 07/209,861, filed Jun. 22, 1988 (abandoned).
The antimicrobial activity of the lanthionine-containing bacteriocin nisin is restricted towards certain gram positive organisms and is optimal at pH 5.0. The antimicrobial activity of nisin is enhanced when used in combination with a chelator such as EDTA. The activity of the nisin-chelator compositions have been found to be significantly greater or optimal at a pH greater than 5.0. For example, it has been determined that the antimicrobial activity towards Staphylococcus aureus of a nisin and EDTA composition is significantly greater at pH 8.0 than the activity of the same composition against S. aureus at pH 5.0. The combination of a chelator with nisin was also found to result in activity towards gram negative bacteria, an activity which is not normally attributed to nisin itself.
The present invention concerns lanthionine-containing bacteriocin compositions which are active in acidic pH below 5.0 and display considerable activity against gram negative bacteria. These low-pH-active compositions may be useful for example in methods of treating or preventing infections or growth of microorganisms in the gastrointestinal tract of humans and animals. These compositions when introduced into the gastrointestinal tract will act as bactericides even in the low-pH environment of the stomach. This antibacterial activity may be useful in containing the growth of infections caused by gastrointentinal pathogens such as species of Helicabacter, Escherichia, Salmonella, Bacillus, Clostridia, Bacteroides, Campylobacter and Yersinia. Such-low-pH active bacteriocin compositions would therefore be useful in the treatment of various diseases or symptoms due to the presence of such pathogenic bacteria.
Various gastrointestinal diseases or symptoms including diarrhea, gastritis, peptic and duodenal ulcer, and gastric carcinoma are due to the presence of pathogenic microorganisms in the gastrointestinal tract. Escherichia and Salmonella, in particular, but also certain species of Clostridia, Bacillus, Bacteroides, Campylobacter and Yerasinia can be responsible for diarrhea especially in neonatal farm animals. (R. E. Holland, 1990, Clin. Microbiol. Rev. 3:345, "Some infectious causes of diarrhea in young farm animals.") Helicobacter pylori are implicated in gastritis, duodenal and peptic ulcer disease. (Peterson, W. L., 1991, New Eng. J. Med. 324: 1043, "Helicobacter pylori and peptic ulcer disease") and are also associated with gastric carcinoma. (Henderson, B. E., Ross, R. K., and Pike, M. C., 1991, Science 254:1131, "Toward the primary prevention of cancer," Nomura, A., Stemmermann, G. A., Chyou, P. H., Kato, I., Perez-Perez, G. and Blaser, M. J. (1991) New Eng. J. Med. 325: 1132 "Helicobacter pylori infection and gastric carcinoma among Japanese Americans in Hawaii."; Parsonnet, J., Friedman, G. D., Vandersteen, D. P., Chang, Y., Vogelman, J. H., Orentreich, N, and Sibley, R. K. (1991) New Eng. J. Med. 325:1127; Forman, D., Sitas, F., Newell, D. G., Stacey, A. R., Boreham, J., Peto, R., Campbell, T. C., Li, J. and Chen, J. (1990) Int. J. Cancer 56:608 "Geographic association of Helicobacter pylori antibody prevalence and gastric cancer mortality in rural China").
Many gastrointestinal pathogens are gram negative bacteria, organisms against which nisin would be expected to be inactive. (Hurst, A., 1981, "Nisin," Adv. in App. Micr. V. 27, p. 85-121.) For example, Helicobacter pylori (which has also been identified in the prior art as Campylobacter pylori) is a gram negative microaerophilic bacillus that colonizes the gastric mucosa. Since 1983, when first reported in association with histologic gastritis, a relationship between suppression of H. pylori infection and improvement of gastric disorders has been noted. However, although numerous antibiotics have been tried against H. pylori infection, none have so far proved acceptable and no agent or regimen has been approved for use against this organism. Long term eradication of the organism has seldom been achieved and antibiotics themselves can produce unacceptable side effects. (Peterson, W. L., 1991, New Eng. J. Med. 324:I043 "Helicobacter pylori and peptic ulcer disease; Warren, J. R., 1983, Lancet 1:1273, "Unidentified curved bacilli on gastric epithelium in active chronic gastritis"; Morgan et al., 1988, Gastroenterology 95:1178, "Nitrofurans in the treatment of gastritis associated with Campylobacter pylori"; Glupczynski, Y. et al., 1988, Am. J. Gastroenterol. 83:365 "Campylobacter pylori-associated gastritis: a double-blind placebo controlled trial with amoxycillin"; Rauws, E. A. et al., 1988, Gastroenterology 94:33, "Campylobacter pylori-associated chronic antral active gastritis"; Glupczynski, Y. 1990 in Helicobacter pylori, gastritis, and peptic ulcer"; Malfertheiner, P., Ditschuneit, H., Eds. Springer-Verlag, Berlin, Germany pp 49-58; Rauws, E. A. and Tytgat, G. N. 1990 Lancet 335:1233 "Cure of duodenal ulcer associated with eradication of Helicobacter pylori. O'Riordan, T. et al., 1990, Gut 31:999 "Adjuvant antibiotic therapy in duodenal ulcers treated with colloidal bismuth subcitrate"; Weil, J. et al., 1990, Aliment. Pharmacol. Ther., 4:651 "Helicobacter pylori infection treated with a tripotassium dicitrato bismuthate and metronidazole combination"; Coghlan, J. G., Gilligan, D., Humphries, H., et al., 1987, Lancet 2:1109 "Campylobacter pylori and recurrence of duodenal ulcer--a 12-month follow-up study"; Marshall, B. J. Goodwin, C. S., Warren, J. R. et al., 1988, Lancet 2:1437, "Prospective double-blind trial of duodenal ulcer relapse after eradication of Campylobacter pylori").
The present invention concerns pharmaceutical compositions comprising a lanthionine-containing bacteriocin such as nisin and a chelating agent with a suitable carrier for use in low-pH environments as bactericides. These compositions are stable and active at acidic pH and are useful for their antibacterial activity against gram negative bacteria in low-pH environments such as encountered in the gastrointestinal tract. Pharmaceutical nisin compositions according to the invention act quickly, so that when delivered into the stomach and gastrointestinal tract their activity should not be limited by the clearance rate of the stomach contents. Furthermore, unlike antibiotics, nisin compositions can be safely ingested. The pharmaceutical compositions may be used alone in treatment regimens or in combination with other pharmaceutical agents or drugs. The invention also concerns methods of using and making such compositions.
DETAILED DESCRIPTION OF THE INVENTION
The efficacy of the present invention has been demonstrated on E. coli bacteria which are found in the mammalian gut and are frequently responsible for gastrointestinal disorders. The survival of E. coli is unaffected by exposure to EDTA or citrate by themselves or by exposure to nisin by itself. In addition, suspensions of E. coli exposed to acid survive well in an acidic environment until the pH drops below pH 2.5. However, as is set forth below, when nisin is combined with EDTA at a range of acidic pH values, significant reduction in the viability of the bacteria was seen after only 1 minute of exposure to the nisin compositions. At pH 3.5, a reduction by more than 6 logarithms in the viable count of bacteria can be attributed to nisin after only 1 minute exposure to the nisin-chelator composition. Below pH 3.5 some reduction of the potency of the nisin compositions is apparent but, nevertheless, an approximately 1000-fold enhancement of nisin activity remains even at pH 2.5 (Table 1).
EDTA-activated nisin is bactericidal towards E. coli in the presence of various acid vehicles including acetate, citrate, lactate, and succinate, as shown in Tables 2-5. As illustrated by results obtained at pH 3.5, the rapid bactericidal activity of the nisin compositions can be influenced by the choice of acid vehicle. In all the illustrated cases, as the concentration of each acid anion is increased, the bactericidal activity of the nisin compositions is observed to decrease. Nevertheless, each of these acid vehicles is suitable for the expression of chelator-enhanced nisin activity. Exposure of the bacteria to these nisin compositions for a longer period than 1 minute is effective in reducing the number of bacteria even when the formulations contain the less effective concentrations of the acid vehicles.
Evaluation of Germicidal Activity of Chelator-Enhanced Nisin in Acid Vehicles towards Gram Negative Bacteria.
The rapid activities of various chelator-enhanced nisin formulations were evaluated in acid vehicles in a germicidal suspension assay.
E. coli cells from an overnight Trypticase soy nutrient agar (TSA) were resuspended to a density measured as an absorbance of 1.0 at 600 nm in sterile ddH 2 O. The reaction of the cells with each of the bactericidal test formulations analyzed was started by addition of 30 μl of cells to 970 μl of test formulation. The reaction mixture was incubated at 37° C for at least 1 minute and then centrifuged in a microfuge for 1 minute. The cell pellet was washed by resuspension in 1 ml of neutralization buffer. (The neutralization buffer: 50 mM Tris-HCl, pH 7.0, 5 mM MgSO 4 , 20 mM CaCl 2 , 0.1 M NaCl and 0.1% gelatin was prepared by first making Tris buffer and adjusting the pH. The salts and gelatin were then added and the solution stirred with heat until the solution was clear. The solution was then autoclaved for 20 min. The neutralization buffer was used without dilution.) The cells were centrifuged in a microfuge for 1 minute and resuspended in 1 ml of neutralization buffer. The viable count was determined by spreading 100 μl of bacterial suspension and serial dilutions thereof in neutralization buffer on nutrient agar and scoring surviving colonies after 24 h at 37° C. Percent survival relative to untreated controls was calculated from the scored values.
EDTA-enhanced activity of nisin is expressed at low pH. Below pH 3.5 the degree of enhancement is reduced, presumably as the carboxyl groups of the chelator are titrated. Nevertheless, an approximately 1000-fold enhancement of nisin by EDTA was observed even at pH 2.5. See results presented in Table 1.
TABLE 1______________________________________EDTA activation of Nisin towards Escherichia coliDependence with respect to acidic pH pH valueEDTA Nisin 7.0 2.0 2.5 3.0 3.5 4.0mM μg/ml % survival at 1 min.sup.a______________________________________0 0 100 -- -- -- 100 --0 100 -- 0.28 3.37 4.43 100 1001.0 0 -- 0.07 -- 5.41 -- --1.0 100 -- 0.01 0.005 0.0007 <10.sup.-4 <10.sup.-4______________________________________ .sup.a Initial viable count 4 × 10.sup.7 colony forming units/ml .sup.b Incubations performed at 37° C. in 20 mM Na acetate buffer adjusted to pH
TABLE 2______________________________________Chelator Activation of Nisin-Acetate towards Escherichia coliDependence with respect to Acetate concentration (% w/v) Acetate pH 3.5EDTA Nisin 0 0.1 0.3 1.0 3.0mM μg/ml % survival at 1 min.sup.a______________________________________0 0 100 55 80 90 10.10 100 -- 9.6 70 100 1001.0 0 -- 40 25 25 10.71.0 100 -- 0.0005 <10.sup.-4 0.02 0.4______________________________________ .sup.a Initial viable count 2 × 10.sup.7 colony forming units/ml .sup.b Incubations performed at 37° C.
TABLE 3______________________________________Chelator Activation of Nisin-Citrate towards Escherichia coliDependence with respect to Citrate concentration (% w/v) Citrate pH 3.5EDTA Nisin 0 0.1 0.3 1.0 3.0mM μg/ml % survival at 1 min.sup.a______________________________________0 0 100 100 56.3 72.9 1000 100 -- 0.003 0.0007 0.56 14.61.0 0 -- 100 50.0 47.9 1001.0 100 -- 0.0006 0.0002 0.69 20.8______________________________________ .sup.a Initial viable count 5 × 10.sup.7 colony forming units/ml .sup.b Incubations perfomed at 37° C.
TABLE 4______________________________________Chelator Activation of Nisin-Lactate towards Escherichia coliDependence with repsect to Lactate concentration (% w/v) Lactate pH 3.5EDTA Nisin 0 0.1 0.3 1.0 3.0mM μg/ml % survival at 1 min.sup.a______________________________________0 0 100 22.2 46.7 35.6 4.20 100 -- 4.4 0.24 17.8 26.71.0 0 -- 5.1 0.46 0.91 1.581.0 100 -- <10.sup.-4 0.02 0.20 2.84______________________________________ .sup.a Initial viable count 5 × 10.sup.7 colony forming units/ml .sup.b Incubations perfomed at 37° C.
TABLE 5______________________________________Chelator Activation of Nisin-Succinate towards Escherichia coliDependence with respect to Succinate concentration (% w/v) Succinate pH 3.5EDTA Nisin 0 0.1 0.3 1.0 3.0mM μg/ml % survival at 1 min.sup.a______________________________________0 0 100 85.5 29.9 36.7 13.90 100 -- 18.3 66.6 83.4 28.41.0 0 -- 56.8 63.6 46.2 43.21.0 100 -- 0.02 6.21 14.2 4.73______________________________________ .sup.a Initial viable count 3.4 × 10.sup.6 colony forming units/ml .sup.b Incubations performed at 37° C.
At pH 3.5 EDTA-enhanced nisin activity was observed in the presence of all acid anions tested (see Tables 2-5). At pH 3.5, lactate at 0.3% was somewhat inhibitory to EDTA-enhanced nisin activity. Nevertheless the activity is still enhanced more than 1000-fold over 0.3% lactate alone and 0.1% lactate is not inhibitory to EDTA-enhanced nisin.
At pH 3.5, up to 0.3% acetate and 0.3% citrate appear compatible with chelator-enhanced nisin germicidal activity towards E. coli suspensions. These anions appear to show the most promise as acid vehicles to be formulated with EDTA-enhanced nisin. Citrate is a most suitable acid vehicle for EDTA-enhanced nisin compositions. Citrate is a naturally occurring food substance and intermediary metabolite and an effective enhancer of nisin bactericidal activity in its own right (Table 3). Nisin-citrate compositions can be expected to be safe and effective for containing or eliminating the growth of undesirable microorganisms in the gastrointestinal tract of humans and animals.
Citrate is a metabolite, it does not inhibit the growth of bacteria and bacteria grow well on nutrient agar supplemented with citrate. However, nisin in the presence of citrate is active against gram negative bacteria. Thus, it is possible to demonstrate the activity of nisin towards gram negative bacteria by performing growth inhibition assays on nutrient agar supplemented with various concentrations of citrate. This nisin-citrate agar assay has much more general applicability. The assay provides a method for screening potential agents other than citrate in combination with nisin for their potential properties as enhancers of nisin's inherent bactericidal activity. Examples of other organic acids in combination with nisin would include acetate, propionate, lactate, succinate, fumarate, malonate, adipate, sorbate, phosphate and ascorbate.
Other agents that potentiate nisin activity include nonionic and amphoteric surfactants and emulsifiers, quaternary compounds, monoglycerides, and fatty acids.
The nisin-citrate agar assay is performed as follows. E. coli is resuspended to an optical density of 1.0 at A 600 . A 100 μl sample of the bacterial suspension is spread uniformly on Trypticase Soy nutrient agar (TSA) supplemented with various concentrations of citrate (e.g. 0.1%, 0.3%, 1.0%, 3.0%) and incubated for 1 hour at 37° C. A nisin stock solution and serial dilutions thereof in 0.1% bovine serum albumin (BSA), are prepared and 5 μl are taken from each and deposited onto the growing bacterial lawn. The TSA plates are then incubated for 24 hours at 37° C. After 24 hours at 37° C., E. coli grown on TSA supplemented with citrate form a confluent lawn. The activity of nisin towards bacteria grown in the presence of citrate is demonstrated by clear zones in the bacterial lawn where the serially diluted nisin samples were deposited. The effectiveness of nisin against the gram negative bacteria can be assessed from determining the minimum amount of nisin required to produce a clear zone of growth inhibition. As the concentration of citrate in the nutrient agar is increased, less nisin is required to inhibit the growth of E. coli, as is illustrated by the data shown in Table 6.
TABLE 6______________________________________The activity of Nisin towards E. coli grownon Nutrient Agar in the presence of Citrate% Citrate Nisin NIC.sup.1/______________________________________ 0% 3,333 μg/ml0.1% 370 μg/ml0.3% 123 μg/ml1.0% 13.7 μg/ml3.0% 0.06 μg/ml______________________________________ .sup.1/ Nominal inhibitory concentration of nisin minimally required to prevent growth of E. coli strain ATCC8739 grown on Trypticase Soy Agar supplemented with the various concentrations of citrate as indicated.
The activity of nisin enhanced with EDTA, citrate or other chelators has also been demonstrated towards several strains of Helicobacter pylori as well as related species, particularly Campylobacter jejuni, by the germicidal suspension assay. Examples are shown in Tables 7-13. Freshly grown H. pylori cells, grown on a nutrient agar plate (Trypticase Soy Agar, BBL 11043, supplemented with 5% defibrinated sheep blood), were harvested and subsequently grown at 37° C. for 72-96 hours in a BBL Gaspak® System chamber with BBL Campy Pak™ Microaerophilic System envelopes and using a Campylobacter microaerophilic gas generator (BBL71034). The cells were then resuspended in sterile, deionized-distilled water to a cell density of 1.0 A 600 to provide a suitable stock suspension. The assay was started by addition of 50 μl of bacterial suspension to 950 μl of test solution, incubated at 37° C. for 5 minutes and then centrifuged for 1 minute in a microfuge. The cell pellet was washed by resuspension in 1 ml of the sterile neutralization buffer described previously and centrifuged for 1 minute in a microfuge. The cells were then resuspended in Brucella-Albimi broth (BBL) and serially diluted in same prior to plating on nutrient agar. The viable count was determined by spreading 100 μl of bacterial suspension and dilutions thereof on the nutrient agar described above and scoring surviving colonies after 72-96 hours' incubation at 37° C. in the modified atmosphere described above. Percent survival relative to untreated controls was calculated from the scored values.
The concentration dependence of the activity of nisin towards Helicobacter pylori in the presence and absence of 0.1% citrate at pH 5.0 is illustrated by the data presented in Table 7. Although H. pylori is a gram negative bacterium, nisin, considered active only against gram positive bacteria, surprisingly exhibits some bactericidal activity towards this organism. However, the activity of nisin towards H. pylori is significantly enhanced by the presence of citrate.
The concentration dependence of the activity of nisin towards H. pylori by citrate at pH 5.0 and pH 7.0 is illustrated by the data presented in Table 8. In general, citrate by itself has little effect on the viability of this bacterial species at pH 5.0, although at pH 7.0 the viability of the organism is somewhat reduced at higher concentrations of citrate. The effects of citrate alone are surprising since citrate is a metabolite. The enhanced activity attributable to nisin in the presence of citrate is sufficient to completely kill a 10 5 cfu/ml suspension of H. pylori within 5 minutes at 37° C.
Data presented in Table 9 illustrate that the activity of nisin towards H. pylori at pH 5.0 and pH 7.0 is also significantly enhanced in the presence of the chelator EDTA. The chelator itself has little effect on the viability of these organisms except at higher concentrations. However, the EDTA-enhanced activity attributable to nisin is sufficient to completely kill a 10 5 cfu/ml suspension of H. pylori within 5 minutes at 37° C.
The bactericidal activity of nisin towards H. pylori in the presence or absence of citrate or EDTA over a range of pH values is illustrated by the data presented in Table 10 and Table 11, respectively. Despite the fact that H. pylori is isolated from the stomach, the lumen of which is acidic, the viability of this organism is surprisingly poor after exposure to low pH conditions. H. pylori colonizes the stomach mucosal epithelia, a less acidic microenvironment than that of the stomach lumen. Despite the limiting viability of H. pylori at low pH in these experiments, the data indicate that nisin with citrate or EDTA can be expected to be bactericidal towards H. pylori under conditions similar to those that prevail in the stomach and its mucosal epithelium where H. pylori is able to thrive.
Campylobacter jejuni is a gram negative bacterium that colonizes the intestines of birds and mammals and has been associated with food poisoning. The bactericidal activity of nisin, in the presence and absence of citrate or EDTA, towards C. jejuni is illustrated by the data presented in Table 12 and Table 13, respectively. Nisin by itself is extremely effective towards this gram negative bacterium. At pH 5.0, higher concentrations of citrate also proved to be toxic towards this bacterium. Thus, combinations of nisin with citrate or EDTA can be expected to be effective towards C. jejuni as is illustrated by the data in Tables 12 and 13.
TABLE 7______________________________________Bactericidal activity of Nisin towards Helicobacter pyloriAcitivty with respect to nisin concentration Nisin (μg/ml)Strain Citrate 0 10 30 100 300ATCC# pH 5.0 % survival at 5 min.sup.a______________________________________ATCC43579 0 100.sup.b 1.31 0.39 0.085 0.0056 0.1% 86.2 0.21 0.008 0.001 1.89 × 10.sup.-5______________________________________ .sup.a Incubations performed at 37° C. .sup.b Initial viable count 3.19 × 10.sup.7 cfu/ml
TABLE 8__________________________________________________________________________Bactericidal activity of Nisin towards Helicobacter pyloriActivity with respect to citrate at pH 5.0 and pH 7.0 (% w/v) CitrateStrain Nisin 0 0.1 0.3 1.0ATCC# pH μg/ml % survival at 5 min.sup.a__________________________________________________________________________ATCC43579 5.0 0 100.sup.b 100 100 100 100 9.62 <0.01 <0.01 <0.01ATCC43504 5.0 0 100.sup.c 83.6 42.9 22.1 0 100.sup.d 25.8 4.39 50.9 100 n.a. 0.033 0.066 0.14 100 0.043 <3.1 × 10.sup.-3 0.92 2.44ATCC43579 7.0 0 100.sup.c 12.1 0.26 0.02 100 0.78 <8.1 × 10.sup.-3 <8.1 × 10.sup.-3 <8.1 × 10.sup.-3ATCC43504 7.0 0 100.sup.f 17.7 8.94 0.82 100 2.08 <0.01 <0.01 <0.01__________________________________________________________________________ .sup.a Incubations performed at 37° C. for 5 minutes .sup.b Initial viable count 1.04 × 10.sup. 4 cfu/ml .sup.c Initial viable count 1.40 × 10.sup.5 cfu/ml .sup.d Initial viable count 3.26 × 10.sup.5 cfu/ml .sup.e Initial viable count 1.24 × 10.sup.5 cfu/ml .sup.f Initial viable count 9.62 × 10.sup.4 cfu/ml < denotes no detectable surviving colonies
TABLE 9__________________________________________________________________________Bactericidal Activity of Nisin Towards Helicobacter pyloriActivity with respect to EDTA at pH 5.0 and pH 7.0 (mM) EDTAStrain Nisin 0 1.0 10 100ATCC# pH μg/ml % survival at 5 min.sup.a__________________________________________________________________________ATCC43579 5.0 0 100.sup.b 13.63 8.82 0.43 100 4.7 <5.0 × 10.sup.-3 <5.0 × 10.sup.-3 <5.0 × 10.sup.-3ATCC43526 7.0 0 100.sup.c 94.1 21.0 1.62 100 5.88 <0.03 <0.03 <0.03__________________________________________________________________________ .sup.a Incubation performed at 37° C. × for 5 minutes .sup.b Initial viable count 2.04 × 10.sup.5 cfu/ml .sup.c Initial viable count 3.40 × 10.sup.4 cfu/ml < denotes no detectable surviving colonies
TABLE 10__________________________________________________________________________Bactericidal Activity of Nisin Towards Helicobacter pyloriDependence with respect to citrate in pH range 2.5 to 5.0 pH valueStrain Citrate Nisin 2.5 3.0 3.5 4.0 5.0ATCC# % μg/ml % survival at 5 min.sup.a__________________________________________________________________________ATCC43579 0 0 -- -- -- -- 100.sup.b 0 100 -- -- -- -- 8.6 × 10.sup.-3 0 100 -- -- -- -- 0.30.sup.c 0.1 0 <5.0 × 10.sup.-4 1.1 × 10.sup.-3 0.18 9.56 97.2 0.1 100 <5.0 × 10.sup.-4 1.1 × 10.sup.-3 1.1 × 10.sup.-3 2.0 × 10.sup.-3 2.7 × 10.sup.-3ATCC43504 0 0 -- -- -- -- 100.sup.d 0 0 -- -- -- -- 100.sup.e 0 100 -- -- -- -- 0.69 0 100 -- -- -- -- 4.86 0.1 0 0.14 <0.004 <0.004 0.36 68.5 0.1 100 <0.004 <0.004 <0.004 <0.004 0.022 0.3 0 0.027 <0.027 29.7 17.6 100 0.3 100 <0.27 <0.027 2.7 0.32 0.18__________________________________________________________________________ .sup.a Incubations for 5 min at 37° C. in citrate adjusted to pH, or 20 mM acetate, pH 5.0. .sup.b Initial viable count 1.85 × 10.sup.6 cfu/ml .sup.c Average of 5 experiments .sup.d Initial viable count 2.7 × 10.sup.5 cfu/ml .sup.e Initial viable count 3.7 × 10.sup.4 cfu/ml < denotes no detectable surviving colonies
TABLE 11__________________________________________________________________________Bactericidal activity of Nisin Towards Helicobacter pyloriActivity with respect to EDTA in the pH range 2.5 to 5.0 pH valueStrain EDTA Nisin 2.5 3.0 3.5 4.0 5.0ATCC# mM μg/ml % survival at 5 min.sup.a__________________________________________________________________________ATCC43504 0 0 -- -- -- -- 100.sup.b 0 0 -- -- -- -- 100.sup.c 0 100 -- -- -- -- 0.021.sup.d 0 100 -- -- -- -- 7.03.sup.e 1.0 0 0.023 <0.021 94.2 11.6 10.0 1.0 0 0.013 <0.001 0.015 16.5 100 1.0 100 <0.021 <0.021 0.012 <0.021 0.53 1.0 100 <0.001 <0.001 0.005 0.54 0.32__________________________________________________________________________ .sup.a Incubations for 5 min at 37° C. in citrate adjusted to pH, or 20 mM acetate, pH 5.0. .sup.b Initial viable count 8.6 × 10.sup.4 cfu/ml .sup.c Initial viable count 9.82 × 10.sup.5 cfu/ml .sup.d Incubated in presence of 0.1% citrate .sup.e Incubated in presence of 20 mM acetate < denotes no detectable surviving colonies
TABLE 12______________________________________Bactericidal Activity of NisinTowards Campylobacter jejuni ATCC29428Dependence with respect to citrate at pH 5.0 (strain ATCC29428)Nisin(% w/v) Citrate pH 5.0μg/0 0.1 0.3 1.0ml % survival at 5 min.sup.a______________________________________ 0 100.sup.b 2.9 <6.4 × 10.sup.-3 <6.4 × 10.sup.-3100 <6.4 × 10.sup.-3 <6.4 × 10.sup.-3 <6.4 × 10.sup.-3 <6.4 × 10.sup.-3______________________________________ .sup.a Incubations performed at 37° C. for 5 minutes .sup.b Initial viable count 1.57 × 10.sup.5 cfu/ml < denotes no detectable surviving colonies
TABLE 13______________________________________Bactericidal Activity of NisinTowards Campylobacter jejuni ATCC29428Dependence with respect to EDTA at pH 5.0 (strain ATCC29428)NisinmM EDTA pH 5.0μg/0 0.1 0.3 1.0ml % survival at 5 min.sup.a______________________________________ 0 100.sup.b 56.5 76.1 76.1100 <5.0 × 10.sup.-4 <5.0 × 10.sup.-4 <5.0 × 10.sup.-4 <5.0 × 10.sup.-4______________________________________ .sup.a Incubations performed at 37° C. for 5 minutes .sup.b Initial viable count 1.84 × 10.sup.6 cfu/ml < denotes no detectable surviving colonies
The activity of nisin enhanced with EDTA, citrate or other chelators can also be demonstrated towards species of Salmonella by germicidal suspension assays. Freshly grown S. typhimurium cells are taken from a nutrient agar plate (Trypticase Soy Agar, BBL11043,) grown at 37° C. for 24 hours. The cells are resuspended to a cell density of 1.0 A 600 to provide a suitable stock suspension. The assay is started by addition of 30 μl of bacterial suspension to 970 μl of test solution and incubated for at least 1 minute and then centrifuged for 1 minute in a microfuge. The cell pellet is washed by resuspension 1 ml of sterile neutralization buffer, resuspended again and then serially diluted in neutralization buffer. The viable count is determined by spreading 100 ul of bacterial suspension and dilutions thereof on nutrient agar and scoring surviving colonies after 24 hours incubation at 37° C. Percent survival relative to untreated controls is calculated from the scored values.
The low-pH-active bacteriocin compositions of the invention are preferably administered orally in the form of a pharmaceutical preparation which contains an effective amount of the lanthionine-containing bacteriocin and a pharmaceutically acceptable carrier. The carrier may also include an effective amount of a chelator and/or an acidic vehicle and/or a surfactant or emulsifier, monoglyceride, or fatty acid. The lanthionine-containing bacteriocin may be selected from the group consisting of nisin, subtilin, epidermin, Pep 5, ancpyenin, gallidermin, duromycin or cinnamycin. Suitable chelating agents include, but are not limited to, EDTA, CaEDTA, CaNa 2 EDTA and other alkyldiamine tetracetates as well as citrate. In certain instances the chelator and the acidic vehicle can be the same, such as when the acidic vehicle and the chelator are both citrate. Suitable acidic vehicles for use in the compositions of this invention are acetate, propionate, citrate, lactate, succinate, fumarate, malonate, adipate, sorbate, phosphate and ascorbate.
The compositions of the invention are also effective at slightly acid pH levels, (e.g., pH 5.0) and even higher pH levels, (e.g., pH 8.0), against pathogenic bacteria which may inhabit the gastrointestinal tract, such as E. coli and S. typhimurium as disclosed in copending application Ser. No. 317,626. The disclosure of Ser. No. 317,626 is hereby incorporated by reference in its entirety.
The pharmaceutical compositions of the invention may thus also be formulated as antacid compositions or administered in combination with an antacid wherein the administration would result for instance in a higher stomach pH environment than that existing prior to administration. The nisin chelator compositions would still be effective against the pathogenic bacteria under such conditions.
The pharmaceutically acceptable carrier may be in the form of a solid, semi-solid or liquid diluent or a capsule. In certain embodiments of the invention the acidic vehicle and the pharmaceutical carrier may be the same. Other pharmaceutically acceptable carriers may be cellulose derivatives, gelatin, lactose, starch, etc.
The pharmaceutical compositions may be in the form of solutions, colloids or emulsions, powders, tablets, capsules or gels.
The dry forms of the compositions active at low pH may be pressed into tablets which may be coated with a concentrated solution of sugar and which may contain other pharmaceutically acceptable substituents such as gum arabic, gelatin, talc, or titanium dioxide and may be also coated with various dyes. Hard gelatin capsules may be prepared which contain granules of the bacteriocin, acid vehicle and chelating agent in combination with a solid carrier such as lactose, potato starch, corn starch, cellulose derivatives or gelatin.
Liquid preparations for oral administration may be prepared in the form of syrups or suspensions comprising the peptide bacteriocin, the chelating agent, the acid vehicle, and sugar, water and glycerol or propylene glycol. If desired, such liquid preparations may contain coloring agents, flavoring agents, sweeteners such as saccharin and thickening agents such as cellulose derivatives.
Delivery of a dosage could obviously be achieved by modifications of the simple aqueous formulations by inclusion of thickeners, emulsifiers, or particulates to effect a colloidal suspension. Alternatively, osmotically balanced solutions containing a suitable dosage could be administered in volumes as little as 10 ml or as large as 4 liters. Osmotically balanced solutions such as those used as gastrointestinal lavage solutions would be suitable (Di Palma, J. A. and Brady, C. E., 1989, Am. J. Gastroenterol. 84:1008, "Colon Cleansing for Diagnostic and Surgical Procedures: Polyethylene glycol Lavage Solution"; Di Palma, J. A. and Marshal, J. B., 1990, Gastrointestinal Endoscopy 1990, 36:285, "Comparison of a new Sulfate-free Polyethylene glycol Electrolyte Lavage Solution versus a Standard Solution for Colonoscopy Cleansing"; Fordtran, J. S., et al., 1990, Gastroenterol. 98:11, "A low-Sodium Solution for Gastrointestinal Lavage"). The performance of gastrointestinal lavage solutions used to cleanse the gastrointestinal tract would be expected to be improved by inclusion of the germicidal compositions described herein.
The typical daily dose of the inventive compositions may vary according to the pathogenic microorganism infection being treated, the site of infection, and the symptoms of the disease being treated. In general, it is expected that oral dosages would range from 0.1 mg per dose to 300 mg per dose of lanthionine-containing bacteriocin substance, and 0.1 g per dose to 30 g per dose of chelator.
For example, since the volume of stomach contents varies as a function of the time lapsed after the last meal, simple aqueous formulations suitable for gastrointestinal use may be prepared as follows:
For a final concentration to be achieved in the stomach at 0.1% citrate+0.001% nisin (10 ug/ml) delivered in 10 ml and assuming approximately 100 ml in stomach:
______________________________________Dosage 1: 1.0 mg nisin and 0.1 g citrate______________________________________Na citrate 1.0%nisin 0.01%saccharin 0.005%polysorbate 20 1.0%glycerol 10.0%water 87.985%______________________________________
For a final concentration to be achieved in the stomach at 3.0% citrate+0.03% nisin (300 ug/ml) delivered in 10 ml and assuming 100 ml in stomach:
______________________________________Dosage 2: 30 mg nisin and 3.0 g citrate______________________________________Na citrate 30.0%nisin 0.3%saccharin 0.005%polysorbate 20 1.0%glycerol 10.0%water 58.695%______________________________________
For a final concentration to be achieved in the stomach at 0.1T citrate+0.001% nisin (10 ug/ml) delivered in 10 ml and assuming 1000 ml in stomach:
______________________________________Dosage 3: 10 mg nisin and 1.0 g citrate______________________________________Na citrate 10.0%nisin 0.1%saccharin 0.005%polysorbate 20 1.0%glycerol 10.0%water 78.896%______________________________________
For a final concentration to be achieved in the stomach at 3.0% citrate +0.03% nisin (300 ug/ml) delivered in 100 ml and assuming 1000 ml in stomach:
______________________________________Dosage 4: 300 mg nisin and 30 g citrate______________________________________Na citrate 30.0%nisin 0.3%saccharin 0.005%polysorbate 20 1.0%glycerol 10.0%water 58.695%______________________________________
For a final concentration to be achieved in the stomach at 3.0% citrate+0.03% nisin (300 ug/ml) delivered in 100 ml and assuming 100 ml in stomach:
______________________________________Dosage 5: 60 mg nisin and 6.0 g citrate______________________________________Na citrate 6.0%nisin 0.06%saccharin 0.005%polysorbate 20 1.0%glycerol 10.0%water 82.935%______________________________________
It is also contemplated that depending on the type of pathogenic microorganism and disease being treated, the treatment regimen may comprise other drugs and pharmaceutical agents either as part of the pharmaceutical composition being administered or in treatment regimens which combine both the low-pH-active bacteriocin composition and another drug effective for treating the gastrointestinal tract. For example, in the treatment of diarrhea which may be caused by infections of a pathogenic microorganism such as one of the species of Salmonella. The bacteriocin composition active at low pH may be administered in a pharmaceutical preparation which also contains kaolin, pectin, or some other binding agent. Such symptoms may also be treated by the concurrent administration of the bacteriocin composition active at low pH and the binding agent. In addition, antacid formulations may be used in such treatment regimens and it is not expected that the antacid will affect the activity of the nisin-chelator composition.
In treating infections of the pathogenic microorganism Helicobacter pylori, the low-pH-active bacteriocin composition may be administered in connection with another pharmaceutically active substance against H. pylori such as a bismuth salt, e.g., bismuth subcitrate or bismuth subsalicylate. The inventive compositions may be administered in connection with other agents such as cimetidine, ranitidine, omeprazole, antacids, urease inhibitors or combinations thereof in order to treat some of the diseases and symptoms associated with the presence of H. pylori in the gastrointestinal tract. It is contemplated that in these therapies the active pharmaceutical agents may be administered concurrently or intermittently with the inventive pharmaceutical compositions and the mode of administration may be varied during the course of the treatment as required.
H. pylori has been isolated from dental plaque which may constitute a reservoir for recurrent infection of the stomach (Desa; H. G., Gill, H. H., Shankaran, K., Mehta, P. R., and Prabha, S. R. (1991) Dental Plaque: a permanent reservoir of Helicobacter pylori? Scand. J. Gastroenterol. 26: 1205 and Shames, B., Krajden, S., Fukasa, M., Babida, C. and Penner, J. L. (1989) Evidence for the Occurrence of the Same Strain of Campylobacter pylori in the Stomach and Dental Plaque. J. Clin. Microbiol. 27: 2849.)
It, therefore, is anticipated that bacteriocin compositions suitable for use against H. pylori in dental plaque may be used in conjunction with the bacteriocin compositions active at low pH against H. pylori in the gastrointestinal tract.
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Compositions comprising lanthionine-containing bacteriocins such as nisin act as bactericides under conditions such as those found in the gastrointestinal tract. In a preferred embodiment pharmaceutical preparations containing the compositions are used for the control of bacteria responsible for disorders of the gastrointestinal tract.
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This application is a continuation-in-part application of application Ser. No. 318,201, filed Jan. 8, 1973, now abandoned, which in turn is a continuation-in-part of application Ser. No. 224,220, filed Feb. 7, 1972, now abandoned.
This invention relates to an improved system and method for preparing enclosed bodies, moldings and casts.
BACKGROUND OF THE INVENTION
Several attempts have been made to adopt modern plastic technology to the production of rigid enclosures for such segments as a living body, human or animal. The use of rigid body and body member casts are important to assist in the healing of tissues and in knitting of fractures of the bone.
Such methods have incorporated systems, which have been disadvantageous for one of many reasons. For example, one method is dependent upon a closed plastic bag which is wrapped around the member and a plastic foam is allowed to develope in the bag. This system of encasement is slow, difficult to apply and very hot and uncomfortable for the wearer. The system does not allow air to enter or leave the appliance.
The conventional plaster of Paris systems have many dissatisfactory properties. Particularly, the casts formed therewith are heavy, X-ray impervious, absorb excessive moisture which thereby destroys the mechanical property, soil rapidly, are difficult to clean, poor shock resistance, lack elasticity, slow to reach ultimate strength, poor abrasive resistance and receptive to bacterial and fungal growth.
It also has been proposed to soften sheets of plastic materials and apply them to the part of the body to be immobilized so as to set upon cooling to a desired position. Unfortunately, the temperature to which such thermoplastic materials must be raised to make them moldable is too high to be endured by a patient unless an insulating intermediate material is first applied.
Certain systems and methods of casting have been proposed which utilize polymerizing systems and polymerizing bandages. However, these systems employ large amounts of liquid volatile and non-volatile diluents to replace part of the monomer as liquid extenders or wetting material. The presence of such volatile liquids are unsatisfactory. The presence of non-volatile viscous diluents do not cause vapor cells and form weak casts due to inadequate wetting of the solid filter or inability to satisfactorily dissolve the polymer formed and the like. Various catalyzed and accelerated mixtures of monomeric solvents within the prior diluent systems attempt to overcome the disadvantages thereof by addition of non-polymerizable polyalcohol esters. The problem of noxious volatile fumes remains. This is highly undesirable when such a system is used in a confined area. Further, the method for body use requires the coating of the body member with petrolatum or other protectant, this prevents air from reaching the injured member.
The prior art, U.S. Pat. No. 3,089,486, discloses a methacrylate polymer impregnant which is imbued into a bandage. The bandage in this form can be stored, however, this requires constant monitoring to insure a usable material. Further, the system described therein requires applying a barrier to the body member prior to applying the monomer component. This presents the disadvantage of placing an air impervious barrier which allows moisture to collect under the barrier from body prespiration, thereby inducing skin irritation.
Means, in U.S. Pat. No. 2,576,027, describes impregnating a cloth such as surgical gauze or the like, with a chemical that acts as a catalyst with reference to a solution of a synthetic resin. The solution of synthetic resin is applied to the gauze to form a rigid solid. The catalyst and synthetic resin relates to a specific urea-formaldehyde system. The catalyst system described by Means is not effective in curing vinyl-type monomers and cannot be used with the instant invention.
The prior art, U.S. Pat. Nos. 3,421,501 and 3,613,675, describe bandages which contain an activated resin. The bandages are cured by exposure to ultraviolet light.
SUMMARY OF THE INVENTION
The present invention possesses definite advantages over the above-described systems. Primarily, it requires neither a pail of plaster of Paris, nor the soaking of a prepared plaster gauze material. Further, there is no need for actinic radiation to catalyze the system into a rigid form. The requirement of ultraviolet irradiation includes the distinct advantage that such a system must be necessarily employed near a source of electrical power. Further, such systems produce a slower cured resin enclosure. It is inherently difficult to irradiate certain areas such as in a cast utility, as under the arm or crotch. Further advantages of the present invention are fast curing and the presence of no volatile solvents. The cured system is light in weight and possesses an open configuration which allows good air exchange with the underlying member. The physical properties of the system are not greatly affected by exposure to water allowing for the possibility of washing the encased or immobilized member.
The present invention relates to a fully usable system which functions without further reference to any other system. It is understood that to be usable, a catalyzed fabric and a resin must be used in combination. Therefore, the improved operable system of this invention relates to the use of wrapping material treated and impregnated with a free radical catalyst, such as organic peroxides, then applying by a suitable means a resin containing active unsaturated radicals, as found in polyesters and acrylics, and containing tertiary aromatic amine accelerator.
The instant invention is contemplated for resin structures and enclosures for a wide variety of uses, e.g., models, toys, linings, shaped articles generally. Porous surgical dressings, orthopedic supports, and like objects, can be readily prepared. Further, for easily prepared plastic shells the present system is easily applicable as well as for repairs and maintenance of such items, ie.g, fiber glass bodies on cars and boats. Without the requirement of heat or special preparation, the instant system is especially useful.
Accordingly, it is a principal object of this invention to provide for the application of orthopedic casts of body members or enclosures of other articles which comprises enclosing said member in an organic peroxide catalyst impregnated, woven or non-woven fabric and applying to said enclosed member a thermosetting polyester or thermosetting acrylic monomer of the dimethacrylate type, containing a tertiary aromatic amine accelerator to form a hard, lightweight, rigid physiologically inert integral enclosure or case.
A further object of this invention is to provide for the application of orthopedic casts or enclosures for articles formed of lightweight plastic wherein the hardening or setting of the plastic is accomplished by an organic peroxide catalyst impregnated in the enclosing fabric.
DETAILED DESCRIPTION OF THE INVENTION
As a general definition, the group of resins include the members defined as thermosetting polyesters and thermosetting acrylics, also known as vinyl resins, those members having active terminal ethylene unsaturation or poly functional unsaturated ester moieties. Representative of this group is the following list:
ethylene glycol dimethacrylate
diethylene glycol dimethacrylate
triethylene glycol dimethacrylate
hexamethylene glycol dimethacrylate
2,2-bis(2-methacrylatoethoxyphenyl)propane
2,2-bis(3-methacrylato-2-hydroxypropoxyphenyl)propane
phthalic-maleic-propylene glycol polyester
Resin blends comprising two or more thermosetting acrylic monomers are also contemplated. Resin blends comprising at least one thermosetting acrylic monomer and one or more thermosetting polyester resins are within the resins defined herein. In some instances, these blends constitute a preferred resin composition for the method of the instant invention, in that they produce the least amount of heat during the curing (i.e., polymerization) of the resin. The cast material can contain a blend of resins of up to about 90 percent, preferably about 65 to 75 percent, of acrylic resin and from about 5 to 35 percent polyester resin, preferably about 25 to 35 percent. These percentages are based upon the total weight of the blended resin.
The monomer or resin-forming component is preferably advanced to an activated state. The activation develops in the resin when the system is combined with an accelerator and in which condition the activated monomer thus prepared retains a reasonable shelf-life. In order to arrive at this activated state in the resin, it is preferred to employ, as an accelerator, a tertiary aromatic amine, which is particularly useful in the instant invention. Examples of members of the class tertiary aromatic amine include N-3-tolyl-diethanol amine and N-4-tolyldiethanol amine. When the activated resin is employed, application to the catalyst-impregnated fabric causes a very rapid curing to a desirable rigid structure. The monomer or resin is generally used in an amount of from about one-half the weight of fabric to two times the weight of fabric. The amount of tertiary aromatic amine as accelerator in the resin is about 0.1 to about 2.0 phr (parts per hundred of resin).
It has been found that certain properties of the resins can be enhanced by the addition of suitable plasticizer to the system. A plasticizer is a material incorporated in a plastic to increase the workability and flexibility or distensibility of the plastic product. Plasticizers may improve impact resistance of the final product. Organic plasticizers are usually moderately high-molecular-weight liquids or occasionally low-melting solids. Most commonly, organic plasticizers are esters of carboxylic acids. Other types also include hydrocarbons, halogenated hydrocarbons, ethers, polyglycols and sulfonamides. The choice of a specific plasticizer for a given use requires a compromise of desirable properties in each case. It is therefore a preferred embodiment of this invention that the resin system contain a plasticizer to enhance the properties as desired. More preferably, a plasticizer content of from about 10 percent to about 50 percent based on the total resin formulation including the plasticizer. By the term "resin" is meant resin blends comprising two or more thermosetting acrylic monomers; blends comprising at least one thermosetting acrylic monomer and one or more thermosetting polyester resin. The percentage composition of the blended resins include the above-mentioned percentages for acrylic resin and polyester resin.
Catalyst for the production of free radical initiators of polymerization may be used to impregnate the fabric of this invention, but preferred is the organic peroxide type. The catalyst-impregnated fabric should be stable at ambient temperatures. Of the preferred organic peroxide catalysts which are within the class include for example:
2,4-dichlorobenzoyl peroxide
caprylyl peroxide
lauraoyl peroxide
benzoyl peroxide
acetyl peroxide
Some mixed peroxides such as acetyl benzoyl peroxides are also suitable.
Prior to the application of the desired catalyst to the fabric, the catalyst may be dissolved in a suitable solvent. For example, benzoyl peroxide in chloroform. Actually, any nonprotonic organic solvent, such as methylene chloride, benzene, cyclohexane and the like, may be employed. The solution of catalyst contains generally the amount from about 1 percent to about 10 percent of catalyst. The solution is applied to the fabric by a suitable means, so as to treat and impregnate the fabric. After application, the catalyst treated fabric is dried to remove the solvent. The fabric then is usable in the dry state. No special handling is required for the peroxide impregnated fabric. Storage should not expose the treated fabric to excessive heat. A variety of techniques may be employed to apply the catalyst, for example, dipping or spraying. The condition to be achieved within the fabric is a thorough intermingling with and in the surrounding area in relation to the threads or fibers of the fabric. It is not indicated that the catalyst is to any extent absorbed by the fibers themselves. It is preferred that for certain uses the fabric have a relatively open, knit structure and the applied resin thereby able to flow in and around the fibers to become rigidly bonded to the fibers and yet retain an open mesh appearance. The catalyst impregnated fabric is furnished in the dry state. The presence of a wet state would be undesirable to the advantages of the instant invention and would incorporate exposure to undesirable solvents.
The fabric material which is impregnated with the preferred organic peroxide-type catalyst described above, may be in the form of a continuous sheet, or of short or long strips. The fabric base can comprise two or more layers folded on each other as in cotton gauze bandages. The material of construction may be of woven or non-woven material, including felt-type materials, as an air-laid felt. The fabric itself is preferably made of cotton, synthetic fiber or fiberglass. However, the particular fabric selected will depend upon the particular application, and accordingly, this invention is not limited to any particular choice of fabric material. The amount of catalyst on the impregnated fabric will depend upon the nature of the fabric. The amount of catalyst present will further depend upon the amount of catalyst retained from the application thereof, i.e., by spraying, dipping, brushing, rolling, or flow techniques.
The activated monomer with the selected accelerator is applied to the dry peroxide catalyst-impregnated fabric. The method of application will vary with the specific use. Contemplated within this invention is the application of the activated vinyl monomer of the polyester or acrylic type described herein by spraying, painting, swabbing and the like. Upon contact with the catalyst-impregnated fabric, the activated resin begins to polymerize almost immediately, such that within a few minutes the composite system is rigid and servicable. The cast or enclosure is light in weight, has an open configuration and conforms to the position and shape of the dry impregnated fabric prior to application of the activated resin. Other layers of fabric can be over laid the initial form almost immediately to obtain a more closed configuration if desired.
Thus, within the skill of those qualified in the orthopedic sciences, the preparation and application of orthopedic casts for use in the treatment of bone fractures or other conditions requiring immobilization of body members may be advantageously formed from the materials and method of this invention. In applying the peroxide catalyst-impregnated fabric from a rolled up material to a body member, the strip of fabric is wrapped around the member in an advancing overlapping manner. When the member has been completely wrapped in the impregnated fabric, an activated vinyl monomer resin described herein is applied, as by spraying, on the fabric. Within one to two minutes, the component system is rigid and usable. The resulting cast thickness will depend upon location of the body portion to be cast; upon the strength and rigidity required.
The examples presented herein serve solely to illustrate the composite system and method of this invention. Accordingly, the examples should not be regarded as limiting the invention in any way. In the examples, the parts and percentages are by weight unless otherwise indicated.
EXAMPLE I
An activated resin was prepared by dissolving 1.0 g. of N-3-tolydiethanol amine in 100.0 g. of ethylene glycol dimethacrylate. This activate resin was sprayed onto a sample of each cotton, nylon and glass cloths which had been dipped into a chloroform solution containing 5 percent benzoyl peroxide. The benzoyl peroxide treated fabric cloths were allowed to dry before application of the activated resin. The resin on the cloth samples began to polymerize and became comfortably warm in 40 seconds. At the end of one minute, the composite system was rigid, hard and servicable.
EXAMPLE II
In a similar method as described in Example I, the following dimethacrylate resins each were used on cotton, nylon and glass cloths. The results in each case are comparable.
a. diethylene glycol dimethacrylate
b. triethylene glycol dimethacrylate
c. hexamethylene glycol dimethacrylate
d. 2,2-bis(2-methacrylatoethoxyphenyl)propane
EXAMPLE III
An activated resin blend was prepared by mixing 100 parts of ethylene glycol dimethacrylate, 100 parts of 2,2-bis(3-methacrylato-2-hydroxypropoxyphenyl)propane and 2 parts of N-3-tolyldiethanol amine. This resin system was sprayed on to benzoyl peroxide catalyzed cloths, prepared in the same manner as Example I. After 20 seconds, the applied resin began to gel and at 30 seconds, the composite system was rigid and servicable. No undesirable heat evolution was detected during gelling of this system.
EXAMPLE IV
In a similar manner as Example III, an activated resin blend was prepared using triethylene glycol dimethacrylate instead of ethylene glycol dimethacrylate. Comparable results were obtained.
EXAMPLE V
An activated vinyl resin blend was prepared by mixing 60 parts triethylene glycol dimethacrylate, 1 part of N-3-tolyldiethanol amine and 40 parts of polyester resin prepared from 2 moles of phthalic anhydride, 1 mole of maleic anhydride and 3 moles of propylene glycol. This resin system was sprayed on to benzoyl peroxide catalyzed cloths, prepared as in Example I. The system gelled in about 2 minutes and became rigid in about 2.5 minutes. No appreciable heat was evolved during the curing of this system. The composite system was rigid and servicable.
EXAMPLE VI
A 4 g. mixture containing 70 percent 2,2-bis(3-methacrylato-2-hydroxypropoxyphenyl)propane and 30 percent of polypropylene glycol (average molecular weight = 400) and 1 percent N-3-tolyldiethanol amine was cured by adding, with mixing 12 drops (about 0.6 g.) of a catalyst solution made from 10 g. triethylene glycol dimethacrylate, 1 g. benzoyl peroxide, and 0.1 g. butylated hydroxytoluene. The system became a hard amber solid in 20 seconds. When a 50--50 percent mixture of resin to polyglycol was used, a milky solid with much poorer physical properties was obtained. Both resin ratios cured when placed upon cloth which had been treated with benzoyl peroxide.
EXAMPLE VII
A resin system was prepared from 70 g. 2,2-bis(3-methacrylato-2-hydroxypropoxyphenyl)propane, 40 g. triethylene glycol dimethacrylate, 30 g. polypropylene glycol (average molecular weight = 400) and 1 g. N-3-tolyldiethanol amine. This system produced a tough amber colored composite solid when applied to cloth which had been treated with benzoyl peroxide.
EXAMPLE VIII
A resin blend was prepared from 25 g. 2,2-bis(3-methacrylato-2-hydroxypropoxyphenol)propane, 25 g. of triethylene glycol dimethacrylate, 25 g. of an isophthalate-maleic acid polyester resin, 25 g. polypropylene glycol (average molecular weight = 400) and 0.7 g. N-3-tolyldiethanol amine. This resin system was applied to glass cloth which had been treated with benzoyl peroxide. The resin began to gel in 20 seconds and was hard in 60 seconds. The composite system was rigid and servicable.
It will readily be appreciated by those skilled in the art that the proportions of the varous components of the system may vary widely depending upon the identity of the components and the conditions under which the system is to be applied and the hardened composite system is to be used. The best proportions in any particular instance can readily be determined on the basis of prior experience and by trial and error. It is also within the scope of the invention to add to the mixture such modifying agents as therapeutic compounds, disinfectants, deodorants and coloring agents, e.g., dyes and pigments. Proportions of such optional components as therapeutic compounds, deodorants, disinfectants, coloring materials, inactive fillers, and the like, are largely a matter of choice, it being understood of course that they should be present only in minor amounts sufficient to accomplish their intended functions and not in quantities large enough to interfere with the primary objectives of the system.
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An improved system and method for producing lightweight and strong rigid enclosures formed by enclosing or wrapping the article in a dry peroxide catalyst-impregnated fabric and applying thereto an activated thermosetting vinyl type resin. The disclosed enclosure is especially useful as a porous surgical dressing or as an orthopedic support.
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CROSS-REFERENCES TO RELATED APPLICATIONS
[0001] This application claims the benefit of U.S. Provisional Application No. 60/701,000, filed Jul. 19, 2005, which is incorporated by reference in its entirety for all purposes.
BACKGROUND OF THE INVENTION
[0002] The invention relates to communications systems, and more particularly to symbol synchronization for OFDM systems.
[0003] In communications systems, the information-bearing signals are transmitted from the source to the destination through a communication channel which causes signal distortion. Depending on the communication channel characteristics, appropriate signal modulation techniques are used.
[0004] OFDM (Orthogonal Frequency Division Multiplexing) is gaining popularity in broadband communications. In OFDM systems, the data signal is distributed among many equally-spaced, mutually-orthogonal sub-carriers. OFDM modulation is typically implemented through the IDFT (Inverse Discrete Fourier Transform, typically implemented more efficiently as IFFT—Inverse Fast Fourier Transform) in the transmitter, and the demodulation is typically implemented through the DFT (Discrete Fourier Transform, typically implemented more efficiently as FFT—Fast Fourier Transform).
[0005] The transmitted signal is grouped as DFT symbols, each of which consists of all the output samples of one IDFT operation. In order to avoid inter-symbol-interference (ISI), the DFT symbols are usually separated by some guard intervals (GI). One type of commonly used guard interval is called cyclic prefix (CP), which is the duplication of the last N g samples of the DFT symbol of N u samples. FIG. 1 illustrates an OFDM symbol with cyclic prefix. The guard interval and the DFT symbol form an OFDM symbol N s =N u +N g samples.
[0006] Given a search window N s , an FFT size N u and guard interval length N g , the initial symbol start time, n′ 0 , may be obtained by Equation 1:
n 0 ′ = arg max n = 0 , … , N - 1 { ∑ i = n n + N g - 1 x ( i ) · x * ( i + N u ) } Eq . ( 1 )
[0007] Note that the operation to compute absolute value may be replaced by alternative operations, such as magnitude square. The search window N s is set to N u +N g . Since n′ 0 is calculated from only one symbol worth of data, the value is noisy at low signal to noise ratio (SNR). A more accurate estimate of symbol start time, n″ 0 is then computed by averaging data over a few symbols around n′ 0 as indicated by Equation 2:
n 0 ″ = arg max n { T ( n ) } ,
T ( n ) = ∑ i = 0 K ′ - 1 ∑ j = n n + N g - 1 x ( i · N + j ) · x * ( i · N + j + N u ) } ,
n 0 ′ - N g - Δ ≤ n ≤ n 0 ′ + N g + Δ ,
Δ = N g r Eq . ( 2 )
[0008] Here, Δ and K′ are the window calculation expansion and the number of symbols for averaging, and r and K′ are integers greater than or equal to 1. For example, r may be set to 16 and K′ may be set to 3 to 5.
[0009] The signal samples used in the correlation T(n) are received signals. Although the N g samples of CP equal exactly the last Ng samples of the DFT symbol in the transmitter, they are not the same at the receiver due to channel distortion. In fact, the first L samples in CP are affected by the previous symbol while the corresponding samples in the DFT symbol are affected by the samples in the same DFT symbol. As a result, this simple peak correlation technique typically works well under relatively good channel conditions, but fails to properly identify the symbol boundaries where the channel conditions are more severe because of the presence of, for example, multi-path and Doppler Effect.
[0010] Therefore, there is a need for techniques which can effectively and accurately identify the OFDM symbol boundary even in the presence of severe channel conditions.
BRIEF SUMMARY OF THE INVENTION
[0011] In accordance with an embodiment of the invention, symbol synchronization in a communication system is carried out as follows. A plurality of symbols corresponding to a transmitted signal are received, where he plurality of symbols include guard intervals. A peak correlation is obtained using the plurality of received symbols. The second derivative of the peak correlation is obtained to identify one or more peaks each corresponding to a channel impulse response within a guard interval. A symbol start time is estimated for each received symbol based on the second derivative of the peak correlation.
[0012] In one embodiment, a position of a window of a predetermined number of samples is located to cover the one or more peaks.
[0013] In another embodiment, the predetermined number of samples is equal to or less than guard interval samples.
[0014] In another embodiment, the second derivative of the peak correlation is used to identify a window of a corresponding guard interval with a maximum spike energy.
[0015] In yet another embodiment, the plurality of symbols are OFDM symbols.
[0016] In yet another embodiment, first and second derivatives of the peak correlation are obtained using samples that are apart from one another a predetermined number of samples.
[0017] In another embodiment, after estimating the symbol start time, the guard intervals are removed from the plurality of symbols.
[0018] In accordance with another embodiment of the invention, symbol synchronization in a communication system is carried out as follows. A plurality of symbols corresponding to a transmitted signal are received, where the plurality of symbols include guard intervals. Peak correlation is obtained using the plurality of received symbols. In each guard interval, a window of samples with the maximum correlation energy based on the peak correlation is obtained. A symbol start time is estimated for each received symbol using the obtained samples.
[0019] In one embodiment, the window of samples is equal to or less than guard interval samples.
[0020] In another embodiment, after estimating the symbol start time, the guard intervals are removed from the plurality of symbols.
[0021] A further understanding of the nature and the advantages of the invention disclosed herein may be realized by reference to the remaining portions of the specification and the attached drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 illustrates an OFDM symbol with cyclic prefix;
[0023] FIG. 2 shows a block diagram of an OFDM-based wireless receiver in which embodiments of the invention are implemented;
[0024] FIG. 3 depicts the correlation T(n) for an ideal channel with no distortion;
[0025] FIG. 4 is a flow chart depicting the sequence of operations carried out by the receiver in FIG. 2 ;
[0026] FIG. 5 is a flow chart illustrating a first technique for symbol synchronization according to one embodiment of the invention;
[0027] FIG. 6 is a flow chart illustrating an alternate technique for symbol synchronization according to another embodiment of the invention; and
[0028] FIGS. 7-10 are simulation results of exemplary multi-path channels used to illustrate some of the advantages of the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0029] In accordance with an exemplary embodiment of the invention, FIG. 2 shows a block diagram of an OFDM-based wireless receiver in which embodiments of the invention are implemented. FIG. 4 is a flow chart which will be used to describe the operation of the receiver in FIG. 2 . RF tuner 100 receives the radio-frequency signal through an antenna. The desired signal is selected by tuner 100 and down-converted and filtered through down-converter/filter block 110 in accordance with known techniques. The output of block 110 is the analog baseband signal (or passband signal at much lower frequency than the original radio frequency) which is converted into digital signal by analog to digital converter 120 using conventional techniques. This is depicted by step 402 in FIG. 4 . Next, in step 404 , the digital signal is grouped into symbols with symbol boundary properly identified in symbol synchronization block 130 using one of the techniques of the present invention. In step 406 , the guard intervals (typically cyclic prefix) are removed by block 140 before the grouped symbols are transferred to FFT block 150 . In steps 408 and 410 , the output of FFT block 150 is further processed by decoder 200 in accordance with conventional techniques. The symbols are separated by some guard interval (cyclic prefix) to help prevent inter-symbol-interference (ISI). Obviously, it is critical to identify the symbol boundary properly.
[0030] As depicted in FIG. 1 , the Ng samples of CP are created by copying the last N g samples in the DFT symbol. This property is used for symbol boundary identification. In one embodiment, the symbol synchronization block 130 may only be active at the start of channel acquisition to obtain the initial estimates of symbol timing. In another embodiment, the values of N u and N g must be known prior to activating symbol synchronization block 130 . Based on the identified symbol boundaries obtained using one of techniques of the present invention, the cyclic prefix removal block 140 removes the cyclic prefix samples from its input before feeding it to the FFT processing block 150 .
[0031] Conventional techniques detect the OFDM symbol boundary mainly based on the peak correlation T(n) shown in Equation 2 above. Suppose the transmission channel has an impulse response CIR with length L CIR . At the receiver, the first L CIR samples of a symbol will be affected by the previous symbol. In fact, the last sample of the previous symbol affects the next L CIR samples, which are the first L CIR samples in CP. Therefore, as long as the impact of the last sample in the previous symbol on the current symbol is avoided, ISI is completely removed. Since the first Ng samples of a symbol are in CP that will be discarded before FFT, as long as L CIR ≦Ng, ISI is completely avoided if the symbol boundary is identified accurately. The impact of the last sample on the current symbol is in the shape of CIR.
[0032] A main objective of the symbol synchronization, in accordance with embodiments of the invention, is to locate the channel impulse response (CIR) within CP, or locate as much energy of CIR within CP as possible. However, the peak correlation T(n) by itself does not easily show the CIR. For example, in FIG. 3 which shows an ideal channel with no distortion, the CIR is just an impulse, and the correlation T(n) has the shape of a triangle with its peak indicating the location of the symbol boundary. For severe channels however, the correlation T(n) by itself does not identify the location of the symbol boundary. FIG. 7 shows the correlation T(n) for an exemplary 3-path channel, where N u is 8,192, N g is 2,048 and the channel is 90% of N g . As can be seen, the CIR is not easily identifiable from the T(n) in FIG. 7 .
[0033] In accordance with a first embodiment of the invention, this problem is addressed as follows. The flow chart in FIG. 5 will be used in describing the first embodiment. Using the digital samples generated by the analog to digital converter block 120 , correlation T(n) is calculated for one n value in step 502 and then for different n values in step 504 , using known techniques. Based on the calculated T(n), the peak is found as n″ 0 . Then, in step 506 , the first and second derivatives of T(n) are computed around n″ 0 , with a window of W samples on each side of n″ 0 . For example, W can be chosen to be equal to N g . Since the difference between consecutive T(n) samples may be noisy, T′(n) and T″(n) are computed using samples that are Δ apart (n=k·Δ+n″ 0 where Δ is an integer greater than or equal to 1, typically a power of 2), as indicated by Equation 3:
T′ ( n )= T ( n )− T ( n −Δ), n=k·Δ+n″ 0 ,−r≦k≦r+ 1
T ″( n )= T ′( n +Δ)− T ′( n ), n=k·Δ+n″ 0 ,−r≦k′≦r
where r is the integer part of W/Δ. Eq. (3)
[0034] Note that at the start of each group, the change in the slope of T(n) has a noticeable corresponding negative spike. These are marked by dashed arrows in FIGS. 7 and 8 . These negative spikes represent the energy spikes in the CIR. By finding a window of Ng with the maximum spike energy, the CIR energy in CP is typically maximized. This feature can be exploited to obtain the final estimate of symbol start time, n 0 , using Equation 4 below:
n 0 = argmin n { f ( n ) } - r Δ / 2 + τ ,
f ( n ) = ∑ i = - r / 2 r / 2 T ″ ( n + i Δ ) ,
n = k · Δ + n 0 ″ ,
- r / 2 ≤ k ≤ r / 2
τ is an adjustment term ,
e . g . ,
τ = min { 16 , Δ 2 } Eq . ( 4 )
[0035] The minimum of ƒ(n) captures the window of N g in length around n″ 0 that contains most negative spikes, which corresponds to the maximum CIR energy, and indicates most likely placement of the channel CIR. Then the start of the channel is the beginning of this window, as shown in the computation of n 0 in Equation 4. The factor τ is the adjustment to n 0 due to the resolution of Δ, with a maximum value of 16 samples, in accordance with one embodiment.
[0036] An alternate embodiment of the invention is depicted by the flow chart in FIG. 6 . Initially, as in steps 502 and 504 of the FIG. 5 embodiment, using the digital samples generated by the analog to digital converter block 120 , correlation T(n) is calculated for one n value in step 602 and then for different n values in step 604 , using known techniques. The peak is then found as n″ 0 based on the calculated T(n). In step 606 , the window of Ng with the maximum correlation energy is calculated according to Equation 5:
n 0 = argmax n { g ( n ) } - r Δ / 2 + τ ,
g ( n ) = ∑ i = - r / 2 r / 2 T ( n + ⅈΔ ) ,
n = k · Δ + n 0 ″ ,
- r / 2 ≤ k ≤ r / 2
τ is an adjustment term ,
e . g . ,
τ = min { 16 , Δ 2 } Eq . ( 5 )
[0037] The two examples respectively depicted by FIGS. 7, 8 and 9 , 10 will be used in conjunction with the ideal channel depicted in FIG. 3 to convey some of the features of the present invention. For an ideal channel depicted in FIG. 3 , T″(k′) would simply be a negative spike, which is a clear indication of the CIR. For a multi-path channel, depicted by FIGS. 7-10 , there are typically multiple spikes, indicating multi-paths in CIR. The FIGS. 7-10 examples, depict 3-path channels. In the examples depicted by FIGS. 7 and 8 , the channel is comprised of a single frequency network (SFN—where the same frequency is used by transmitters in various locations) channel with three independent fading groups, each group being 5 μs long and representing the Raleigh fading signal emitting from a single transmitter at 5.4 dB C/N and 150 Hz Doppler. The groups are placed at 0, 0.5*N g and 0.9*N g apart, with the last tap of the channel being at 90% point of N g . Its T(n) and T″(k′) are shown in FIGS. 7 and 8 , respectively.
[0038] Because each group in the SFN channel is fading independently with various strengths, the peak of T(n) may not occur in the middle of the SFN groups. FIG. 9 shows the T(n) of a 3-path channel where there are three groups in CIR, and the largest peak is the third one. If the start of a symbol is solely determined by the peak of T(n) as in conventional approach, then an SFN channel realization that produces the T(n) illustrated in FIG. 9 will result in significant symbol misalignment and ISI. If the peak occurs at each group position with equal probability, then the probability of making a large timing misalignment using the convention peak correlation approach is ⅔. In accordance with an embodiment of the present invention, T″(k′) picks up the negative spike produced by all groups, including the very first group, as illustrated by the dashed arrows in FIGS. 9 and 10 , thus enabling selecting a n 0 that is close to ideal. This better estimate of no results in significantly less ISI and therefore better overall system performance.
[0039] The performance of an exemplary symbol timing estimator measured by the mean channel energy captured (MCEC) within CP is summarized in Table 1. In Table 1, MCEC values are tabulated for SNR=5.4 dB, Doppler=150 Hz, Carrier Offset=1500 Hz, BW=8 MHz, 200 trials using the first embodiment in FIG. 5 .
TABLE 1 Number of MCEC L CIR /N g Groups N g /N u N u = 2K N u = 4K N u = 8K 90% 3 ¼ 97.5% 99.2% 99.1% ⅛ 95.2% 97.6% 97.0% 2 ¼ 99.4% 99.8% 99.7% ⅛ 92.2% 98.5% 98.3% 50% 3 ¼ 99.5% 100.0% 100.0% ⅛ 97.2% 99.1% 100.0% 2 ¼ 99.5% 99.9% 100.0% ⅛ 98.7% 99.9% 100.0%
[0040] Each channel realization is an SFN channel with two or three independent Raleigh fading groups. The separation between the groups is about 50% of L CIR in the three group case and about 95% of L CIR in the two group case. The length of the CIR L CIR is either 90% or 50% of N g . N g of length N u /4 and N u /8 are simulated as shorter guard intervals are not suitable for such an SFN operating environment. Compared to the performance of the conventional peak correlation method, which at best is 67% for three groups and 75% for two groups under channels that are 90% of N g in length, the embodiments of the invention provide significant performance improvement.
[0041] Another way to gage the performance of the symbol timing estimator is the mean missed distance (MMD) in samples. The missed distance is defined as the difference between the estimated symbol start time and the edges of a “don't care” window. The right edge of the window represents the exact symbol start time, while the left edge of the window represents how much earlier the symbol start estimate can be compared to the exact start time without incurring any ISI. If the symbol start estimate falls outside of this window, then ISI occurs. The length of this window depends on the length of the guard interval length N g and the length of the channel impulse response L CIR .
[0042] Table 2 below summarizes the performance of the symbol timing estimator in terms of MMD under the same simulation conditions as in Table 1, using the first embodiment in FIG. 5 . That is, Table 2 shows the MMD in samples for SNR=5.4 dB, Doppler=150 Hz, Carrier Offset=1500 Hz, BW=8 MHz, 200 trials, using the first embodiment in FIG. 5 . Using conventional methods, the MMD in channels whose L CIR are 90% of N g in length are 46.7% and 45% of N g for three and two groups, respectively. Again, compared to the convention method, the embodiments of the invention provide significant improvements when the channel length L CIR exceeds 50% of N g .
TABLE 2 Number of MMD L CIR /N g Groups N g /N u N u = 2K N u = 4K N u = 8K 90% 3 ¼ 4.22 3.83 1.89 ⅛ 7.86 6.56 3.65 2 ¼ 1.73 0.37 0.40 ⅛ 5.09 5.95 2.45 50% 3 ¼ 0.13 0.00 0.00 ⅛ 1.55 0.67 0.14 2 ¼ 0.14 0.86 0.00 ⅛ 1.45 0.02 0.14
[0043] Tables 3 and 4 below respectively tabulate simulated MCEC and MMD values obtained under the same simulation conditions as in Tables 1 and 2, using the alternate embodiment in FIG. 6 .
TABLE 3 Number of MCEC L CIR /N g Groups N g /N u N u = 2K N u = 4K N u = 8K 90% 3 ¼ 89.5% 88.2% 85.6% ⅛ 94.9% 88.7% 88.1% 2 ¼ 76.3% 71.4% 73.2% ⅛ 89.4% 78.0% 73.6% 50% 3 ¼ 100.0% 100.0% 100.0% ⅛ 100.0% 100.0% 100.0% 2 ¼ 100.0% 100.0% 100.0% ⅛ 100.0% 100.0% 100.0%
[0044]
TABLE 4
Number of
MMD
L CIR /N g
Groups
N g /N u
N u = 2K
N u = 4K
N u = 8K
90%
3
¼
19.3
38.3
80.0
⅛
6.4
18.8
36.6
2
¼
46.4
103.2
175.5
⅛
16.6
44.7
89.7
50%
3
¼
0.0
0.0
0.0
⅛
0.0
0.0
0.0
2
¼
0.0
0.0
0.0
⅛
0.0
0.0
0.0
[0045] Tables 5 and 6 below respectively tabulate simulated MCEC and MMD values obtained under the same simulation conditions as in Tables 1-4, using the conventional method based on the peak of correlation.
TABLE 5 Number of MCEC L CIR /N g Groups N g /N u N u = 2K N u = 4K N u = 8K 90% 3 ¼ 45.1% 47.1% 45.7% ⅛ 49.0% 46.6% 37.5% 2 ¼ 47.5% 49.6% 42.0% ⅛ 45.1% 49.1% 31.6% 50% 3 ¼ 46.8% 45.3% 46.9% ⅛ 45.5% 46.6% 45.3% 2 ¼ 45.8% 51.7% 44.8% ⅛ 46.2% 49.8% 42.9%
[0046]
TABLE 6
Channel
Length
Number of
MMD
(in N g )
Groups
N g /N u
N u = 2K
N u = 4K
N u = 8K
90%
3
¼
260.9
480.1
1025.3
⅛
131.3
265.1
512.6
2
¼
187.1
451.1
1075.2
⅛
95.0
213.1
492.0
50%
3
¼
145.2
288.5
582.2
⅛
71.5
152.2
289.8
2
¼
112.7
198.0
529.2
⅛
52.0
122.5
218.1
[0047] The performance of the symbol timing estimator is also evaluated under a static channel condition with only one group, as shown in Tables 7 and 8. In Tables 7 and 8, MCEC and MMD values are tabulated for SNR=5.4 dB, Carrier Offset=1500 Hz, BW=8 MHz, single group, 200 trials using the first embodiment in FIG. 5 . The length of the group is about 3.3 μs and the channel bandwidth is 8 MHz. If N g is 1/16 of N u , the channel length L CIR is about 24%, 12% and 6% of N g for FFT sizes of 2K, 4K and 8K, respectively. If N g is 1/32 of N u , then the ratios between the channel length and N g are doubled. As can be seen, the symbol timing estimator still performs well under these conditions.
TABLE 7 MCEC N g /N u N u = 2K N u = 4K N u = 8K 1/16 99.89% 100.0% 100.0% 1/32 98.28% 99.9% 100.0%
[0048]
TABLE 8
MMD
N g /N u
N u = 2K
N u = 4K
N u = 8K
1/16
0.02
0.00
0.00
1/32
7.87
0.30
0.00
[0049] Tables 9 and 10 below respectively tabulate simulated MCEC and MMD values obtained under the same simulation conditions as in Tables 7 and 8, using the alternate embodiment in FIG. 6 .
TABLE 9 MCEC N g /N u N u = 2K N u = 4K N u = 8K 1/16 100.0% 100.0% 100.0% 1/32 99.9% 100.0% 100.0%
[0050]
TABLE 10
MMD
N g /N u
N u = 2K
N u = 4K
N u = 8K
1/16
0.00
0.00
0.00
1/32
0.40
0.00
0.00
[0051] Tables 11 and 12 below respectively tabulate simulated MCEC and MMD values obtained under the same simulation conditions as in Tables 7-10, using the conventional method based on the peak of correlation.
TABLE 11 MCEC N g /N u N u = 2K N u = 4K N u = 8K 1/16 89.7% 68.9% 95.8% 1/32 85.3% 89.1% 91.5%
[0052]
TABLE 12
MMD
N g /N u
N u = 2K
N u = 4K
N u = 8K
1/16
0.66
1.16
0.74
1/32
1.15
1.30
1.37
[0053] From these results, it can be seen that the embodiments of the present invention outperform conventional techniques by a large margin, especially in the presence of severe wireless channels.
[0054] While the above provides a complete description of the preferred embodiments of the invention, many alternatives, modifications, and equivalents are possible. Further, the features of one or more embodiments of the invention may be combined with one or more features of other embodiments of the invention without departing from the scope of the invention. For these and other reasons, therefore, the above description should not be taken as limiting the scope of the invention, which is defined by the appended claims.
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Symbol synchronization in a communication system is carried out as follows. A plurality of symbols corresponding to a transmitted signal is received, where the plurality of symbols include guard intervals. Peak correlation is obtained using the plurality of received symbols. The second derivative of the peak correlation is obtained, and one or more peaks within a corresponding guard interval are identified from the second derivative. A symbol start time for each received symbol is estimated based on the second derivative of the peak correlation.
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BACKGROUND OF THE INVENTION
The invention relates to a double helix comprising two helix elements made of plastic wire with the longitudinal axes of the two helix elements extending in parallel, to the production of such helices in which two plastic wires are wound on a mandrel, and to the use of the double helices to produce a spiral belt of the type wherein the helices are engaged with their windings in zipper fashion and are secured by a pintle wire.
Spiral belts comprised of helices are used as conveyor belts and as papermachine clothing. The costs involved in the manufacture of such belts are highly dependent on the production costs of the helices. Likewise, the production capacity of the belts depends primarily on that of the helices. In general, the production capacity of a machine assembling the helices to form a spiral belt is so high that a great number of helix producing machines operating at maximum speed are required to feed the assembling machine. Therefore, to minimize the helix production costs, it is essential that the output of the individual helix making machines be maximized.
The capacity of a helix producing machine can be increased by winding double helices instead of a single helix element. A double helix and a method for producing same are known from German Auslegeschrift No. 2,003,344. In this method, the two helix elements of the double helix are readily separated by laterally pulling the helices apart. This is accomplished by a complicated method in which the two helix wires are wound on a mandrel so as to alternately cross each other. Owing to these crossings, however, the helices have an asymmetrical cross section which makes them unsuited for the assembly of spiral belts having a smooth surface. Moreover, this reference fails to describe how the helices can be further processed to form a screen belt. Double helices have also been known from European patent application No. 18200. However, the double helices disclosed in this application are used with their longitudinal axes congruent i.e., without lateral displacement.
Spiral belts assembled from a multiplicity of helices in which the windings of the individual helices are intertwined are disclosed in German Pat. Nos. 54,525, 77,147 and 80,763. In these belts, pintle wires can be additionally inserted between the entwined windings. However, assembly of these belts from single helix structures requires that each new helix be screwed into the preceding helix. Such spiral belts are thus far more expensive to produce than are the spiral belts disclosed, for example, in German OS No. 2,938,221 where the helices mesh normal to their longitudinal axes and are secured in position by pintle wires.
It is therefore a primary object of the present invention to reduce the overall costs of producing spiral belts by reducing the cost factor of helix production.
SUMMARY OF THE INVENTION
In accordance with the principles of the present invention, the above and other objectives are realized in a double helix comprising two helix elements with intertwined windings and by producing such a double helix by applying two plastic wires in parallel on a mandrel. In making double helices in accordance with the invention, it is preferable that the two plastic wires are wound closely so that each helix element has a pitch equal to twice the diameter of the plastic wire.
In a further aspect of the invention, such double helices are used to assemble a screen belt by mutually offseting the helix elements of each double helix normal to their longitudinal axes and securing these elements in offset position. The secured elements are then assembled to form a screen belt substantially in the same manner as single helix structures and are interconnected by pintle wires.
In yet a further aspect of the invention, spiral belts are produced from double helices by separating the double helices into individual helices by rotating one about the other while retaining their orientation. The helices are then assembled into a spiral belt in the same manner as single helix structures.
A primary advantage attainable by the present invention is an increase in the capacity of helix winding machines. Furthermore, conventional helix winding machines can be adapted to produce double helices in a simple way.
When using a double helix in accordance with the invention to form a spiral belt, the two helix elements of the double helix are mutually offset normal to their longitudinal axes with their windings intertwined. If the two helix elements were left unrestrained in the offset condition, they would immediately slip back to form a double helix. Therefore, in accordance with the invention, the offset position of the helix elements is maintained by securing the elements in these positions. Preferably this is accomplished by using an adhesive tape.
Mutual offsetting of the helix elements may be effected by guiding the helices over two wires contained within the hollow spaces of the helix elements. In order to prevent the wires from being carried along by the helices they may be of curved configuration, e.g., U-shaped. By using rollers to engage the outside of the helix elements especially in the concave portions of their curved regions, the wires are prevented from being carried along by the advancing helix elements and slide within the hollow interiors thereof. Before the helix elements leave the wires the adhesive tape may be applied.
The two offset helix elements of the double helix can be assembled with other like helices to form a spiral belt in the customary way by intermeshing adjacent windings and inserting a pintle into the passage thereby formed. Thereafter the assembled belt may be thermoset as described in German Offenlegungsschrift No. 2,938,221. The temperature and the tension exerted on the belt by such processing are such that the windings of the helices penetrate into the material of the pintle wires leaving to some extent undular deformation therein. The helices are positioned closely side by side without any tension spring-like bias so that the wavelength of the undular pintle wire is about equal to twice the diameter of the plastic wire of the helices.
A spiral belt so formed has openings of different widths, which may be undesirable for use as clothing for papermaking machines. This can be largely eliminated by inserting a pintle wire between the intertwined windings of the helix elements of the double helix. The windings of the helix elements engage this pintle wire at the same place in the longitudinal direction of the pintle wire and only on opposite sides thereof so that this pintle wire will not be undularly deformed during thermosetting.
A further method of processing double helices to form a spiral belt in accordance with the invention comprises separating each double helix into two individual non-coherent helices. To this end, the two helix elements of the double helix are rotated to perform a circular motion one about the other while the orientation of the helix elements is maintained. Surprisingly the double helix thereby separates into two separate single helices. If the rotated helix elements are to be used to form a spiral belt for use as papermachine clothing, it is advantageous that the helix elements have a pitch equal to twice the wire thickness. This prevents the occurrence of any tension spring-like bias prior to thermosetting during assembly.
The method of separating each double helix into two separate single helices in accordance with the invention is very simple and can, therefore, be carried out at high speed. A single separator can thus process the output of several helix forming machines so that the cost savings of the invention are largely retained.
The method of the invention can generally be applied to multiple helices. Thus, for instance, three plastic wires can be wound side by side in parallel on a winding mandrel. The triple helix can then be separated into three individual helices by rotating the three helix elements about a common center while maintaining their orientation. Each of the three helices then has a pitch equal to thrice the wire thickness.
BRIEF DESCRIPTION OF THE DRAWINGS
The above and other features and aspects of the present invention will become more apparent upon reading the following detailed description in conjunction with the accompanying drawings, in which:
FIG. 1 shows a helix in accordance with the prior art;
FIG. 2 shows a double helix comprising two helix elements;
FIG. 3 illustrates a double helix with two mutually offset helix elements;
FIG. 4 shows a device for mutually offsetting the two helix elements of a double helix;
FIG. 5 is a section through the two helix elements of FIG. 4 passing over wires; and
FIGS. 6 and 7 show spiral belts composed of double helices.
DETAILED DESCRIPTION
FIG. 1 shows a prior art helix. The pitch of the helix is depicted as greater than it actually is in the helices used for the assembly of screen or spiral belts. Normally, such helices have a pitch equal to the wire diameter or up to twice the wire diameter at the most.
FIG. 2 shows a double helix 3 comprising two intertwined helix elements 1, 2. In the helices shown in FIGS. 1 and 2 the spacing of the windings is equal. In the double helix, each helix element 1 and 2, taken by itself, has twice the pitch and the pitch angle is accordingly wider. As a consequence, double helices cannot be assembled into a spiral belt in the same way as single helices. On account of the greater pitch angle of the windings, intermeshed double helices immediately slip apart. i.e., they separate spontaneously and do not permit the insertion of a pintle wire. Hence, double helices would have to be held together by suitable means in order that a pintle wire can be inserted. However, this would complicate the method for producing the spiral belt to such an extent as to offset any reduction in costs attained by an increase in capacity of the helix forming machines. It has to be borne in mind that for assembly a double helix would first have to be pulled apart so far that the windings are spaced apart a distance at least equal to the wire diameter. Each helix element 1, 2 would thus have to have a pitch equal to four times the wire diameter.
FIG. 3 illustrates a double helix 3 in which the two helix elements 1 and 2, respectively, are mutually offset so that the windings thereof intertwine. Two such double helices can be intermeshed because each of the offset helix elements 1 or 2, respectively, has a pitch equal to only twice the wire diameter. In the production thereof the double helix can be wound without leaving any space between windings, i.e., side by side. However, if the elements 1 and 2 are merely offset without doing more, the two helix elements 1, 2 immediately slip together again, i.e., they assume the position shown in FIG. 2 in which the longitudinal axes of the helix elements 1, 2 coincide. This occurs as soon as the forces laterally offsetting the helix elements are eliminated.
FIG. 4 shows an apparatus for laterally offsetting the helix elements 1, 2 and for securing them in their offset positions. The apparatus includes a roll or roller 11 and a pair of rolls 12 driven at equal peripheral speeds. Two U-shaped stiff wires 13 are spaced about the roll 11 and through the gap of the roll pair 12. Each helix element 1 and 2, respectively, moves onto one of the two wires 13 so that the helix elements 1, 2 are pulled apart normal to the longitudinal axes thereof whereby two helix elements with intertwining windings are obtained. This method is comparable to that described in German application No. P 32 20 517.1.
The helix elements are advanced by means of the roll 11 and are pushed over the U-shaped wires 13. The rolls are arranged and the form of the wires 13 is selected so that the wires 13 cannot be carried along by the advancing helices.
FIG. 5 shows a section through the offset helix elements 1, 2 moving on the wires 13. The cross section of the wires is adapted, as to shape and dimension, to fit the free space within the coherent helix elements.
In this laterally offset state, an adhesive tape 14 is introduced into the nip of the roll pair 12 and is applied on the two helix elements 1, 2. The adhesive tape 14 prevents the helix elements 1, 2 from slipping one into the other again. The helix elements provided with the adhesive tape are then deposited in a can and can be readily assembled to form a screen belt without any difficulty and in the same manner as single helices. After assembly and insertion of the pintle wires the adhesive tape can then be removed.
As is apparent, the device of FIG. 4 for laterally offsetting helix elements and securing the elements in the offset position is of simple construction and permits a high operation speed so that the double helices produced by about ten helix winding machines can be processed by a single offsetting device. Also the removal of the adhesive tape is simple and does not cause any appreciable expense.
FIG. 6 shows a section of a spiral belt assembled from double helices with offset helix elements. As can be seen, the windings of each helix element of a double helix mesh with the windings of the helix element of the next following double helix, and through the passage formed by the overlapping region of the windings of the two helix elements a pintle wire 6 is inserted. On account of the different size of the openings remaining between the helix elements, the permeability of the spiral belt shown in FIG. 6 is not uniform. Therefore, it may sometimes be advantageous to insert additional pintle wires 7 between the entwined windings of the helix elements 1, 2 of a double helix as shown in FIG. 7. This substantially increases the uniformity of the spiral belt permeability.
Another method of using double helices in the assembly of a spiral belt is to disassemble the double helix into two single helices. A double helix can be separated into two single helices relatively simply by causing one helix element of a double helix to perform a circular motion about the other one while both helix elements retain their directional orientaion. Each one of the resulting single helices has a pitch equal to twice the wire thickness.
The latter described method can also be carried out at high speed so that it does not add any substantial costs.
The single helices obtained in this way can be assembled into a spiral belt in the conventional way, and the structure of the resultant spiral belt corresponds to that described in German OS No. 2,938,221.
In all cases it is understood that the above-identified arrangements are merely illustrative of the many possible specific embodiments which represent applications of the present invention. Numerous and varied other arrangements can readily be devised in accordance with the principles of the present invention without departing from the spirit and scope of the invention.
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Double helices each comprising two helix elements made from plastic wire with the longitudinal axes of the two helix elements extending in parallel and with the windings of the two helix elements intertwined, the double helices being formed by winding two plastic wires in parallel and without twist on a mandrel and being used to assemble a spiral belt by interengaging in zipper fashion a multiplicity of helices via meshing the windings of one helix with the windings of the next helix, and by inserting a pintle wire into the passage formed by the overlapping windings.
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BACKGROUND OF THE DISCLOSURE
The present invention is directed to an improved wall framing system, particularly, to an external veneer cap mounted to an existing wall system of a building and the method of installation of the veneer cap.
Wall framing systems for buildings have been used for some time. In such systems, structural members such as sills, jambs, and mullions grip the edges of glass panels or the like to form the wall system. Such a wall system, for example, may be of the curtain wall, skylight, or slopped glazing type. Typically, the wall framing members include two primary parts, an interior part and an exterior part. The glass panels are captured between the interior and exterior frame members to form the completed system. The interior and exterior frame members are connected together by various means for securely gripping the glass panels. Seals or gaskets are typically installed along the connection, thereby forming a watertight seal between the wall frame members and the glass panels.
A common problem encountered with most, if not all, wall systems is intrusion of water and air past the gasket seals or other type of connection and into the building interior. Rain water, condensation, and water from window washing are the typical sources of water intruding into the wall framing system. Most buildings encounter this problem. After a period of time, the panel gasket seals become brittle and crack. The gasket seals may also be abraded by particles in the air or by routine maintenance, such as window washing. Consequently, most a relatively short period of time, most building wall systems require extensive maintenance to repair the panel gasket seals, which maintenance may include the replacement or recaulking of the panel gasket seals.
A significant problem associated with maintenance of the panel gasket seals is that repairs must often be made both from the interior and exterior of the wall system. This is always objectionable to the occupants of the building which are inconvenienced by the interruption in their work schedule.
It is, therefore, an object of the present disclosure to provide an external wall maintenance system which is watertight.
It is a further object of the invention is to provide an external wall maintenance system which may be completely installed from the exterior of the building.
It is yet another object of the invention to provide a method of installing the wall maintenance system.
SUMMARY OF THE INVENTION
The invention of the present disclosure is directed to a veneer cap installed on the external surface of a wall system and the method of installation. The veneer cap of the invention comprises a series of both vertical and horizontal members which bridge the existing system mullion, sill and jamb connections thereby providing a panel-to-panel seal over the panel gasket seals of the wall system. The veneer cap includes a bridging member having a pair of parallel, spaced legs extending therefrom. The legs terminate at flange members which extend substantially perpendicular to the leg members. A double sides adhesive tape initially secures the veneer cap to the external surface of the wall system over the panel gasket junction. A structural silicone adhesive sealant permanently bonds the veneer cap to the external surface of the wall system.
BRIEF DESCRIPTION OF THE DRAWINGS
So that the manner in which the above recited features, advantages and objects of the present invention are attained and can be understood in detail, a more particular description of the invention, briefly summarized above, may be had by reference to the embodiments thereof which are illustrated in the appended drawings.
It is to be noted, however, that the appended drawings illustrate only typical embodiments of this invention and are, therefore, not to be considered limiting of its scope, for the invention may admit to other equally effective embodiments.
FIG. 1 is a perspective view of a portion of a wall system having the veneer cap of the invention mounted thereon;
FIG. 2 is a sectional view showing the veneer cap of the invention bridging over the panel connection of the wall system;
FIG. 3 is a partial, exploded view showing the vertical and horizontal components forming the veneer cap of the invention;
FIG. 4 is an enlarged plan view showing the junction of the vertical and horizontal components of the veneer cap of the invention;
FIG. 5 is a sectional view taken along line 5--5 of FIG. 4;
FIG. 6 is a sectional view taken along line 6--6 of FIG. 4;
FIG. 7 is a sectional view of an alternate embodiment of the veneer cap of the invention; and
FIG. 8 is a sectional view of yet another alternate embodiment of the veneer cap of the invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Referring first to FIG. 1, a portion of an existing wall system of a building is shown and generally designated by the numeral 10. The wall system 10 includes a series of glass panels 12 connected by mullions 14 and sills 16. As best shown in FIG. 2, the mullion 14 of the wall system 10 is of typical construction known in the prior art. The mullion 14 includes an interior metal connector 18 and an external connector seal 20. The forward end of the metal connector 18 is provided with a pair of channels 22 which extend the full length of the metal connector 18. The walls of the channels 22 are provided with serrations or teeth 24 for gripping a pair of legs 26 which project from the bottom surface of the external connector seal 20 and are received within the channels 22. The metal connector 18 is also provided with connector clips 28 which fasten thereon. The connector clips 28 include gripping flanges 30 which secure an internal seal 32 against the interior edges of the glass panels 12. The sill 16 is of similar construction for gripping the horizontal edges of the glass panels 12 as shown in FIG. 1. It will be observed that the glass panels 12 of the wall system 10 shown in FIGS. 1 and 2 are gripped between an interior and exterior member which are joined together and grip the panels 12 along the edges thereof. The wall system 10 is typical of many wall systems on existing buildings.
Referring again to FIG. 2, it is readily apparent that water intrusion into the building is highly likely along the external connector seal 20 and the internal seal 32. Climatic conditions and any number of other factors may quickly weaken the seal structure of the wall system 10 permitting intrusion of water and/or air. Prior to the present disclosure, costly repairs and business disruptions were required to remedy such a problem.
Referring now to FIG. 3, the veneer cap of the invention is generally identified by the numeral 40. The veneer cap 40 comprises a series of vertical members 42 and horizontal members 44. The veneer cap members 42 and 44 are fabricated of extruded aluminum and may be cut to any desired length as required for a particular wall system. Aluminum is a lightweight material and particularly suited for this purpose, however, the veneer cap 40 of the invention may be fabricated of any material suitable for external wall systems. For example, extruded plastic or vinyl is well suited for this purpose.
The veneer cap 40 is mounted to the external surface of the wall system 10 and is secured directly to the panels 12. The mullion, sill and jamb structures and the seals associated therewith are not affected or altered during the installation of the veneer cap 40. The intersection of vertical and horizontal external connector seals 20 is bridged over by a channel splice 46 which will be described in greater detail hereinafter.
Returning again to FIG. 2, it will be observed that the vertical veneer cap member 42 defines a substantially channel-like configuration formed by a cover plate 48 and a pair of spaced, parallel leg members 50 extending therefrom. The leg members 50 terminate in L-shaped flanges 52 which extend inwardly from the leg members 50 and are substantially parallel to the cover plate 48.
The veneer cap 40 is initially secured to the panels 12 by a double sided adhesive tape 54. The tape 54 has some thickness and for purposes of illustration, may be approximately 3/16 inch by 1/4 inch. Thus, upon securing the veneer cap 40 to the panels 12, a gap of approximately 3/16 of an inch is defined between the surface of the panels 12 and the flanges 52 of the veneer cap 40. The gap is filled with structural silicon 56. The consistency of the silicon 56 is much like that of caulk used in weather stripping and therefore it does not tend to run. The silicone 56 is smoothed out to present a clean appearance. The cure time for the structural silicon 56 may vary depending on the type used. The cure time for Dow Cornig 795 silicone, which has been found to be particularly suitable for this purpose, is approximately 21 days. Once the silicon 56 has cured, a permanent and waterproof panel-to-panel seal is formed about the external connector seal 20.
For purposes of illustration only, the veneer cap 40 is shown as having a substantially U-shaped channel-like configuration. It is understood, however, that the shape of the veneer cap 40 is not particularly significant and may be any shape which will bridge over the external connector seal 20 or external connecting member of the wall structure to provide a panel-to-panel seal. The profile of the vertical veneer cap member 42 and horizontal veneer cap member 44 is substantially the same, however, the horizontal veneer cap member 44 is slotted to receive the channel splice 46 as shown in FIG. 3.
Referring now collectively to FIGS. 4, 5 and 6, the junction of the vertical cap member 42 and the horizontal cap member 44 is shown. To bridge the external connector seal 20 at a four corner junction, the channel splice 46 is adhesively mounted to the horizontal veneer cap member 44. The member 44 is measured and slotted so that the channel splice 46 may be centered over the vertical external connector seal 20. Likewise, the channel splice 46 includes a slot 49 which bridges over the horizontally extending external connector seal 20. The channel splice 46 is substantially U-shaped in profile having a longitudinal length slightly greater than the width of the horizontal veneer cap member 44 so that each end of the channel splice 46 projects outwardly from the member 44 when it is adhesively mounted thereto as shown in FIG. 5. The channel splice 46 is dimensioned so that the projecting ends thereof fit snugly within the channel formed by the vertical veneer cap member 42. The projecting ends of the channel splice 46 are wrapped with bond breaker tape and the vertical veneer cap member 42 is slid about the projecting ends of the channel splice 46 and aligned with the horizontal veneer cap member 44 and slightly spaced therefrom. Thus, a gap 43 is defined between the end of the vertical veneer cap member 42 and a side leg member of the horizontal veneer cap member 44 as shown in FIGS. 4 and 5. The gap 43 is filled with the silicone 56, thereby forming a seal at the junction of the veneer cap sealant members 42 and 44 which extends from one panel 12 across the top of the channel splice 46 to the opposite panel 12. In this manner, a seal is provided between the channel splice 46, the vertical veneer cap member 42 and the horizontal veneer cap member 44, thereby completely sealing about the four corner junction.
Referring now to FIGS. 7 and 8, alternate embodiments of the veneer cap 40 are shown. In the embodiment of FIG. 7, the veneer cap 40 has been modified to provide a bridging seal between a panel 12 and a wall member 60. The veneer cap 40 is modified along one longitudinal end to include a flange 62 extending inwardly and substantially parallel to the leg member 50. The adhesive tape 54 is positioned interiorly of the flange 62 and adhesively mounts an edge of the cover plate 48 adjacent to the flange 62 and to the top face of the external connector seal 20. A bond breaker tape 64 extends from the flange 62 to the wall 60 to cover the gasket seal of the wall system. The gap formed between the flange 62 and wall 60 is filled with the silicone sealant 56 in the same manner as previously described.
The alternate embodiment of FIG. 8 is substantially similar to the embodiment shown in FIG. 7. However, the veneer cap 40 has been modified to include a leg member 68 which extends outwardly from the cover plate 48 in a direction opposite the leg member 50. A cross member 70 connects the leg member 68 to a flange 72. The flange 72 provides a surface for adhesively mounting the veneer cap 40 to the wall 60. The gap defined therebetween is filled with silicone sealant 56 to complete the installation of the veneer cap 40 bridging between the plate 12 and the wall 60.
The veneer cap 40 of the invention may be installed on most existing wall systems. The veneer cap 40 is installed from the exterior of the building and therefore does not interrupt the daily routine of the building occupants. Prior to installation, the panels 12 are cleaned thoroughly along the area adjacent the external connector seal 20. The external connector seal 20 is also wiped clean with a solvent so that all contact areas are clean. If not already prepared, the horizontal veneer cap member 44 is cut to length and slotted to receive the channel splice 46. The channel splice 46 then is adhesively mounted to the horizontal veneer cap member 44 in the slotted area. The veneer cap member 44 is then aligned to bridge over a horizontal external connector seal 20 of the wall system 10. Backing tape on the adhesive tape 54 is removed and the horizontal veneer cap member 44 is pressed against the panels 12. The process is repeated to secure the horizontal veneer cap member 44 to the panels 12 until all the horizontal veneer cap members 44 to be installed are adhesively secured to the panels 12.
The vertical veneer cap members 42 are prepared in a similar fashion. Each vertical veneer cap member 42 is first tested to insure that there is a proper fit about the projecting ends of the channel splice 46. The vertical veneer cap member 42 is then aligned and the tape backing is removed from the tape 54 permitting the vertical veneer cap member 42 to be adhesively mounted to the panels 12. After installation of the vertical veneer cap members 42 is completed, the silicone sealant 56 is applied and smoothed to complete the installation.
While the foregoing is directed to the preferred embodiments of the present invention, other and further embodiments of the invention may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims which follow.
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Disclosed is a wall system having vertical and horizontal panel gripping members connecting a plurality of panel members. The vertical and horizontal panel gripping members are covered by a veneer cap extending over the vertical and horizontal panel gripping members and being bonded to the panel members providing a panel-to-panel seal about the panel gripping members on the exterior of the wall system.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The present invention relates to a method for controlling the degree of side-etch occuring in case of selectively etching a solid oxide thin film, especialy of silicon oxides, which is used for a semiconductor device and which has surface hydroxyl groups on its surface.
2. Description of the Prior Art
Photo-etching is a technique for protecting selected areas of the surface of a thin film by an organic polymer and etching the remaining portion of the surface in the manufacture of various articles such as semiconductor devices and printed circuit cards.
Concretely, the photosensitive organic polymer generally termed "photoresist" (including two sorts of the negative type photo-resist and the positive type photoresist, the former of which is polymerized and becomes insoluble in a solvent when exposed to light and the latter is depolymerized and becomes soluble when exposed to light) is applied onto the surface of the thin film. The photoresist is exposed to light through a mask of black and white, to polymerize the photoresist at the selected areas (depolymerize the same in case of the positive type photoresist) and render it insoluble (soluble in case of the positive type photoresist) in the solvent. Thereafter, the photoresist in the unpolymerized portion is dissolved and removed. Through a photoresist mask thus formed on the thin film, the selected areas of the thin film are chemically etched.
The prior art photo-etching technique has the disadvantage that when the film material with the photoresist applied as the mask is immersed in an etchant, the etchant permeates between the photoresist material and the thin film material due to inferior affinity between both the materials. This gives rise to the side-etch (the proceeding of etching to the part of the thin film to-be-protected), so that a fine pattern is not etched at good reproducibility.
In some extreme cases, the photoresist exfoliates from the surface of the thin film, and its effect as the mask is fully lost.
It is considered that such phenomena are prone to arise where the affinity between the thin film and the photoresist is bad. In order to reduce the side-etch, a variety of measures have hitherto been adopted. These measures include conducting the baking after applying the photoresist on the thin film material, adding an adhesion accelerator or a surface-active agent at the etchant and changing the composition or temperature of the etchant so as to increase the etching rate.
Since, however, the property of the surface of the thin film greatly differs in dependence on, not only the sort of the material of the thin film, but also the process history, etc. thereof, it has been very difficult with the prior-art technique to perform a photo-etching working of high finishing accuracy at good reproducibility.
In the case of subjecting a thin film material, 1 μm - several μm thick, to the photo-etching working, a phenomenon just converse to the foregoing problem is sometimes the cause for generating defectives. For example, where after forming an uneven pattern in the first thin film of a thickness of several μm by the photo-etching working, the second thin film is to be formed thereon, it can occur that the formation of the second thin film is partially obstructed by the unevenness of the first thin film or that the second thin film formed severs on the end part of a convex portion of the first thin film.
In such case, it is desirable to make the unevenness of the first thin film less severe. In other words, it is desirable that the degree of side-etch can be controlled in the photo-etching working.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a model-like sectional view of a usual SiO 2 surface;
FIG. 2 is a sectional view showing a model-like manner an SiO 2 surface subjected to a surface treatment with butanol;
FIG. 3 shows perspective views of photo-etched surfaces of a polycrystal silicon film as correspond to FIGS. 4 to 7; and
FIGS. 4 to 7 are photographs obtained when the photo-etched surfaces of a specimen with polycrystalline silicon deposited and with no surface treatment made, a specimen subjected to a surface treatment with butanol, a specimen subjected to a surface treatment with trimethylchlorosilane and a specimen subjected to a surface treatment with hexamethyldisilazane were observed by a scanning electron microscope (x1300), respepctively.
SUMMARY OF THE INVENTION
An object of the present invention is to solve the problems in the photo-etching working as stated above, and to control the worked profile of a thin film material by photo-etching by controlling the degree of side-etch (i.e., to reduce or in some cases to increase the degree of side-etch).
Another object of the present invention is to enhance the reproducibility of the photo-etching working by deliberately making certain surface properties irrespective of the history of a thin film material.
The objects are accomplished as stated below.
It is generally considered that thin films of silicon aluminum, etc., have their surface layer oxidized under the influences of oxygen, moisture, etc., in the atmosphere air, and that the properties of the surfaces of these thin films are similar to the properties of their oxides. Accordingly, the case of a thin SiO 2 film is taken as an example.
FIG. 1 illustrates a surface structure of usual SiO 2 in a model-like manner. A surface S - S' is of a cross-linked structure which consists of Si 4 + ions 11 and O 2 - ions 12. Onto the Si 4 + ions 11 exposed to the surface, H 2 O in the atmospheric air is chemisorbed, to form surface hydroxyl groups 15 (-OH). In the figure, a circle just above the surface S - S' represents an oxygen atom, and a small circle 13 with oblique lines represents a hydrogen atom. Since the surface hydroxyl groups are chemically reative, organic radicals can be formed on the thin film surface in such a way that, as will be described later, the thin film is surface-treated under specified conditions by the use of an organic compound such as alcohol, silane derivatives, silylamine derivatives and phenols containing active hydrogen atoms, halogen atoms, nitrogen atoms, etc. within its molecules.
More specifically, as illustrated in FIG. 2, when the SiO 2 surface is treted with butanol, butoxy groups 25 can be formed on the SiO 2 surface S - S'. The property of the surface thus covered with the organic radicals is determined by the property and number of the organic radicals.
In FIG. 2, reference numeral 21 designates an Si 4 + ion, 22 an O 2 - ion, 23 a hydrogen atom and 24 a carbon atom.
The hydroxyl groups 15 in FIG. 1 are substituted by the butoxy groups in FIG. 2. The organic radicals represented by the butoxy groups affect the affinity between the photoresist and the thin film surface.
The subject matter of the present invention is based on the finding that organic radicals are stuck to the thin film surface by the chemical procedure as explained above, thereby providing means to deliberately control the property of the thin film surface and to regulate the degree of side-etch.
According to the photo-etching method of the present invention, the SiO 2 surface has its property turned from hydrophilic to lyophilic (which can alternatively be called hydrophobic) by a certain kind or organic radicals, so that the affinity between the SiO 2 surface and the photoresist is improved, with the result that the permeation of an etchant between the SiO 2 surface and the photoresist is reduced and that the degree of side-etch diminishes. To the contrary, another kind of organic radical can increase the side-etch.
In other words, the photo-etching method according to the present invention consists in that, before performing the conventional photo-etching, a solid oxide thin film having chemisorbed hydroxyl groups on its surface is surface-treated by an organic compound which has within its molecule a functional group reacting with the hydroxyl group. As regards the method of the surface treatment, the same operating procedures apply irrespective of the materials of the thin films to be surface-treated. Therefore, the procedures will be collectively explained here.
(1). Surface treatment with Alcohol
The method to be now stated is applicable to all the alcohols of primary and secondary alcohols, monofunctional and polyfunctional alcohols and aliphatic and aromatic alcohols and to phenols. The following exemplifies a case of the surface treatment with n-butanol (n-C 4 H 9 OH).
A thin film specimen and 66 ml of butanol are placed in an autoclave made of stainless steel (one of a capacity of 200 ml was used in our case). After substituting air within the autoclave with dry nitrogen, the autoclave is hermetically closed. Subsequently, the autoclave is gradually heated while continuously measuring the temperature and pressure in the autoclave. When the temperature and pressure in the autoclave have reached critical conditions (288° C. and 49 atmospheres in the case of butanol), the heating is stopped. The autoclave is opened to permit butanol vapor to blow out, and is let to stand for cooling. Such method is termed the autoclave method.
While the ideal conditions of the surface treatment with alcohol has been described above, the surface treatment can also be performed under conditions stated below.
It is possible that the alcohol is used in the form of a solution employing a nonpolar organic solvent such as n-hexane (n-C 6 H 14 ), and that the reaction is carried out caused at the critical temperature of the solvent. This method is valuable, in case of using an alcohol of high critical temperature, to lower the reaction temperature (the critical temperature of n-hexane is 235° C.).
The reaction temperature and pressure need not always be the critical temperature and the critical pressure. However, a temperature above the boiling point of the alcohol and a pressure above the atmospheric pressure are required.
When the thin film surface is treated with alcohol by the method stated above, the hydroxyl group on the thin film surface is substituted into an alkexy group. In this reaction, the condensation with elimination of water takes place between the hydroxyl group of the alcohol and the surface hydroxyl group on the thin film surface. The reaction mechanism is described in U.S. Pat. No. 2,913,358.
(2). Surface Treatment with Silane Derivative
The method to be described here is applicable to all the silane derivatives such as trimethylchlorosilane ((CH 3 ) 3 SiCl) and trimethylmethoxysilane ((CH 3 ) 3 SiOCH 3 ). Descriptionn will be made of a case of the trimethylchlorosilane treatment.
A thin film specimen placed in a quartz sample tube is vacuum-evacuatd at 200° C. under 5 × 10 - 5 Torr. for 2 hours. Thereafter, the sample tube is shut off from a vacuum pump. Subsequently, 50 Torr. of trimethylchlorosilane vapor is introduced into the sample tube. The thin film surface is exposed to the vapor, and the tube is let to stand in this state for at least 1 hour.
By following the above operations, the condensation with elimination of hydrogen chloride is induced between the hydroxyl group of the thin film surface and the trimethylchlorosilane. As the result, an organic radical (OH 3 ) 3 SiO-- can be formed on the thin film surface. Such method is named the vapor phase reaction method.
In this operating method, the thin film specimen is vacuum-evacuated before being exposed to the trimethylchlorosilane vapor. The vacuum evacuation is for removing physically adsorbed water on the surface hydroxyl group (chemically adsorbed water) of the thin film so as to make the surface hydroxyl group more reactive, and it does not restrict the operating method.
(3). Surface Treatment with Silylamine Derivative
The surface treatment with any of silylamine derivatives represented by hexamethyldisilazane ((CH 3 ) 3 SiNHS:(CH 3 ) 3 ) can be carried out by the vapor phase reaction method quite similar to the foregoing case of silane derivatives. Herein, the condensation with elimination of ammonia takes place between the hydroxyl group of the thin film surface and the hexamethyldisilazane.
(4). Surface Treatment with Phenol or its Derivative
This method modifies the property of a thin film surface by performing the surface treatment of a thin film material with any of the phenols, such as phenol, cresol, catechol, pyrogallol, aminophenol, phenol halide and nitrophenol, and phenol derivatives.
A solution in which 10 gr. of phenol is dissolved in 60 ml of n-hexane, and a thin film specimen are placed in an autoclave made of stainless steel and having a capacity of 200 ml.
Subsequently, air within the autoclave is replaced by dry nitrogen, and the autoclave is hermetically closed. While measuring the temperature and pressure in the autoclave, the autoclave is gradually heated to 235° C. (the rate of rising the temperature is about 8° C/min.). The raised temperature is held for 30 minutes, to cause the phenol to react on the thin film surface. During this period, the pressure in the autoclave is 38 atmospheres. Lastly, the autoclave is opened, has vapor in the interior blown out, and is let to stand for cooling.
When the thin film surface is treated with phenol or its drivative by the method stated above, the dehydration reaction takes place between the hydroxyl group of the phenol and the hydroxyl group of the thin film surface, and a phenoxyl group is formed on the thin film surface.
Quite the same operations can be applied to alkyl-, alkene-, aromatic-, amino- and halogen-substituted derivatives of phenol, such as cresol, anol, thymol, hydroxydiphenyl, aminophenol and chlorophenol. Mixed solutions consisting of these compounds and alcohols can also achieve similar effects.
By performing the surface treatment with the organic substance in conformity to the methods described above, the property of the thin fim surface is modified, with the result that the degree of side-etch can be controlled. In order to clarify the effect of the surface treatment, the invention will be explained in detail hereunder in connection with specific embodiments.
The surfce treatment process of the present invention can be applied to all the thin film material of oxides, silicon, etc. Of the oxides, SiO 2 and metal oxides such as Al 2 O 3 are particularly noteworthy. Here, description will be made of a polycrystalline silicon film which has been known to be extremely side-etched with the conventional method and an SiO 2 film which has been known to be, conversely, little side-etched.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Embodiment 1
The effect of the present invention in the photo-etching working of a polycrystalline silicon film will be explained.
First, on a silicon wafer with its surface oxidized by about 5,000 A, polycrystalline silicon was formed by about 5,000 A by thermal decomposition of silane at 650° C.
Subsequently, in accordance with the foregoing methods, surface treatments were conducted with alcohols, a silane derivative and a silylamine derivative.
Conditions of the surface treatments are listed in Table 1.
Table 1______________________________________Conditions of Surface TreatmentsWith Organic SubstancesOrganic Substance Temperature Pressure Remarks(Chemical Formula) (°C) (atm.)______________________________________Methanol (CH.sub.3 OH) 240 78Ethanol (C.sub.2 H.sub.5 OH) 243 63Propanol (C.sub.3 H.sub.7 OH) 263 50 autoclave methodButanol (C.sub.4 H.sub.9 OH) 288 49Pentanol (C.sub.6 H.sub.11 OH) 300 26Decanol (C.sub.10 H.sub.21 OH) 300 22______________________________________Trimethylchlorosilane 200 0.1 vapor ((CH.sub.3).sub.3 SiCl) phase reactionHexamethyldisilazane 200 0.1 method ((CH.sub.3).sub.3 SiNHSi(CH.sub.3).sub.3)______________________________________
Using a negative type photoresist containing polyisoprene as its main component, for example, OMR (i.e., a product of Tokyo Oka Co.), KTFR (i.e., a product of Kodak), etc., which, among photoresists commercially available, is considered to be very poor in the affinity with the polycrystalline silicon, a photo-etching working was carried out by the conventional method. An etchant was a mixed solution consisting of HF, HNO 3 and CH 3 COOH (1 : 50 : 25 in volumetric ratio), at a temperature of 22° C. Since the etching rate was approximately 2,500 A/min., the polycrystalline silicon film 5,000 A thick could be etched in about 2 minutes.
In order that the effect of the surface treatment according to the present invention may be intuitively understood, scanning electron microscope-photographs of the surfaces after the etching are shown in FIGS. 4 to 7. FIG. 3 ilustrates in a model-like manner the structures of the photographs shown in FIGS. 4 to 7.
More specifically, by the photo-etching working, two etch pits are formed at each of parts 31 and 32 of the polycrystalline silicon film and at intervals of 20 μm. The oblique line portion is a section of the side-etched polycrystalline silicon film.
If there is quite no side-etch, both the intervals d and d' ought to become 20 μm (mask dimensions). In actuality, the interval is shorter on account of the side-etch.
FIG. 4 corresponds to the polycrystalline film which has been untreated, FIG. 5 corresponds to that subjected to the surface treatment with butanol, FIG. 6 corresponds to that subjected to the surface treatment with trimethylchlorosilane, and FIG. 7 corresponds to that subjected to the surface treatment with hexamethyldisilazane. By comparisons of the four typical examples shown in FIGS. 4 to 7, it is understood that the degree of side-etch in the photo-etching working can be controlled by applying the surface treatment process according to the present invention.
Further, in order to quantitatively demonstrate the effect of the present invention, measured results of the etch factor which is defined by the following equation (1) will be given: ##EQU1##
(degree of side-etch) = (d - d')/2
Table 2 compares the etch factors of polycrystalline silicon films subjected to various surface treatments, with that of an untreated polycrystalline silicon film.
Table 2______________________________________Etch Factors of Polycrystalline Silicon FilmsAgent of Surface Thickness of Poly- EtchTreatment crystalline Silicon Factor______________________________________(untreated) 5,500 A 0.06methanol 6,000 0.14ethanol 5,700 0.16n-propanol 5,600 0.29n-butanol 5,100 0.61n-pentanol 5,300 0.29n-decanol 5,600 0.25______________________________________trimethylchlorosilane 5,100 0.26hexamethyldisilazane 5,000 1.0______________________________________
As understood from the examples in Table 2, in the case of photo-etching the polycrystalline silicon film, the untreated specimen has a very great degree of side-etch and consequently has etch factors as small as 0.06, whereas the application of the surface treatment process of the present invention makes it possible to control the etch factor in a range of 0.14 - 1.0.
Embodiment 2
Description will now be made of the photo-etching working of SiO 2 which is formed by the chemical vapor deposition (abbreviated to CVD in this specification). Used as each specimen was a CVD.sup.. SiO 2 film deposited on a silicon wafer by oxidizing silane at 430° C. KTFR (i.e., a product of Kodak heretofore described as having polyisoprene as its main component, a negative type) was employed as the photoresist, while a mixed solution consisting of HF and NH 4 F at 1 : 6 in volume ratio was employed as the etchant.
In case of SiO 2 as deposited, the etch factor was 1.3 - 1.5. When it was surface treated with 1,4-butanediol (HO-(CH 2 ) 4 -OH) and 1,3-propanediol (HO--(CH 2 ) 2 --OH), the etch factor became 0.7 - 1.0 in both the cases.
Conversely, when the specimen was surface-treated with the organic compounds given in Table 2, the etch factor became 1.5 - 1.8.
Embodiment 3
Further, description will be made of the photo-etching working of CVD.sup.. phosphorsilicate glass (abbreviated to PSG in this specification). As each specimen, there was used a CVD.sup.. PSG film deposited on a silicon wafer by oxidizing at 430° C. a mixed gas consisting of silane and phosphine.
The photoresist, the etchant and the other photo-etching conditions were all the same as in the case of CVD.sup.. SiO 2 .
The etch factor of the CVD.sup.. PSG film as deposited depended on the concentration of phosphorus in the film, and became smaller as the phosphorus concentraton was higher. In case of a phosphorus concentration of 4 mol %, the etch factor was 1.2, while in case of a phosphorus concentration of 8 mol %, it was 1.0. When the CVD.sup.. PSG film was surface-treated with 1,3-butanediol (CH 3 CH(OH)(CH 2 ) 2 OH) and 1,2-propanediol (CH 3 CH(OH)CH 2 OH), the etch factor became 0.6 - 0.8 independently of the phosphorus concentraton.
Where the surface treatments were made with the organic compounds given in Table 2, the etch factor increased as in Embodiment 2. It was found that, even in this case, the degree of side-etch was independent of the phosphorus concentration.
Embodiment 4
A solution in which 10 gr. of phenol was dissolved in 60 ml of n-hexane, and a specimen in which a polycrystalline silicon thin film was deposited on a silicon wafer, with its surface oxidized by 5,000A, by the thermal decomposition of silane at 650° C. were placed in a stainless steel-made autoclave of a capacity of 200 ml.
Subsequently, air within the autoclave was replaced by dry nitrogen, and the autoclave was hermetically closed. While measuring the temperature and pressure within the autoclave, the autoclave was gradually heated to 235° C. (the rate of rising the temperature was about 8° C/min.). The raised temperature was held for 30 minutes, to give rise to the reaction. Meantime, the pressure within the autoclave was 38 atmospheres. Finally, the autoclave was opened, had vapor in the interior blown out, and was let to stand for cooling.
Thereafter, the specimen was processed similarly to Embodiment 1. When the etch factor was measured, it was 0.02.
Embodiment 5
In a stainless steel-made autoclave having a capacity of 200 ml, there were placed a solution (surface-treating agent) in which 13 ml of n-octanol and 10 gr. of phenol were dissolved in 60 ml of n-hexane and a material in which a polycrystal silicon thin film was deposited on a silicon wafer, with its surface oxidized by 5,000A, by the thermal decomposition of monosilane at 650° C.
The specimen was surface-treated by the same treatment method as in Embodiment 4. Thereafter, the etch factor was measured in the same way as in Embodiment 1. Then, a value of 0.05 was obtained.
Besides the foregoing, combinations between phenols and alcohols as hereunder mentioned can also achieve similar effects.
Phenols;
aliphatic-, aromatic-, amino- and halogen-derivatives of phenols such as phenol, cresol, anol, thymol, hydroxydiphenyl, aminophenol and chlorophenol.
Alcohols;
primary and secondary alcohols, unsaturated alcohol, aromatic alcohol, halogenoalcohol, aminoalcohol, nitroalcohol, diol, etc.
As described above, according to the present invention, a thin film material such as silicon and oxides thereof is surface-treated with an organic compound, to deliberately control the property of the surface of the thin film, whereby the degree of side-etch is controlled, making it possible to control the profile of an etched secton in the photo-etching working.
In addition, the reproducibility of the finishing accuracy can be made extraordinarily good irrespective of the history of the thin film.
That is, the present invention brings forth much excellent results over the conventional method in points of the control of the profile of an etched section and the reproducility of the accuracy of finishing, and is greatly effective in practical use.
In the vapor phase reaction method described above, it will be understood that the minimum temperature is 50° C and that the pressure ranges from 0.1 Torr. to 1 atmosphere. In the autoclave method and the vapor phase reaction method, reaction times are 30 minutes or longer.
It also will be appreciated from the foregoing examples that the effect of the organic compound on the degree of side-etch is dependent upon the structure of the organic compound. Normal alcohols, silane derivatives and silylamine derivatives reduce the degree of side-etch; whereas, polyfunctional alcohols and phenols increase the degree of side-etch in a controlled manner. Moreover, suitable solvents for use with such organic compound include liquid alkanes.
Furthermore, it should be recognized that numerous photoresist materials may be used for the purpose of the subject invention and that the photo-etching technique per se is effected according to conventional procedures such as those disclosed by the manuals of Kodak.
Furthermore, it will also be recognized that in additon to silicon, the oxides of silicon and Al 2 O 3 other oxide surfaces can be treated so long as the surfaces possess the characteristic of having chemisorbed hydroxy groups thereon.
While the novel embodiments of the inveniton have been described, it will be understood that various omissions, modifications and changes in these embodiments may be made by one skilled in the art without departing from the spirit and scope of the invention.
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In selectively etching a solid oxide thin film which has chemisorbed water (surface hydroxyl groups) in its surface, the thin film is surface-treated with an organic compound which has within its molecule a functional group to react with the surface hydroxyl groups. Thereafter, photo-etching is performed by the conventional method by applying a thin film of a photosensitive organic polymer onto the treated thin film. Through selection of the sort of the organic compound, the degree of side-etch arising in the process of the selective etch can be controlled.
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A CROSS REFERENCE OF RELATED APPLICATIONS
[0001] This application claims priority to U.S. provisional patent application 61/324,983 filed on Apr. 16, 2010, the entire contents of which are incorporated by reference herein.
TECHNICAL FIELD
[0002] The present invention relates to a method for masking the unfavorable flavor of curcumine to obtain a preparation that can be taken without resistance.
BACKGROUND ART
[0003] Turmeric (Turmeric, Curcuma longa L.) is a foodstuff that has been widely used as a natural food additive or a spice. Various foods and beverages containing turmeric are available in the marketplace. It has recently been reported that turmeric has an antioxidant effect, an antiinflammatory effect, and an anticarcinogenic effect, and turmeric has been attracting attention as a functional natural material. Turmeric comprises curcumine as a yellow main component, and research on its bioactivity is being conducted.
[0004] However, because turmeric has a peculiar flavor, many people tend to avoid consuming it.
[0005] Therefore, there is a tendency for people to widely use curcumine, i.e., the yellow main component described above, rather than a turmeric extract. Maltodextrin, cyclodextrin, trehalose and the like have been used as masking agents for turmeric (Patent Literature 1); however, these masking agents still have room for improvement in their flavor masking effects.
CITATION LIST
Patent Literature
[0000]
PTL 1: Japanese Unexamined Patent Publication No. 2009-28042
SUMMARY OF INVENTION
Technical Problem
[0007] An object of the present invention is to improve the scent, flavor (bitterness, smell) and the like peculiar to curcumine by the use of masking.
Solution to Problem
[0008] The present inventors conducted research aimed at finding a method for masking the flavor that is peculiar to curcumine to reduce people's resistance to consuming curcumine so that the functions possessed by turmeric or curcumine can be utilized. As a result, the inventors found that the flavor of curcumine can be effectively masked by using a modified starch as a masking agent, and adding it to curcumine. The present invention has been accomplished based on this finding.
[0009] Specifically, the present invention provides the following items.
[0010] Item 1. A method for masking curcumine flavor comprising: mixing curcumine with a modified starch.
[0011] Item 2. The method for masking curcumine flavor according to Item 1, wherein the amount of modified starch is 0.01 to 10 parts by mass per 1 part by mass of curcumine.
[0012] Item 3. The method for masking curcumine flavor according to Item 1 or 2, wherein the modified starch is at least one member selected from the group consisting of acetylated distarch adipate, acetylated oxidized starch, acetylated distarch phosphate, oxidized starch, hydroxypropyl starch, hydroxypropyl distarch phosphate, carboxymethyl starch, starch acetate, starch octenyl succinate, monostarch phosphate, distarch phosphate, and phosphated distarch phosphate.
[0013] Item 4. A method for preparing a curcumine composition comprising mixing a modified starch with curcumine in order to mask the flavor of curcumine.
Advantageous Effects of Invention
[0014] The invention provides foods and beverages having a reduced curcumine-peculiar flavor by adding curcumine and a modified starch that serves as a masking agent to the foods and beverages.
DESCRIPTION OF EMBODIMENTS
Method for Masking Curcumine Flavor
[0015] The present invention provides a method for masking curcumine flavor comprising a step of mixing curcumine with a modified starch.
[0016] The modified starches used in the present invention can be obtained by using corn, potato, sweet potato, wheat, rice, glutinous rice, tapioca, sago palm and like starches as raw materials, and subjecting these starches to a chemical treatment that can be roughly classified into the two categories of decomposition treatment and addition treatment. These raw material starches may be used singly or in a combination of two or more. Preferable examples of raw material starches include corn and tapioca. Examples of known kinds of corns include dent corn ( Zea mays Linn. var. indentata Sturt ), flint corn ( Zea mays Linn. var. indurata Sturt ), soft corn ( Zea mays Linn. var. amylacea Sturt ), sweet corn ( Zea mays Linn. var. saccharata Sturt ), popcorn ( Zea mays Linn. var. everta Sturt ) and glutinous corn (waxy corn, Zea mays Linn. var. ceratina Sturt ). There is no particular limitation to the type of corn used in the present invention and any type of corn can be used as a raw material starch. Preferably the starch is derived from glutinous corn, i.e., waxy corn (hereafter simply referred to as “waxy corn”).
[0017] Examples of modified starches usable in the present invention include starches obtainable by processing the raw material starches mentioned above, specifically, acetylated distarch adipate, acetylated oxidized starch, acetylated distarch phosphate, oxidized starch, hydroxypropyl starch, hydroxypropyl distarch phosphate, carboxymethyl starch, starch acetate, starch octenyl succinate, monostarch phosphate, distarch phosphate, phosphated distarch phosphate and the like. Among these, hydroxypropyl starch, hydroxypropyl distarch phosphate and starch octenyl succinate are preferable and starch octenyl succinate is particularly preferable. These modified starches may be used singly or in a combination of two or more.
[0018] According to the present invention, by adding the modified starch to curcumine, the flavor of curcumine can be masked.
[0019] The amount of modified starch relative to curcumine is not particularly limited, and generally 0.01 to 10 parts by mass, and preferably 0.1 to 10 parts by mass of modified starch is added per 1 part by mass of curcumine.
[0020] As the preferable examples for adding the modified starch of the present invention to curcumine, the modified starch and curcumine may be formed into a composition, and the modified starch and curcumine may be added to foods and beverages. Furthermore, curcumine and a modified starch may be formed into a preparation.
[0021] The curcumine used as the raw material for the masking method of the present invention is preferably used in a form contained in a turmeric pigment or a turmeric extract.
[0022] The curcumine used in the present invention is that obtainable from the rhizome of Curcuma longa LINNE.
[0023] Preferably, the curcumine is that obtained by subjecting dried turmeric rhizome (turmeric powder) to extraction using warmed ethanol, using a heated oil or fat or propylene glycol, or using room-temperature to heated hexane or acetone. Crystalline curcumine is more preferable. Crystalline curcumine can be obtained by extracting turmeric powder using hexane and acetone, subjecting the resulting extract to filtration, and drying it to volatilize the solvent. Alternatively, synthesized products may be used.
[0024] Conventionally, commercially available turmeric pigments (curcumine powder: crystalline) can be used. Such curcumine powders are available from San-Ei Gen F.F.I., Inc., etc.
[0025] Preferably, the modified starch is first dissolved in a solvent to form a modified starch solution, and then curcumine is added to and mixed with the modified starch solution. The solvents used to dissolve the modified starch are not limited as long as they can be added to foodstuffs and do not dissolve curcumine. Preferable examples thereof include water, and mixed solvents of water and solvents compatible with water. Examples of solvents compatible with water include ethanol and like lower alcohols; propylene glycol, glycerin and like polyhydric alcohols; fructose-glucose solutions, sucrose solutions, isomerized sugar solutions and like sugar solutions; crystalline fructose; etc. In this specification, these solvents are collectively referred to as a “hydrous solvent”. The modified starch solutions, in which the modified starch described above is dissolved in such a solvent, are collectively referred to as a “modified starch hydrous solution”.
[0026] The modified starch is dissolved in a hydrous solvent (preferably water) in such a manner that the ultimate concentration becomes 0.00001 to 20 mass %, preferably 0.0001 to 15 mass %, and more preferably 0.001 to 10 mass %. Subsequently, curcumine is added to the modified starch hydrous solution thus obtained and then mixed.
[0027] The method for mixing the modified starch hydrous solution with curcumine is not particularly limited as long as they can be mixed, and the mixing can be performed by agitation using a conventional agitator. For example, mixing can be performed by adding curcumine to a modified starch hydrous solution, followed by agitation using a propeller stirrer or the like. The temperature for the mixing by agitation is not particularly limited, and can be set, for example, within the range of 1 to 100° C. The duration of the mixing by agitation is not particularly limited as it depends on the scale of the production, and can be set, for example, within the range of 1 to 60 minutes. The agitation speed is not particularly limited as it also depends on the scale of the production, and can be set, for example, at within the range of 1 to 3,000 rpm.
[0028] The mixture of modified starch hydrous solution and curcumine after undergoing mixing by agitation may subsequently be supplied to a grinding treatment (pulverization). The grinding treatment (pulverization) is preferably conducted by a physical crushing method. One example of a physical crushing method is that performed by using a wet grinding mill. Specific examples of wet grinding mills include the Ultra visco mill and Dyno-Mill. Wet grinding mills such as a sand mill and a Co-ball mill can also be used by inserting beads and the like as modifications.
[0029] The curcumine liquid composition obtained by adding curcumine to a modified starch hydrous solution or grinding curcumine in a modified starch hydrous solution may be further subjected to homogenization, if necessary, in order to homogeneously mix the pulverized turmeric pigment and other components. The homogenization method is not particularly limited as long as it can homogeneously disperse the curcumine and other components, and can be conducted using an emulsification and dispersion apparatus such as a nanomizer, microfluidizer and homogenizer, or an ultrasonic dispersion apparatus. The conduction of homogenization loosens the aggregation of curcumine, further increasing its dispersibility to water and dispersion stability in water.
[0030] The pH may be suitably controlled depending on the target product to which the curcumine liquid composition will be added (e.g., the target product to be colored (herein referred to as a product to be colored)). Preferably, the pH value is controlled to be 8 or lower. Examples of pH adjusters include phosphoric acid, sulfuric acid, hydrochloric acid and like inorganic acids; and citric acid, lactic acid, malic acid and like organic acids. These pH adjusters may be suitably selected depending on the type of product to be colored, and the targeted pH.
[0031] A curcumine composition in a powder form (hereafter referred to as a curcumine powder composition) can be prepared, if necessary, by drying and powderizing the curcumine liquid composition obtained by the aforementioned method. The curcumine powder composition thus obtained is advantageous in that it is useful to prepare a product that contains curcumine with an extremely high concentration; it can be used to produce a dry product, such as a food or a tablet, with a dry method; it is highly preservable without requiring the addition of a preservative; etc. The dryer used in the drying and powderization is not particularly limited, and examples thereof include a spray dryer, a slurry dryer and like spray dryers; a freeze dryer; etc.
[0032] By further subjecting the curcumine powder composition to granulation or subsequent tableting, if necessary, the curcumine composition can be formed into granules (curcumine granular compositions) or tablets (curcumine tablet composition). Such granules and tablets can be produced by adding additives known in the art (e.g., excipient, binder, lubricant, disintegrator, etc.) if necessary, according to a conventional preparation technique. In particular, a curcumine composition having a granular form is advantageous in that it exhibits high solubility and promptly dissolves when it is added to an aqueous product such as a beverage or a cosmetic lotion.
[0033] Insofar as the effect of the invention can be achieved, a polysaccharide thickener, flavoring agent, pigment, antioxidant, shelf life extenders, preservative, saccharide and like additives may be used together with the curcumine composition. By using these additives, the taste, scent, and texture of the curcumine composition can be changed, allowing a more palatable curcumine composition to be prepared.
Method for Preparing a Curcumine Composition
[0034] The present invention provides a method for preparing a curcumine composition characterized in that a composition is obtained by mixing a modified starch with curcumine, thus masking the curcumine flavor.
[0035] The modified starch and curcumine used in the method of the present invention, and the method for preparing a curcumine composition, can employ the same conditions as those of the masking method described above.
Use of Curcumine Composition
(1) Use as a Food Additive or Additive
[0036] The curcumine composition of the present invention is usable, for example, as a food additive or an additive. More specifically, the curcumine composition of the present invention can be used as a flavoring agent or a coloring agent in various food products (including general food products (which also include health foods) and supplements such as dietary supplements), and cosmetics.
[0037] The foods may be in any form of liquid, semi solid, or solid, and specific examples thereof are as listed below.
[0038] Beverages (e.g., carbonated beverages, fruit beverages (including fruit juices, fruit juice-containing soft drinks, fruit juice-containing carbonated beverages, fruit pulp-containing beverages), vegetable beverages, vegetable/fruit beverages, low-alcohol beverages, coffee beverages, powdered beverages, sport drinks, supplement beverages, black tea beverages, green teas, blended teas, etc.); desserts (e.g., custard puddings, milk puddings, fruit juice-containing puddings, jelly, Bavarian cream, etc.); frozen desserts (e.g., ice cream, milk ice cream, fruit juice-containing ice cream, soft ice cream, ice candies, sorbets, etc.); gum (e.g., chewing gum, bubble gum, etc.); chocolates (e.g., marble chocolate and like coating chocolates, strawberry chocolate, blueberry chocolate, melon chocolate, etc.); candies (e.g., hard candies (including bon-bons, butter balls, marbles, etc.)), soft candies (including caramel, nougat, gummy candy, marshmallows, etc.), drops, toffee, etc.); other confections (e.g., baked confections such as hard biscuits, cookies, okaki (rice crackers), senbei (rice crackers), etc.); soups (e.g., consomme soups, potage soups, pumpkin soups, etc.); tsukemono (Japanese pickles, e.g., asa-zuke, shoyu-zuke, shio-zuke, miso-zuke, kasu-zuke, koji-zuke, nuka-zuke, su-zuke, karashi-zuke, moromi-zuke, ume-zuke, fukujin-zuke, shiba-zuke, shoga-zuke, umezu-zuke, etc.); jams (e.g., strawberry jam, blueberry jam, marmalade, apple jam, apricot jam, etc.); milk products (e.g., milk beverages, lactic fermented milk drinks), yogurt, cheese, etc.); oil or fat-containing food products (e.g., butter, margarine, etc.); processed grain foods (e.g., breads, noodles, pasta, etc.); processed fish or animal food products (e.g., ham, sausage, kamaboko, chikuwa, etc.); seasonings (e.g., miso, tare (Japanese style sauces), sauces, bottled lemon juice, vinegar, mayonnaise, salad dressings, curry roux, etc.); cooked food products (e.g., tamago-yaki (Japanese omelets), omelets, curry, stew, hamburger patties, croquette, soups, okonomi-yaki (pan cakes with vegetables, meat or seafood), gyoza (fried or boiled dumplings), fruit jam, etc.).
[0039] Among these, beverages, jams, tsukemono, and liquid seasonings belonging to the sauce category are preferable, and beverages are particularly preferable. In the case of dietary supplements and like supplements, syrups, liquids and solutions, drinkable preparations, tablets, pills, powders, granules, and capsules are preferable.
[0040] When the curcumine composition of the present invention is used as a food additive or additive (coloring agent or flavoring agent), the product to be colored or flavored (e.g., foods, beverages, and cosmetics) can be produced by adding the curcumine composition of the present invention as a coloring agent or a flavoring agent in any step of producing the target product. Such a product can be produced according to a conventional method except that the aforementioned step is added.
[0041] In this case, the amount of the curcumine composition is not particularly limited as long as it serves the desired purpose. When coloring is the goal, specifically, the curcumine composition of the present invention may be added in such an amount that its proportion relative to the final product becomes 0.01 mass % at minimum.
[0042] Here, an example of known curcumine (a conventional curcumine composition) is a liquid, solubilized curcumine composition that can be obtained by extracting curcumine powder by hydrous ethanol using the crude curcumine and production method disclosed in the List of Existing Food Additives (Appendix 1 for Labeling and Specifications under the Food Sanitation Law in Notice No. 56, published May 23, 1996, by the Director-General of the Environmental Health Bureau, Ministry of Health and Welfare).
(2) Use as a Functional Component
[0043] When the bioactive function of curcumine is targeted, the curcumine composition of the present invention itself can be used as supplements such as dietary supplements.
[0044] In this case, the curcumine composition of the present invention can be formed into “orally administered curcumine preparations”, i.e., orally administrable preparations, such as hard capsules, soft capsules, tablets, granules, powders, fine granules, pills, troches, syrups, liquids and solutions, drinkable preparations, etc.
[0045] In this case, the dosage of the curcumine composition of the present invention (an orally administered curcumine preparation) depends on the consumer's age, body weight and condition, dosage form, duration of treatment and the like.
[0046] According to the Technical Report from WHO, the ADI (Acceptable Daily Intake) of curcumine is 0 to 3 mg/kg of body weight/day, and the NOAEL (no-observed-adverse-effect level) is 250 to 320 mg/kg of body weight/day (WHO Technical Report Series: page 33). Therefore, the curcumine composition can be administered at one time or divided into several times within this range.
[0047] The present invention is explained in detail below with reference to Production Examples, Examples, Comparative Examples and the like. However, the present invention is not limited to these examples. Note that the unit used in the formulation is “part by mass” unless otherwise specified.
EXAMPLES
Production Example 1
Method for Preparing Curcumine Composition
[0048] 60 g of starch octenyl succinate (Purity BE, produced by Nippon NSC Ltd.) was added to 830 g of water as a modified starch, and the mixture was then heated to 90° C. to obtain an aqueous solution. Subsequently, 110 g of curcumine powder (curcumine powder No. 3705, produced by San-Ei Gen F.F.I., Inc., crystalline, curcumine content of 88.3%) was added to the resulting aqueous solution, followed by dispersive mixing. The amount of dispersion water was adjusted to obtain a mass of 1,000 g.
[0049] The mixture containing curcumine powder dispersed therein was supplied to a wet type mill (dyno-mill, DYNO-Mill KDL: produced by Willy A. Bochofen AG Maschinenfabrik) to perform wet grinding. Thereafter, the ground mixture was subjected to homogenization by dispersion one time using a homogenizer (high pressure homogenizer, model 15MR-8TA: produced by APV Gaulin Inc.) at room temperature and a pressure of 20 MPa to obtain a curcumine preparation in a liquid form (a liquid curcumine preparation). The average particle diameter (particle size distribution (D50)) was 0.22 μm.
Production Example 2
Preparation of Powder Curcumine Composition
[0050] 83 g of Dextrin NSD-C (produced by Nissi Co., Ltd.) was added to 119 g of water. The mixture was heated to 60° C. to homogeneously dissolve the dextrin. 100 g of the curcumine composition prepared in Production Example 1 was added to the mixture, followed by homogenization using a homogenizer. The homogenized mixture was then subjected to dry powderization using a spray dryer (produced by Tokyo Rikakikai Co, Ltd.). The resulting powder (curcumine powder composition) had a curcumine content of 9.7%.
Test Example 1
Objective
[0051] Using the curcumine powder composition described above that was prepared using a modified starch, the curcumine flavor improvement effect was examined (Example 1). As Comparative Examples, the curcumine compositions disclosed in Japanese Unexamined Patent Publication No. 2009-28042 were prepared according to the formulations shown in Table 1 and the Preparation Method 1 described below to investigate the flavor improvement effects (Comparative Examples 1 to 4).
[0000]
TABLE 1
Formulations
Comparative
Comparative
Comparative
Comparative
Example 1
Example 1
Example 2
Example 3
Example 4
Blank
Crystalline fructose
7.5
7.5
7.5
7.5
7.5
7.5
Citric acid
0.2
0.2
0.2
0.2
0.2
0.2
Sodium citrate
0.05
0.05
0.05
0.05
0.05
0.05
Curcumine composition
0.62
(Curcumine content: 9.7%)
Bulk curcumine powder
0.068
0.068
0.068
0.068
0.068
(Curcumine content: 88.3%)
Gellan gum (stabilizer)
0.03
0.03
0.03
0.03
0.03
Maltodextrin
0.5
1
Cyclodextrin
0.5
1
Trehalose
1
Adding ion-exchanged
100
100
100
100
100
100
water (to result in 100%)
Details of Starting Materials
[0052] Crystalline fructose: Krystar 300, produced by Danisco A/S
[0053] Curcumine composition: Curcumine powder preparation (Curcumine content: 9.7%, modified starch content: 6%)
[0054] Bulk curcumine powder: Curcumine powder No. 3705 (produced by San-Ei Gen F.F.I., Inc., curcumine content: 88.3%)
[0055] Gellan gum: Kelcogel LT-100, produced by CP Kelco
[0056] Maltodextrin: Sunmalt (Midori), produced by Hayashibara Co., Ltd.
[0057] Cyclodextrin: Dexypearl K-100, produced by Ensuiko Sugar Refining Co., Ltd.
Preparation Method 1
[0058] Gellan gum, crystalline fructose, citric acid, and sodium citrate were heated at 90° C. for 10 minutes to prepare an aqueous solution in advance. Subsequently, maltodextrin, cyclodextrin, and trehalose were added and dissolved in the aqueous solution. A curcumine composition or bulk curcumine powder was added to the resulting solution, followed by hot packing at 93° C.
Sensory Evaluation 1
[0059] Four panelists (A to D) evaluated the differences in the flavors of the samples from that of a blank solution.
[0060] Evaluation scale:
5: Similar to the blank solution 4: A very small improvement in curcumine flavor compared to the blank solution 3: Some improvement in curcumine flavor compared to the blank solution 2: A significant improvement in curcumine flavor compared to the blank solution 1: A remarkable improvement in curcumine flavor compared to the blank solution
[0000]
TABLE 2
Exam-
Comparative
Comparative
Comparative
Comparative
ple 1
Example 1
Example 2
Example 3
Example 4
A
1
4
5
4
5
B
2
4
4
4
5
C
1
3
4
3
4
D
2
4
5
4
5
Aver-
1.5
3.75
4.5
3.75
4.75
age
Result 1
[0066] As the above results show, an apparent improvement in flavor was confirmed when the curcumine composition of Example 1 was used.
Test Example 2
[0067] The flavor improvement effect was examined by changing the amount of modified starch contained. Specifically, curcumine compositions were prepared into the formulations shown in Table 3 according to Preparation Method 2 described below to investigate the flavor improvement effect (Comparative Examples 2 to 5).
[0000]
TABLE 3
Exam-
Exam-
Exam-
Exam-
ple 2
ple 3
ple 4
ple 5
Blank
Crystalline fructose
7.5
7.5
7.5
7.5
7.5
Citric acid
0.2
0.2
0.2
0.2
0.2
Sodium citrate
0.05
0.05
0.05
0.05
0.05
Bulk curcumine
0.068
0.068
0.068
0.068
0.068
powder (Curcumine
content: 88.3%)
Gellan gum
0.03
0.03
0.03
0.03
0.03
Modified starch
0.6
0.06
0.006
0.0006
Adding ion-exchanged
100
100
100
100
100
water (to result in
100%)
Preparation Method 2
[0068] Gellan gum (Kelcogel LT-100, produced by CP Kelco), crystalline fructose (Krystar 300, produced by Danisco A/S), citric acid, sodium citrate, and modified starch (Purity BE, produced by Nippon NSC Ltd.) were heated at 90° C. for 10 minutes to prepare an aqueous solution in advance. Bulk curcumine powder was added to the aqueous solution in the proportions shown in Table 3 while stirring at 1,000 rpm. The resulting curcumine-containing compositions were hot packed at 93° C.
Sensory Evaluation 2
[0069] Differences in the flavors from a blank solution were evaluated using the same method and evaluation scale as in Sensory Evaluation 1 in Test Example 1. Table 4 shows the results.
[0000]
TABLE 4
Example 2
Example 3
Example 4
Example 5
A
2
2
3
4
B
2
3
3
3
C
2
2
3
3
D
2
3
3
4
Average
2
2.5
3
3.5
Result 2
[0070] An improvement in curcumine flavor was confirmed in Examples 2 to 5 in which the proportion of modified starch was 0.01 to 10 parts by mass relative to 1 part by mass of curcumine.
Test Example 3
[0071] The flavor improvement effect was examiner by changing the kind of modified starch contained.
[0000]
TABLE 5
Example 6
Example 7
Blank
Crystalline fructose
7.5
7.5
7.5
Citric acid
0.2
0.2
0.2
Sodium citrate
0.05
0.05
0.05
Bulk curcumine powder
0.068
0.068
0.068
(Curcumine content: 88.3%)
Gellan gum
0.03
0.03
0.03
Hydroxypropyl starch
0.6
Hydroxypropyl distarch
0.6
phosphate
Adding ion-exchanged water
100
100
100
(to result in 100%)
Preparation Method 3
[0072] Curcumine-containing compositions were prepared in the same manner as in Example 2 (Preparation Method 2) except that hydroxypropyl starch (National 7, produced by Nippon NSC Ltd.) or hydroxypropyl distarch phosphate (Purity 87, produced by Nippon NSC Ltd.) was used as the modified starch instead of starch octenyl succinate (Purity BE, produced by Nippon NSC Ltd.) (Examples 6 and 7).
Sensory Evaluation 3
[0073] Differences in the flavors from the blank solution were evaluated using the same method and evaluation scale as in Sensory Evaluation 1 in Test Example 1. Table 6 shows the results.
[0000]
TABLE 6
Example 6
Example 7
E
3
4
F
3
3
G
4
3
H
3
3
Average
3.25
3.25
Result 3
[0074] An improvement in curcumine flavor was also confirmed in the cases where hydroxypropyl starch or hydroxypropyl distarch phosphate was used instead of the modified starch (Purity BE, produced by Nippon NSC Ltd.).
|
[Object]
An object of the present invention is to improve the smell, flavor and the like peculiar to curcumine by masking.
[Method for Achieving the Object]
The present invention provides a method for masking curcumine flavor comprising mixing curcumine with a modified starch.
[Selected Figure] None
| 0
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CROSS-REFERENCE TO RELATED APPLICATION
This application claims the benefit of U.S. Provisional Patent Application Serial No. 60/318,831, filed Sep. 12, 2001, which is hereby incorporated herein by reference in its entirety for all purposes.
FIELD OF THE INVENTION
The present invention relates generally to the field of pattern and character recognition; and more particularly to an “activity”-based system and method for feature extraction, representation and character recognition that reduces the required processing capacity for recognizing single stroke characters (or multiple strokes concatenated into one stroke) or patterns, with the intent that said characters or patterns may be created, removed, or edited from an alphabet by an individual for the purpose of personalization, without a method redesign. Further, the system and method of the present invention provide a parameter set such that its variance over an arbitrary alphabet can optimize recognition accuracy specific to that alphabet.
BACKGROUND OF THE INVENTION
Methods for character, handwriting and pattern recognition for the purpose of alphanumeric or symbolic data (collectively referred to herein as “text”) entry into computer systems has been a key research area for electrical engineers and computer scientists since the earliest days of computers. In fact, handwriting-based input systems were designed and attempted as early as about 1959, prior to the widespread use of alphanumeric keyboards. Even these systems are based on the symbol recognition technologies of about the early 1950s. Most early methods were “off-line” processing methods, which used both temporal and string contextual information to increase recognition accuracy. “On-line” recognition uses only temporal drawing information to recognize while a user is writing. Generally, on-line methods sacrifice accuracy for real-time performance speeds. That sacrifice typically is not necessary for off-line recognition.
During the bulk of the 1960s, the keyboard was the premier form of text input as well as primary human interface to the computer. With the introduction of Douglas Engelbart's “mouse” and “graphical user interface” (GUI) in 1968, and the advent of digitizing tablets in the late 1960s, focus returned to research dealing with more natural human interfaces for manipulating digitized information. This remains the trend today with the various mainstream operating systems and desktop environments such as Apple's Macintosh OS, X-Windows for the various Unix systems, and Microsoft's Windows operating systems. In these systems, the mouse or some other pointing device such as a tablet or stylus are used to visually manipulate the organization of information on a screen (e.g., moving a window from the left side of the screen to the right, or to select a block of text). The text input mechanisms to all these systems, however, is still based primarily on the keyboard.
In the modern world, computing devices are getting smaller and more powerful (sometimes exceeding the power of five year old desktop personal computers) and are cheaper to produce. These small devices require text input devices that are not as cumbersome as keyboards. One potential alternative is handwriting recognition. Devices such as Apple's Newton provided this technology, but with unacceptable performance. This is due to the complex issues of not only character recognition, but of trying to separate individual characters and symbols from handwritten words, sentences or complete documents prior to recognizing each character. Only recently has a viable solution to character separation been proposed.
In about 1993, the concept of writing characters one on top of the other in single strokes so that each character is automatically separated by “pen events” (such as pressing the pen to the writing surface to signify the start of a new character, dragging the pen along the writing surface to represent the structure of the character, and lifting the pen from the writing surface to signify the end of a character) was introduced. This reduces recognition tasks to the character level. Personal digital assistants (PDAs) like the Palm Pilot and iPaq have become mainstream and are incorporating this character recognition concept with great success.
The recognition accuracy of these devices is compromised, however, in the attempt to provide a specialized alphabet that is accessible to all users, along with a recognition method robust enough to handle the different writing styles of an arbitrary user. Palm's Graffiti language, for example forces users to learn an alphabet that is potentially different from the day-to-day alphabet they are accustomed to. This adds user error to the recognition failure rates as they may continue to draw the letter ‘Q’ as they would on paper while trying to enter text into the Palm Pilot. This is an unnecessary constraint on the user, especially those who lack the motor control required to perform some of the Graffiti strokes. This would included sufferers of Parkinson's disease, Multiple Sclerosis (MS) and Muscular Dystrophy (MD). Additionally, the Palm recognition method does not appear to be robust enough to distinguish letters like ‘U’ and ‘V’ naturally, and so a serif was added onto the tail of the ‘V’ for greater separation. While this improves the distinction between such letters, it adds even greater difficulty to learning the new alphabet. In order to avoid these unnatural characters, one recognition system adds code that, when determining that the input character was either a ‘P’ or ‘D’, compares the height of the stem to the height of the attached curve in order to properly recognize. This does improve accuracy, but suggests that additional changes to the alphabet would require more character specific code to be written to handle new similarities, thus preventing the user from updating the character dictionary herself.
Some character recognition techniques such as structural matching and elastic relaxation employ complex feature manipulation methods for converting a “sloppy” character to one that is stored in a character dictionary. These methods are difficult to comprehend and deploy by most vendors (in practice) and have high computational requirements. While the Merlin system was designed to be interpreted (Java) on weak devices such as portable phones, its incorporation of these methods detract from its speed.
Presently, most research in on-line character recognition has centered around single character entry systems. Characters are entered one at a time and the recognizer classifies the character before the next is written. This provides the user immediate feedback so that errors can be corrected as they occur. Typically, there is a simple method for the user to depict the beginning and end of each character—commonly accomplished by pen down and up events.
Unistrokes, developed at Xerox Corporation in about 1993, is a well known example of a single character, pen-event system. Unistrokes characters were designed to be written one on top of another so as to minimize the real estate required for recognition and to allow for “eyes free operation”. The Unistrokes alphabet is based on five basic strokes and their rotational deformations. While several characters (‘i’, ‘j’, ‘L’, ‘o’, ‘s’, ‘v’ and ‘z’ for example) are represented by strokes similar to their Roman drawings, most characters' strokes require memorization. Additionally, a model has been developed for predicting the time required to enter arbitrary text with Unistrokes by an expert user. This is particularly useful since several variations of the Unistrokes alphabet have been introduced over the past nine years.
Since about the mid 1990's online character recognition has become widely employed in Personal Digital Assistants (PDA's), beginning with the Palm OS device, which primarily defined the product category. A popular variation of Unistrokes is the Graffiti system used in the Palm OS family of PDA's. Graffiti improved upon Unistrokes by representing characters with symbols that are, for the most part, quite like their Roman counterparts. A disadvantage of both Graffiti and Unistrokes is that their alphabets are static. As users change applications, more or fewer characters may be required. For example, there is little need for a simple, arithmetic calculator to recognize characters other than digits, some punctuation, and operators. Reducing the size of the alphabet in these situations might also increase recognition accuracy. Graffiti has several characters that are composed of multiple strokes in order to allow a more natural writing style. A number of factors, however have limited the use of character recognition to this category of device, and has even, for some PDA users, proven too frustrating. Some factors that have limited wider acceptance of character recognition include:
Lower real-world accuracy rates than advertised
Fairly significant requirements for memory and processor speed
Perceived complexity to develop
Dependence on a stylized alphabet that users are forced to learn
T-Cube, developed at Apple Computers in about 1994, is a self-disclosing method for character input. Nine pie-shaped menus are shown on a screen (or tablet), each menu containing eight characters or character commands. Characters are input by “flicking” a stylus from the center of a pie to one of its eight characters. This approach significantly decreases the amount of stylus-to-pad time required to draw an arbitrary character since each drawing is a unidirectional flick. T-Cube also uses a variety of earcons to aid users in their writing. There are two basic problems that prevent T-Cube from being an acceptable form of character input in mobile or wearable devices. First, because of the visual aspect of the pies, eyes-free operation is impossible. Second, circular shaped menus have been shown to be difficult to scan with the eye for many users, reducing the speed at which they can be correctly accessed.
Two other notable self-disclosing systems that incorporate circular forms are Quikwriting and Cirrin. These two systems are quite similar. Each maps the characters of the alphabet about the perimeter of a circular or rectangular form. Characters are drawn by sliding a stylus from the center of the form to a character. By sliding rather than flicking, users can write entire words with one long stroke, sliding from character to character. These two systems suffer the same problems as T-Cube.
In about 2000, the Minimal Device Independent Text Input Method (MDITIM) was developed. MDITIM represented drawings of characters with a chain of the four cardinal directions. This coarse grain resolution allows for a wide variety of input devices other than a stylus and pad (e.g., touchpads, mice, joysticks and keyboards). As with Quikwriting and Cirrin, MDITIM allows users to draw entire words with a single, long stroke. The disadvantage of MDITIM is that the drawings representing characters are not intuitive and require a bit of memorization.
Some of the most robust recognizers in development today are based on elastic, structural matching. While recognition accuracy for these algorithms is very high (averaging 97-98%), their recognition speed can be slow. For example, a known algorithm is capable of recognizing only up to about 2.8 characters per second on an Intel 486 50 MHz processor. Another algorithm is reported to perform at rates up to about 3.03 characters per second on an Intel StrongArm processor (approximately 133 MHz). Other algorithms have an average speed of 7.5 characters per second running on a Sun SPARC 10 Unix workstation.
Thus, it can be seen that needs exist for improved systems and methods for character recognition. It is to the provision of improved systems and methods for character recognition meeting these and other needs that the present invention is primarily directed.
SUMMARY OF THE INVENTION
Example embodiments of the present invention provide an algorithm that, by means of an improved feature extraction technique, significantly reduces the computational overhead required to support robust, online character recognition, and permits the use of arbitrary alphabets. The algorithm can be made adaptive, so that it transparently modifies the parameters of the recognition algorithm to increase accuracy with a particular alphabet as used by a single user, over time. The system and method of the present invention is adaptable to a variety of applications and many types of devices. First, devices with very little computational capability can now incorporate character recognition, for example, a 20 MHz, 8-bit microcontroller using 40 K bytes of memory. Thus, toys, pagers, mobile phones, and many other small, inexpensive devices can take advantage of character recognition for command and data entry. Second, the alphabet independence of the algorithm makes it attractive for use by those who require application specific alphabets. Any set of marks can be assigned arbitrary meanings since the algorithm does not require the use of particular features of the Roman alphabet or any other. The algorithm can be made adaptive, so that the idiosyncrasies of the writing of any particular user can be incorporated and thus increase the accuracy of the recognition. Finally, this algorithm, in practice, appears to exhibit an immunity to noise that makes it forgiving of the writing style of someone writing in a noisy environment (such as on a subway, for example), or suffering from a tremor, nervous or motor condition.
Preferred forms of the invention provide a system and method for on-line character recognition that is fast, portable, and consumes very little memory for code or data. The algorithm is alphabet-independent, and does not require training beyond entering the alphabet once. The algorithm uses an “activity” value in performing feature extraction, to achieve a high rate of accuracy. The recognition is improved dynamically without further input from the user, and brings character recognition capability to classes of devices that heretofore have not possessed that capability due to limited computing resources, including toys, two-way pagers, and other small devices. An example embodiment of the invention achieves a recognition rate of 16.8 characters per second on a 20 MHz, 8-bit microcontroller without floating-point. The alphabet-independent nature of the algorithm, as well as the ease with which recognition may be optimized dynamically, makes it particularly well suited for enhancing the capability of persons with impaired motor skills to communicate by writing.
In one aspect, the invention is a method for character recognition, the method preferably comprising receiving input data representing an input character; extracting at least one feature from the said input data, the at least one feature including an activity metric; comparing the feature(s) extracted from the input data to an alphabet comprising a plurality of output characters; and selecting an output character based on the comparison of feature(s).
In another aspect, the invention is a method of recognizing an input character representation, the method preferably comprising collecting data corresponding to at least a portion of a character stroke; mapping the collected data to at least one directional code; and approximating the number of directional codes occurring in the character stroke portion.
In yet another aspect, the invention is computer executable software for implementing either of the above-described methods; computer readable media comprising said software; and/or a computer programmed to execute that software.
In yet another aspect, the invention is a system for recognizing an input character representation. The system preferably includes an input device for receiving and collecting data corresponding to at least a portion of an input character stroke; and a processor for mapping the collected data to at least one directional code, and approximating the number of directional codes occurring in the character stroke portion. In a further preferred embodiment, the system optionally further comprises memory for storing an alphabet of characters for comparison to collected data corresponding to at least a portion of an input character stroke.
These and other aspects, features and advantages of the invention will be understood with reference to the drawing figures and detailed description herein, and will be realized by means of the various elements and combinations particularly pointed out in the appended claims. It is to be understood that both the foregoing general description and the following brief description of the drawings and detailed description of the invention are exemplary and explanatory of preferred embodiments of the invention, and are not restrictive of the invention, as claimed.
BRIEF DESCRIPTION OF THE DRAWING FIGURES
FIG. 1 shows several examples of a handwritten character capable of recognition as the letter “G” according to an example embodiment of the present invention.
FIG. 2 shows three directional code mappings suitable for use in connection with example embodiments of the present invention.
FIG. 3 shows directional code representations of the letters “D”, “P”, “W”, “V” and “A” according to example embodiments of the present invention.
FIG. 4 shows activity regions and measures for the letter “W”, according to an example embodiment of the present invention.
FIG. 5 shows a screen print of an example user interface of a windows-based alphabet editor according to an example embodiment of the present invention.
FIG. 6 shows a screen print of example recognition, alphabet and character editing screens for a Palm OS-based editor according to an example embodiment of the present invention.
FIG. 7 shows front and back views of an 8-bit microcontroller-based system according to an example embodiment of the present invention.
FIG. 8 shows a character recognition system according to an example embodiment of the present invention.
FIG. 9 shows an example alphabet for use in connection with the method and device of the present invention.
FIG. 10 shows two example directional mappings for use in connection with the method and device of the present invention.
FIG. 11 shows an example mapped vector for the character “W” according to another embodiment of the present invention.
FIG. 12 is an example division of activity regions and determination of the activity metric for each activity region, according to an example embodiment of the present invention.
FIG. 13 is a screen print from a system according to an example embodiment of the present invention.
DETAILED DESCRIPTION
The present invention may be understood more readily by reference to the following detailed description of the invention taken in connection with the accompanying drawing figures, which form a part of this disclosure. It is to be understood that this invention is not limited to the specific devices, methods, conditions or parameters described and/or shown herein, and that the terminology used herein is for the purpose of describing particular embodiments by way of example only and is not intended to be limiting of the claimed invention. Also, as used in the specification including the appended claims, the singular forms “a,” “an,” and “the” include the plural, and reference to a particular numerical value includes at least that particular value, unless the context clearly dictates otherwise. Ranges may be expressed herein as from “about” or “approximately” one particular value and/or to “about” or “approximately” another particular value. When such a range is expressed, another embodiment includes from the one particular value and/or to the other particular value. Similarly, when values are expressed as approximations, by use of the antecedent “about,” it will be understood that the particular value forms another embodiment.
In example embodiments, the present invention is a computer-based system and method for recognition of single-stroke, handwritten characters or symbols. Unlike existing methods which are designed around a particular alphabet (e.g., Palm's Graffiti, Jot, or Unistrokes), this invention is designed to be robust enough to handle arbitrary characters and symbols so that each user can design their own alphabet or symbol library based on the way they already write with a pen or pencil. The method provides a parameter set such that recognition can be optimized based on each user's idiosyncrasies. All regular noise (i.e., wave or tremor oriented) is eliminated to the degree that what might appear as a large collection of scribbles (say from writing on a subway) is easily recognized based on temporal sequencing. Varying angles of writing are also handled quite well with a theoretical range of +/−180 degrees (dependent on the alphabet.) Letters which are graphically similar (e.g., ‘D’ and ‘P’) are handled without specific non-ambiguity code as found in most character recognition methods. Also, the storage and recognition of characters is designed such that both noise reduction and rotation are handled implicitly, affording much shorter code, and higher recognition speeds. This allows the method to be applied on relatively slow computing devices such as hand-held PDAs, and cheap microprocessors. The runtime recognition method is deterministic. This method can be used in conjunction with any pointing device (i.e., mouse, stylus, touch-pad, etc.)
The algorithm presented in this paper enables the use of a low-resolution mapping system that affords device independence. Example embodiments are implemented using both a stylus/pad combination and an inexpensive touchpad. In comparison to previously known systems, example embodiments of the system and algorithm of the present invention have produced an average recognition speed of 16.8 characters per second on a relatively resource limited implementation—namely a 20 MHz, 8 bit microcontroller.
Preprocessing
Typically, before recognition of characters is performed, a drawing of a character is preprocessed so that it can be described in the format native to the recognition algorithm. This generally affords greater recognition rates and allows instances of characters to be stored efficiently.
Resampling
When drawing a character, it is quite likely that the speed of the pen will vary over different portions of the stroke. For example, while drawing the capital letter ‘V’, the device capturing the pen movement will probably capture few, well separated coordinates along the left and right slopes, and many tightly packed coordinates around the base joint. This irregular distribution is typically due to the pen slowing down in anticipation of returning in an upward direction. Additionally, there is no guarantee that the same number of coordinates will be captured each time the same character is drawn.
To deal with these issues, the algorithm of the present invention preferably resamples the drawing of a character by linearly interpolating N+1 Cartesian coordinates into a vector R=(r 1 , r 2 , . . . , r N+1 ) over the length of the drawing, so that line segments between consecutive coordinates are of equal length and both the first and last coordinates are the same as those captured in the original drawing. As well as helping to insure that each R is of constant size, spatially resampling a drawing in this manner also aids in dampening regular noise and tremor and has been shown to benefit recognition. FIG. 1 shows four example drawings of the letter ‘G’ that are each correctly classified by an example algorithm according to the present invention. The leftmost drawing is very close to the character class for ‘G’ in the test alphabet. The next two examples in the figure were drawn with exaggerated regular noise. Proper classification of these types of drawings is in part due to the noise reduction that resampling provides. Some noise that is introduced into drawings of a character is not regular, say noise that occurs as the result of writing on a bus. Resampling cannot be relied on to eliminate this kind of noise. The rightmost drawing of the figure has several instances of this type of noise and is recognizable by the use of the feature extraction method described herein, which dampens the noise that spatial resampling typically cannot eliminate.
Directional Codes
While size and position of a drawing on the writing surface could be relevant in enhancing recognition, this algorithm of the present invention preferably emphasizes the direction of pen movement over the course of the stroke. This provides for eyes-free use, where a user is likely to draw the same character in many different locations on the writing surface, as well as in varied size. Each consecutive coordinate pair (r i , r i+1 )εR is used to create a vector from the first element of the pair to the second. This vector is then mapped to one of a finite number of directional codes stored in a vector D=<d 1 , d 2 , . . . , d N > where d i =DirCodeMapping(r i , r i+1 ). Freeman's chain code (See Herbert Freeman, Computer Processing of Line - Drawing Images , ACM Computing Surveys, 6(1):57-97, March 1974, hereby incorporated herein by reference), which divides vector space into the eight cardinal directions E, NE, N, NW, W, SW, S, and SE (enumerated 0 , . . . , 7 respectively), as in FIG. 2 ( a ), is frequently used for this. Since the present algorithm is intended to work with custom alphabets, a generalized direction mapping (based on Freeman's code) preferably is used, so that certain ranges of vector space can be emphasized over others with respect to a particular alphabet and user.
Additionally, these ranges can be optimized over an alphabet to further separate characters, thereby improving recognition. For example, if a particular user draws the vertical and horizontal portions of characters in an alphabet in a close to vertical and horizontal manner (with only rare deformations), the ranges for directions 0 , 2 , 4 , and 6 , in Freeman's mapping could be reduced as in FIG. 2 ( b ). Further, if few characters in an alphabet require W, SW or S pen movements, the directional mapping could be altered to allow greater discrimination in the other directions, as in FIG. 2 ( c ). Various methods may be utilized for automating the creation and optimization of directional code mappings, and comparing the recognition rates of these mappings to the traditional Freeman mapping.
Activity
While a vector of Freeman's chain codes could be used alone to describe a drawing of a character, generally no single vector element can be used to derive information about the overall drawing since deformations tend to be localized. The algorithm of the present invention addresses this issue by introducing a feature extraction metric that further compresses the information gained from directional codes and provides insight into the entire drawing in a general manner, as well as into important subregions. This metric is designated “activity” and may be defined over a vector D as follows: Activity ( D ) = Length ( D ) Dominance ( D )
where Dominance(D) is the frequency of the dominant (most common) directional code. The activity metric is intended to approximate (quite loosely) the number of unique directional codes required to describe a given vector. If the directional code mapping used enumerates 8 unique values (as in Freeman's chain code), the value of activity over an arbitrary vector of these codes can range generally from 1.0 (only one directional code is present) to 8.0 (all possible codes appear in equal frequency). For example, the directional code vector < 0 , 0 , 0 , 0 , 0 , 0 , 0 , 0 , 1 , 0 , 0 , 7 > has an activity of 1.2. While there are clearly three distinct directional codes in the vector, the non-0 directions are both isolated and could likely be considered noise. The activity measured suggests that the drawing has a single dominant direction with few deformations, thereby significantly dampening noise that remained after spatial resampling. Stating the vector has three different directions, 0 , 1 and 7 , severely undermines the dominance of 0 and esthetically over-emphasizes the presence of 1 and 7 .
In order to better understand the reasoning behind the activity metric, a brief discussion of the environment for which the algorithm of the present invention was developed will be provided. Originally, an algorithm for online character recognition was needed for use in small, low powered, wireless devices for note taking in an electronic classroom environment. The algorithm would preferably function with a variety of alphabets, and would preferably include the capability to switch between alphabets and to allow modifications or additions at any time. This would allow those individuals with shorthand skills to accelerate their note taking and additionally provide the capability for one to take notes using characters from a non-Roman alphabet such as Cyrillic.
The runtime complexity of elastic matching was found to be too great for some potential target processors (such as a Zilog Z80), in part due to the multiple levels of deformation. Additionally, similar characters sometimes required the algorithm designer to develop code specifically to distinguish them. For example, the character ‘D’ could be described as a line in direction N ( 6 ) followed by a clockwise curve starting in direction E ( 0 ) and ending in direction W ( 4 ). Unfortunately, the same description could be used to describe the character ‘P’. To resolve conflicts between the two characters, code would be added to calculate the ratio of the height of the curve to the height of the line. Were the ratio above some threshold, the ‘P’ is recognized, otherwise ‘D’ is recognized. This generally eliminates the possibility of modifying an alphabet after deployment. For example, consider the directional code vectors representing ‘D’ and ‘P’ as shown in FIG. 3 . The activity measured over the ‘D’ is approximately 2.91, while the measure of ‘P’ is 1.6. The ‘P’ is primarily a line in a single direction with deformations (the curve at the end) totaling half the line's length, whereas the ‘D’ is mostly curve—thereby a higher activity. Additionally, notice that the curve in ‘P’ adding 0.6 to the straight line activity (1.0) is consistent with the relationship between the heights of the line and curve ratio. It is notable that the activity metric does not compare the heights of lines and curves; rather, it provides a separation measure, for most such problematic character combinations (e.g., ‘u’ and ‘y’). No instance-specific code is required. FIG. 1 shows Directional Code representations of the letters ‘D’, ‘P’, ‘W’, ‘V’ and ‘A’.
Activity Regions
In order to further increase the usefulness of activity, it is preferable to measure the activity of portions of a drawing rather than only measuring over the entire length of the stroke. Activity regions define these directional subvectors. To this point, only the region spanning the length of the stroke has been considered. It has been found beneficial to character recognition to additionally measure activity over regions covering the first and second halves of the drawing, as well as each quarter of drawing. This totals seven activity regions, and is depicted in FIG. 4 . While the number and location of regions used for a given implementation or alphabet may differ—or perhaps even evolve with usage, these seven regions have been chosen for usefulness with a variety of alphabets. For example, the activity measure over the full drawings for ‘W’ and ‘V’ in FIG. 3 are both 2.0, which does enable differentiation. Measuring activity on the first halves of each of these characters, 1.6 and 1.0 respectively, and further on the remaining regions more clearly separates the two. Additionally, since one region may cover a greater portion of the drawing than another, the activity measured over each region can optionally be weighted or biased by some selected scalar to emphasize the importance of a particular region in distinguishing characters of the alphabet.
Augmenting Activity with Directional Code Information
Regardless of the general success that is achieved using activity over multiple regions of a drawing, activity may fail to aid recognition under certain conditions. Take, for example, the seven activity regions on the characters ‘A’ and ‘V’ in FIG. 3 —they are all identical. In fact, no region can be defined such that the activity for both characters is not equivalent. This means that activity alone cannot distinguish these two character drawings. The reason for this failure is that activity, while being a measure of direction, in no way reflects direction. A drawing with a full activity of 1.0 has only one direction code present after spatial resampling. What cannot be determined from activity is the actual direction of the stroke. To resolve this issue, elements of the directional codes are preferably maintained along with activity so that recognition between these classes of characters is possible.
Recognition
Prior to using the recognition algorithm, an alphabet to recognize must be provided. It is envisioned that users will either create alphabets from scratch or customize existing alphabets. To prepare a new (custom) alphabet, the user preferably draws each character of the desired alphabet at least once for the recognition system, helping to insure that the character classes in the alphabet contain the irregularities introduced by a given individual's writing style. This affords improved recognition for the user since the irregularities can be used to further separate characters rather than “test” the classifier in spite of them. Additionally, this method of alphabet generation allows the uses of non-Roman characters. This may be tremendously beneficial, not only to users who wish to include such characters, but to individuals with motor or nervous disorders as well. These individuals often perform the drawing of Roman characters with great irregularity. The described character representation in the alphabet already provides robust recognition capabilities for high noise environments, as can be seen in FIG. 1 . Accounting for noise that is likely to exist in each drawing within the alphabet can only aid recognition.
Each character drawing to be included in the alphabet is preferably defined by an activity vector, a directional code vector and the character associated with the drawing. The inclusion of the directional code vector compensates for activity's lack of directional information. Care should be should taken when determining the length of each vector to ensure that both direction and activity have appropriate influence in the character classes. In example implementations described herein, drawings were preprocessed to a directional vector of length 32 , and the resulting vector included as the directional code vector in the character. The activity vector used in complement is length 7 over the regions described above. To ensure that the activity vector has approximately the same total influence as the directional vector, a scalar bias of 1.222 was applied to each activity measure upon its calculation.
Once an alphabet is constructed, the recognition process is undertaken. A new drawing is introduced to the system and described as a directional code and activity vector pair (as above). This character is then compared against each member of the alphabet as a point in multi-dimensional hyperspace (39 dimensional space in the example implementations). A Euclidean-squared distance is used in example embodiments to measure the variance of a drawing and members of the alphabet. In alternate embodiments, other metrics may be equally useful. Classification over the calculated distances can be implemented with a K nearest-neighbor voting mechanism, or with other appropriate selection mechanisms. The set of K closest character classes is preferably found with respect to a given drawing, and the character with the most (either instance or weight-based) influence over the set is recognized.
Implementations and Results
Selected embodiments of the described algorithm have been implemented on three example platforms: Intel x86, Motorola Dragonball (Palm), and Rabbit Semiconductor 2000, which is a Z-80 compatible 20 MHz, 8-bit microcontroller with 128 K SRAM, 256 K flash, and onboard serial I/O. Various other systems, including without limitation a Parallax BASIC-Stamp and the like, also are readily adaptable for implementation of this algorithm in similar fashion.
The example Intel implementation was done using Borland C++ Builder on Windows 98. It consisted of an alphabet creation/maintenance application and a notepad type application for testing recognition. The primary interface of the editor is shown according to an example embodiment in FIG. 5 . Each character was described as a length 32 vector of directional codes and a length 7 activity vector. The direction mapping used was the Freeman mapping. To balance the influence of direction and activity, a scalar bias of 1.222 was applied to activity measure upon its calculation. This value was determined in the following manner: the maximum difference between two Freeman codes is 4, and between two Freeman activities the maximum difference is 7.0, thus the balanced Euclidean-squared influence equation is:
7(7.0×Bias) 2 =32(4) 2
and Bias≈1:222. A comparison was done to measure the pairwise separation between characters in a test alphabet using:
1. Nearest-neighbor distance calculation in the 32-dimensional space of directional codes;
2. Same Euclidean distance calculation in 39-dimensional space of directional codes and activity; and
3. Euclidean-Squared distance calculation in 7-dimensional space of only activity.
The use of both Freeman directions and activity levels in calculation of nearest neighbor with activity level weighted by the above bias provided significantly better separation of similar characters (and hence better overall recognition) than the use of either directional codes or activity levels alone.
The small size of the Windows code (only about 149 lines of C++, excluding the code for the user interface) and the small data structures required (less than about 30 K of data) indicated the ability to implement the algorithm on much smaller, slower processors. Given that handwriting recognition is now a common feature of PDA's, a fixed-point implementation was developed for Palm OS devices. The parameters used for this example implementation of the algorithm were identical to those in the Windows implementation other than the modifications required to scale for fixed point. The Palm implementation required about 35 K bytes for code and data, and about 6 K of persistent storage for an alphabet of 26 characters, space and backspace (all data is unpacked). The recognition screen and alphabet editor screens from the Palm application are depicted in FIG. 6 . As the bulk of time spent in recognizing a character is typically in the calculation of distance between members of the alphabet, this implementation was also optimized by making two intermediate checks of the total distance. Since the variance range for an activity measure is twice that of a directional code, the activity vector is used to form the initial squared sum and a check was made after 12 and 24 dimensions of the direction vector. This allows for terminating the distance calculation if the partially calculated distance is already greater than the total distance to the closest character found so far. This resulted in a 22% speed increase at recognition time, based on internal clock measurements.
An 8-bit microcontroller implementation on a 20 MHz processor with very small onboard SRAM and flash memories proved the viability of the algorithm for adding character recognition capability to very inexpensive devices. The input device was a Fellowes Touch Mouse and the output device was a 2×20 line LCD display. Code size was about 1349 lines of Dynamic C (about 332 lines for recognition code). Including an alphabet comparable to that used in the Palm OS implementation, the binary image for this application is about 40 K bytes. No additional memories are required at runtime as no dynamic memory allocation is used. Thus, a processor with a 64 K address space is adequate. Measurements using the onboard timer on the Rabbit Semiconductor 2000 indicate a maximum character recognition speed on this very slow device of about 16.8 characters per second, significantly faster than humans are capable of drawing characters. The hardware is shown front and back in FIG. 7 . It should be noted that most of the board pictured is an unused prototyping area—the only chips used are the microcontroller, an RS232 driver and an inverter. Due to the limited interface capabilities of this implementation, the alphabet editor written for the Windows environment was used to facilitate the creation of an alphabet. A Perl script was written to convert the files generated by the editor to the binary format required by the Rabbit. These files were then downloaded into flash memory using the Rabbit field utility.
Thus, it can be seen that the method of the present invention is suitable for implementation in a variety of devices, including relatively computationally weak devices. As a result, handwriting recognition capability can be added to any device possessing an 8-bit microcontroller with 64 K of program and data storage capability for the cost of the input device, which is likely to be only a few dollars in OEM quantities. The method permits the user to customize an alphabet to account for personal preferences or limitations in motor skills, without the need for post-deployment design. The recognition accuracy of the algorithm is comparable to or better than that of the algorithms currently shipping with Palm OS and Pocket PC devices.
Example Embodiments
The on-line character and symbol (collectively referred to herein as “Character”) recognition method of the present invention will now be explained further with respect to the following embodiments, which are provided as examples only, and are not intended to be limiting. The user preferably provides a plurality of Inputs with the intent of building an Alphabet, whereupon the Alphabet is generated with a set of determined Parameters. Had an Alphabet been generated once before without change to these Parameters, it may rather be pulled from a storage. The user may then offer Inputs, one at a time, whereupon each Input is digitized from its Raw Vector to a representative Tuple with respect to the Parameters of the Alphabet. Said Tuple is then compared to each Tuple in the Alphabet. The Tuple in the Alphabet which is most sufficiently equivalent to said Tuple, considering Bias in the Alphabet, becomes the Output.
One or more external devices (collectively referred to herein as “Pointers”) from which (X,Y) coordinate data may be collected and organized in a sequenced, temporal fashion are provided. Pointers provide a means for a user to “draw” a Character in some two-dimensional space. A storage (referred to herein as the “Alphabet”) containing a plurality of Tuples representing Characters drawn by the user to provide a point of comparison, so that Inputs may be recognized by finding a sufficiently equivalent Tuple in the Alphabet. The Alphabet also contains Parameters. Parameters are global to all Tuples in Alphabet as well as to Inputs to be recognized against Alphabet.
A vector (referred to herein as “Activity Region Vector”) of, for example, R elements storing the bounds of R Activity Regions in Mapped Vector is determined. A vector (referred to herein as “Activity Vector”) of R Activities is determined. A scalar vector (referred to herein as “Bias”) of K+R elements is determined. A vector (referred to herein as “Code Vector”) of X elements is determined. A vector (referred to herein as “Distance Vector”) of equal length to Raw Vector is determined. A vector (referred to herein as “Mapped Vector”) with K elements is determined. A vector (referred to herein as “Raw Vector”) of (X,Y) coordinate pairs is determined. A vector (referred to herein as “Substroke Vector”) of, say K+1, (X,Y) coordinates is determined. An enumerable set of X directional codes (referred to herein as “Codes”) is determined. A distance metric is determined a priori. A metric (referred to herein as “Activity”) for evaluating some Activity Region is determined. A tuple representation (referred to herein as “Tuple”) of a Character comprising a Mapped Vector and Activity Vector is determined. A tuple (referred to herein as “Parameters”), comprising K, a Directional Mapping, R, and a Bias is determined. Any change in Parameters initiates an update of each Tuple in Alphabet with respect to the corresponding Substroke Vector. Parameters may be varied upon creation of Alphabet so as to optimize recognition with respect to a given state of Alphabet.
A method for mapping (referred to herein as “Directional Mapping”) a directional vector to Codes is also provided. A plurality of Characters are drawn with Pointers (referred to herein as “Input”), which the user wishes to have recognized. A plurality of substrings (referred to herein as “Activity Regions”) of Mapped Vector are defined. Each Activity Region preferably comprises at least one element. A means (referred to herein as “Output”) of returning a recognized Tuple in Alphabet as a Character to the user is preferably provided.
The means for determining Activity over some Activity Region in Mapped Vector is preferably as follows: a Code Vector of X elements is determined over Activity Region where element x of Code Vector is the number of instances of Code x in said Activity Region. The element of Code Vector of greatest value is D. The length of said Activity Region in Mapped Vector is N. Activity, then, for said Activity Region in Mapped Vector is N/D.
The above-described composition is preferably such that for each element in Raw Vector, a corresponding distance measure may be acquired and stored in Distance Vector. The first element of Distance Vector is preferably always 0 . Each element of Distance Vector after the first is the distance (as prescribed by the above metric) between the corresponding element in Raw Vector and the previous element in Raw Vector added to the previous element of Distance Vector. By this, each element of Distance Vector represents the distance (as prescribed by the above metric) into the user's Character with respect to each corresponding element of Raw Vector. The last element of Distance Vector is the total length of the Character with respect to the above distance measure.
The composition of the Substroke Vector, where the coordinates of Substroke Vector are interpolated/extrapolated from Raw Strokes and Distance Vector, is preferably carried out such that the distance (as prescribed by the distance metric) between each element of Substroke Vector (save the first element) and the previous element of Substroke Vector are equivalent. The first element of Substroke Vector is equivalent to the first element of Raw Vector. The last element of Substroke Vector is equivalent to the last element of Raw Vector. The Mapped Vector is composed of K elements, where each element k of Mapped vector is the Directional Mapping of the vector from element k of Substroke Vector to element k+1 of Substroke Vector. The Activity Vector is composed of R Activities, where each element r of Activity Vector is the Activity measure of the Mapped Vector substring whose bounds are stored in element r of Activity Region Vector. The composition of Bias of K+R elements, where the first K elements of Bias correspond to the K elements of Mapped Vector and the last R elements of Bias correspond to the R elements of Activity Vector. Bias is used to accentuate those elements of Tuple's vector that are of distinguishable importance to Alphabet.
The composition of Raw Vector is defined by the user drawn Character generated by manipulating Pointers, having the character represented for the method as Raw Vector, whose (X,Y) coordinates are temporally sequenced such that the first element of the Raw Vector represents the initial point of the character, and the last element of the Raw Vector represents the terminating point of the character. Raw Vector is a single, pseudo-stroke representation of the user's character, which may consist of one or more actual drawn strokes (e.g., the character ‘T’ is typically drawn with two strokes while ‘O’ is typically drawn with only one).
The system of the present invention follows the basic premise that an Alphabet is generated and stored based on Parameters, and a user then draws Inputs which are recognized by the process and returned as Outputs. What is key is that Parameters may be chosen a priori, empirically, heuristically (so as to optimize recognition on Alphabet), and that Alphabet could be designed and generated by an individual for deployment to multiple users, or by an individual user for there own personal use.
An example embodiment of the system of the present invention is shown in FIG. 8, for implementation on a desktop computer 10 . Pointers were a radio sensitive tablet 12 with stylus 14 and a mouse 16 which could be used interchangeably. A user drew 29 Characters including each of the 26 capital letters, a symbol for the “Space” Character, a symbol for the “Backspace” Character, a symbol for the “Carriage Return” Character, and a dot symbol for the “Period” Character to create an alphabet as shown in FIG. 9 . Since the user was familiar with Palm Graffiti, the alphabet generated was very similar to graffiti with only several changes (e.g., ‘B’, ‘D’, ‘F’, ‘G’, ‘Q’, ‘V’, and ‘Y’). A Distance Metric (Euclidean distance) was chosen. A Directional Mapping to eight Codes was chosen (FIG. 10 a ). The length of the Substroke Vector was 33. Consequently, the length of Mapped Vector (FIG. 11) was 32. The length of Activity Region Vector (FIG. 12 a ) and Activity Vector (FIG. 12 b ) were 7. The Bias vector contained the scalar “1” for the first 32 elements and the scalar “1.25” for the last 7. Alphabet was then generated as described above and stored in a file local to the desktop computer. Sufficient equivalence of Tuples was performed using “Single Nearest Neighbor” in a 39 dimensional Euclidean hyper-space. A desktop application was written where the user could provide Inputs, and Outputs were provided on the screen (FIG. 13 ).
In an alternate embodiment of a system for implementation on a desktop computer 10 , pointers were a radio sensitive tablet 12 with stylus 14 and a mouse 16 (FIG. 8) which could be used interchangeably. A user drew 29 Characters including each of the 26 capital letters, a symbol for the “Space” Character, a symbol for the “Backspace” Character, a symbol for the “Carriage Return” Character, and a dot symbol for the “Period” Character to create an alphabet (FIG. 9 ). Since the user was familiar with Palm Graffiti, the alphabet generated was very similar to graffiti with only several changes (e.g., ‘B’, ‘D’, ‘F’, ‘G’, ‘Q’, ‘V’, and ‘Y’). A Distance Metric (Euclidean distance) was chosen. A Directional Mapping to eight Codes was chosen (FIG. 10 b ). The length of the Substroke Vector was 33. Consequently, the length of Mapped Vector (FIG. 11) was 32. The length of Activity Region Vector (FIG. 12 a ) and Activity Vector were 7. The Bias vector contained the scalar “1” for the first 32 elements and the scalar “1.727” for the last 7. Alphabet was then generated as described above and stored in a file local to the desktop computer. Sufficient equivalence of Tuples was performed using “Single Nearest Neighbor” in a 39 dimensional Euclidean hyper-space. A desktop application was written where the user could provide Inputs, and Outputs were provided on the screen (FIG. 13 ).
Another embodiment of the system of the present invention is implemented on an 8-bit microprocessor 20 (such as the Rabbit Semiconductor 2000, a Zilog Z-80 processor system, A Parallax BASIC-stamp system, etc.), with a Pointer constructed of a touch-sensitive finger-pad 22 (FIG. 7 ). A user drew 29 Characters including each of the 26 capital letters, a symbol for the “Space” Character, a symbol for the “Backspace” Character, a symbol for the “Carriage Return” Character, and a dot symbol for the “Period” Character to create an alphabet (FIG. 9 ). Since the user was familiar with Palm Graffiti, the alphabet generated was very similar to graffiti with only several changes (e.g., ‘B’, ‘D’, ‘F’, ‘G’, ‘Q’, ‘V’, and ‘Y’). A Distance Metric (Euclidean-squared distance) was chosen. A Directional Mapping to eight Codes was chosen (FIG. 10 b ). The length of the Substroke Vector was 33. Consequently, the length of Mapped Vector (FIG. 11) was 32. The length of Activity Region Vector (FIG. 12 a ) and Activity Vector were 7. The Bias vector contained the scalar “1” for the first 32 elements and the scalar “1.727” for the last 7. Alphabet was then generated as described above and stored in a memory on the Rabbit Semiconductor 2000. Sufficient equivalence of Tuples was performed using “Single Nearest Neighbor” in a 39 dimensional Euclidean-squared hyper-space. The touch-sensitive finger-pad 22 was used to provide Inputs, and Outputs were stored in memory on the Rabbit Semiconductor 2000 and displayed on a small LCD 24 .
Another embodiment of the system of the present invention is geared toward individuals with a motor disability of some variety (e.g., Parkinson's disease, MS or MD). The system is substantially similar to one of the above-described embodiments, with the exception that the user provides an Alphabet that is visually non-similar to a known alphabet (e.g., Roman, Cyrilic).
Still another embodiment of the system of the present invention is geared toward individuals in active environments (e.g., subways, helicopter, etc.). The system is substantially similar to one of the above-described embodiments, with the exception that an Alphabet is provided that is visually non-similar to a known alphabet (e.g., Roman, Cyrilic) so that Inputs are more reliably recognized.
Another embodiment of the system of the present invention is substantially similar to one of the above-described embodiments, with the exception that the user provides an Alphabet distinct to her needs, a heuristic (e.g., a genetic algorithm) alters Parameters and regenerates Alphabet accordingly with the intent to separate Characters in Alphabet in order to optimize recognition on Alphabet.
A more efficient data structure may be developed for storing the alphabet, using the activity level for the whole stroke to organize the characters into a search tree. This may improve the recognition time yet further, as it replaces a linear search with a potentially logarithmic one. Additionally, heuristics may be developed to optimize the number of activity regions and directional codes, the placement and lengths of the activity regions, the scalar bias of the activity levels versus the directional codes in the distance calculation, and the angles defining the boundaries between adjacent directional codes. Dynamic modification of all the above parameters may be implemented using the “backspace” character as in indication of incorrect recognition. And alternate distance metrics may be employed, in addition to or instead of those discussed herein.
While the invention has been described with reference to preferred and example embodiments, it will be understood by those skilled in the art that a number of modifications, additions and deletions are within the scope of the invention, as defined by the following claims.
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An “activity”-based system and method for on-line character recognition that requires reduced amounts of memory for code or data, is alphabet-independent, and can be trained by entering the alphabet once. The alphabet-independent nature of the algorithm, as well as the ease with which recognition may be optimized dynamically, makes it particularly well suited for writing in noisy environments (e.g., mobile or on a subway) or by persons with impaired motor skills or nervous conditions.
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BACKGROUND OF THE INVENTION
In scientific studies and various applications, there is a need for a device to detect very small displacements in the position of an object with respect to a reference. Some state of the art methods to accomplish the foregoing include techniques associated with piezoresistive bridges, F. M. microphones, laser interference and fiber optics. These methods differ from one another in their operating power requirements, linearity and resolution of the desired data in low signal to noise environments. Characteristically, all of these methods involve fairly high voltage and/or current for operation, making them unsuitable in applications where only very low power is available. The need exists for a displacement transducer which can operate at low power levels, that is, of the order of 100 microamperes, has high linearity over a large dynamic range and is capable of resolving displacements down to a few hundred Angstroms. The acoustic detector of the present invention meets these criteria.
SUMMARY OF THE INVENTION
In accordance with the present invention, the displacement detecting device utilizes a self oscillating piezoelectric crystal as a coherent oscillator and audio source. Moreover, the oscillator is a Q dependent receiver for its own audio component reflected by the object or member whose displacement is to be detected. As the phase of the reflected acoustic energy varies in response to the position of the member with respect to the position of the crystal, the efficiency of energy storage within the latter is varied. Thus action results in a change in the amplitude of the oscillations. The waveform envelope produced by the modulation of the oscillations is detected by electronic circuit means. The resulting signals are then amplified, corrected for voltage offsets and outputted as a DC voltage having instantaneous amplitudes indicative of the displacement of the member.
The device of the present invention is characterized by its ability to transduce the position of a member comprised of material which may be electrically conductive or nonconductive and which is placed in proximity to a simple radio crystal which also serves as a position reference. Concomitant with its displacement detection function, the device also finds application in detecting variations in pressure, temperature, and the refractive index of gases as a function of either of the latter, where the instantaneous position of a diaphragm-like member with respect to the oscillating crystal is a function of the foregoing parameters.
Other features and advantages of the present invention will become apparent in the detailed description of the invention which follows.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a combined pictorial representation and electrical schematic of the acoustic interference displacement detector system of the present invention.
FIG. 2 is an optico-acoustic radiometer which may be utilized in the system of FIG. 1.
DESCRIPTION OF THE PREFERRED EMBODIMENT
With reference to FIG. 1, the displacement detecting system of the present invention comprises the transducer 10 and the accompanying electrical circuit 12. Transducer 10 includes a housing 14 formed of electrically conductive material which is connected to the circuit reference or ground potential. A fundamental radio frequency crystal 16 having respective orthogonal mechanical and electrical axes 18 and 20, is situated within housing 14. Mechanical support for the crystal 16 is provided by electrical conductors or wires 22. The latter also carry the signal oscillations from the crystal 16 to circuit 12 via connectors 24 placed within insulating member 26 disposed in housing 14.
An object 28 depicted diagrammatically in FIG. 1 represents the member whose displacement with respect to crystal 16 is to be monitored.
Circuit 12 comprises an N channel field effect transistor (FET) 30, a Bifet having sections 32a and 32b, a pair of CMOS or JFET input operational amplifiers 34 and 36 and an analog switch 38.
In operation, the system employs a self oscillating crystal 16 as a coherent oscillator with an air acoustic reflecting path along the mechanical or acoustic axis 18 of crystal 16. Sufficient AC coupling to implement Miller effect oscillations is provided by capacitor 40, in the highly Q dependent oscillator network which includes FET 30. Acoustic energy is transmitted from the crystal 16 and reflected by object 28 which is oriented normally to the mechanical axis 18 of the crystal. The object 28 may be formed of electrically conductive or nonconductive material and may be external to housing 14 (as shown in FIG. 1) or may be located within the housing. As the phase of the reflected acoustic energy is varied by the position of object 28, the efficiency of energy storage within crystal 16 is varied. This results in a variation of the amplitude of oscillation of crystal 16 and a consequent modulation of the AC amplitude of the electrical signal at the source electrode of the oscillator N channel FET 30. In effect the crystal oscillator circuit represents an interferometer, having the usual reference path against which the interference is to be measured, and an active path. By limiting the power dissipation in the tanking mode of the crystal through limited drive energy, the reference path may be thought of as being folded around into itself. This arrangement produces an analog device in which the crystal output may be conveniently modulated, and in which, extreme sensitivity to the displacement of an object and its reflected acoustic energy is achieved.
The oscillator signal consisting of an AC wave disposed on a DC level, appearing on the source electrode of FET 30, is coupled via capacitor 42 to the gate electrode of an N channel JFET section 32a of the Bifet. Section 32a functions as a positive edge detector and in effect exhibits substantially the properties of an "ideal" diode. That is, the variations in the amplitude of oscillations is translated by Bifet section 32a into a variation in the DC voltage of a positive envelope detected voltage. The latter appears on the source electrode of section 32a and is integrated by virtue of capacitor 44. Moreover, the high frequency AC component of the oscillator is almost eliminated from the positive envelope. A further stage of low pass filtering in resistor 46 and capacitor 48 completes the elimination of the high frequency oscillations.
Amplification of the low frequency components of the signal induced by extremely small displacements in the position of object 28 is accomplished by operational amplifier 34--the output of the low pass filter being applied to the "+" terminal of the amplifier. The DC nulling of all voltage offsets, input bias current induced voltages, and input offset current induced voltages is accomplished by a feedback loop coupling the output terminal of amplifier 34 to its "-" input terminal. Included in the feedback loop are a resistor 50 connecting the output terminal of amplifier 34 to one terminal of an analog switch 38. The other switch terminal is connected to the "+" input terminal of operational amplifier 36. The analog switch 38 responsive to control signals derived for example, from a microprocessor (not shown) provides initilization of the detector, that is, establishment of quiescent circuit conditions in minimal time. In addition, during detector operation, analog switch 38 sets the time constant for the output signal V O . Thus, if little displacement activity is present, the duty cycle or ON time of the switch may be lengthened by the control signals, and the time constant increased. Conversely, in periods of high activity, short time constants are provided. A storage and hold capacitor 52 is coupled between the "+" input terminal of operational amplifier 36 and the circuit ground. The value of capacitor 52 is chosen to be sufficiently large so that the present system may be utilized as a DC coupled displacement detector with a fast level correction required every few tens of seconds.
The output of operational amplifier 36 is applied to the gate electrode of section 32b of the Bifet. The signal appearing on the source electrode of the latter section is applied to the "-" terminal of operational amplifier 34. The DC signal V O appearing on the output terminal of amplifier 34 is a function of the instantaneous position of object 28 with respect to crystal 16.
FIG. 2 represents in diagrammatic fashion an optico-acoustic radiometer 54. Such a radiometer operates upon the principle of thermalization of infrared radiation within an absorbing gas system. The detector system of the present invention described hereinbefore has been utilized with such a radiometer.
Briefly, the radiometer 54 of FIG. 2 is comprised of respective inner and outer electrically conductive housings 56 and 58. The relative position of the housings with respect to each other is adjustable by the mating threads 60. A diaphragm 62 functionally equivalent to the object 28 in FIG. 1 is supported at one extremity of outer housing 58 by retaining ring 64. A fundamental radio frequency crystal 66 having respective orthogonal mechanical and electrical axes 68 and 70, is situated within the housings. Mechanical support for the crystal 66 is provided by electrical conductors 72 The latter also carry the signal oscillations from the crystal 66 via connectors 74 placed within the insulating member 76 to a circuit substantially the same as circuit 12 of FIG. 1. An entry port controlled by valve 78 is provided for the admission of an infrared energy absorbing gas, such as carbon dioxide.
The diaphragm 62 represented in FIG. 2 is assumed to be transparent to both visible and infrared radiation, thereby providing the means for radiation admission within the housing and for the resolution of the level of infrared energy admitted. As the temperature of the gas within the housing increases due to an increase in the impinging radiation, the diaphragm 62 expands outward by virtue of the miniscule increase in internal pressure within the housing. This shifts the acoustic interference phase at the crystal 66 and consequently the amplitude of oscillations, in the same manner as taught hereinbefore. The peak voltage change is subsequently detected as a DC output as described in connection with circuit 12 of FIG. 1.
In an actual operative embodiment of the invention, a 184.506 Khz. Reves-Hoffman fundamental radio crystal was used. Standard 1/8 wavelength minimum to maximum amplitude variations were obtained as the position of the reflective object is passed through the 1/8 wavelength pattern. For the crystal identified above, a wavelength of 1.817 mm yielded a 1.4 volt shift in amplitude for a 0.22714 mm displacement--the reflective 1/4 wavelength distance. The analog switch 38 of circuit 12 is a section of the RCA 4066. It should be understood that the foregoing components and parameters have been included solely for purposes of example and are not to be construed as limitative
Finally, it should be apparent from the foregoing description of the invention and its mode of operation that there is provided an improved displacement detector. The device performs its detection function with a degree of resolution and stability suitable for a wide range of applications. Moreover, the device utilizes a minimum number of components and provides for very low power operation.
It should be understood that changes and modifications of the arrangements described herein may be required to fit particular operating requirements. These changes and modifications, in so far as they are not departures from the true scope of the invention, are intended to be covered by the following claims.
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The present disclosure describes a system for detecting very small displacements of an object with respect to a self oscillating piezoelectric crystal by means of acoustic interference at the crystal. Acoustic energy transmitted by the oscillator is reflected by the object, and movement of the latter causes changes in the phase of the reflected energy. Such changes in turn result in variations in the amplitude of the oscillations. An electronic circuit responsive to the last mentioned variations generates output signals indicative of the instantaneous position of the object.
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FIELD OF THE INVENTION
[0001] The present invention generally relates to a method and apparatus for underwater pelletizing and subsequent drying of polyethylene terephthalate (PET) polymers. More specifically, the present invention relates to a method and apparatus for underwater pelletizing PET polymers and subsequent drying the PET polymer pellets in a manner to self-initiate the crystallization process of the PET particles and produce pellets having a crystalline structure rather than an amorphous structure.
BACKGROUND OF INVENTION AND PRIOR ART
[0002] Underwater pelletizing systems for producing pellets of polymeric or other plastic materials has been known for many years. The starting materials such as plastic polymers, coloring agents, additives, fillers and reinforcing agents, and modifiers, are mixed in kneaders. In the process, a melt is produced which is extruded or pressed through dies to form strands which are immediately cut by rotating cutter blades in the water box of the underwater pelletizer. Water with or without additives is continuously flowing through the water box to cool and solidify the polymer strands and pellets and carry the pellets out of the water box through transport piping to a dryer, such as a centrifugal dryer, where the water is removed from the pellets.
[0003] For quite some time, the polymer industry has sought to process PET polymers into a pellet shape using underwater pelletizer systems. The major drawback of using underwater pelletizing for processing PET into pellet shapes is the typically amorphous condition of these pellets when they leave the dryer of the underwater pelletizing system. The amorphous nature of the resulting pellet is caused by the fast cooling of the PET material once introduced into the water flow in the water box of underwater pelletizer and while the water and pellet slurry is being transported by appropriate piping to the dryer.
[0004] End users of PET polymer pellets typically require that the pellets be in a crystalline state, rather than an amorphous state, principally for two reasons, both relating to the fact that the end user wants to process the PET pellets in a substantially dry condition, without any water content. First, PET polymers are very hygroscopic, and crystalline PET pellets absorb considerably less moisture during shipment and storage than amorphous PET pellets. Accordingly, crystalline PET pellets can be dried to the requisite zero or near zero moisture content more easily by the end user. Second, the temperature required to completely dry PET polymers is higher than the temperature at which amorphous PET pellets convert to the crystalline form. Therefore, when drying amorphous PET pellets, it is necessary to first achieve crystallization at the requisite lower temperature before raising the temperature to the drying temperature. Otherwise, the amorphous PET polymer pellets may agglomerate and destroy the pellet form.
[0005] As a result, manufacturers of PET pellets must typically subject the amorphous PET pellets to a secondary heating step of several hours at a very high temperatures, usually in excess of 80-1000° C., to change the amorphous structure of the pellets to a crystalline structure. This is a very expensive second step in order to convert the PET polymer pellets into the desired crystalline state.
[0006] It is also known generally that air can be injected into the exit stream of a water and pellet slurry from a pelletizer in order to enhance the transport of the water/pellet slurry. See, for example, U.S. Pat. No. 3,988,085.
SUMMARY OF THE INVENTION
[0007] In order to achieve a processed PET polymer pellet having the desired crystallinity, the pellet must exit the underwater pelletizing system at a temperature higher than about 1350° C. At temperatures at or above this temperature, PET pellets can self-initiate the crystallization process and ultimately provide a crystalline character instead of an amorphous one. Therefore, in accordance with the present invention, the underwater pelletizing system should produce PET pellets in a hot enough condition to self-initiate the desired crystallization. This elevated heat condition can be accomplished by reducing the residence time of the pellets in the water slurry in order to leave enough heat in the PET pellets during the pelletizing and drying stages so that the crystallization process is initiated from inside the pellets. If desired, the pellets can be stored in a heat retaining condition, such as in a heat insulating container, to complete the crystallization process. For example, coated steel or plastic containers should be acceptable, instead of the stainless steel boxes conventionally used.
[0008] Typically, increasing the water flow through the water box of the underwater pelletizer and increasing the water temperature, along with pipe dimensional changes and reducing the distance between the pelletizer and dryer unit does not help to increase the pellet temperature sufficiently. Under such circumstances, the PET pellets still leave the dryer at a temperature, usually below 100° C., which is below the temperature (about 135° C.) at which crystalline pellets can form. Accordingly, it is necessary to significantly increase the speed of pellet flow from the exit of the underwater pelletizer and into and through the dryer.
[0009] This increased pellet speed is accomplished in accordance with the present invention by injecting air or other suitable gas into the transportation piping leading to the dryer just after the cut pellets and water slurry exit the water box of the pelletizer unit. It has been found that the injected air helps to separate the water from the pellets in the transportation piping, significantly speeds up the transport of the pellets to the dryer and can serve to generate a pellet temperature exiting the dryer at greater than about 145° C. While the PET polymer pellets may come out of the dryer in an amorphous condition, there is still sufficient heat remaining inside the pellets to start the crystallization process and finally produce crystalline pellets without the necessity of the second heating stage heretofore used to make PET pellets using underwater pelletizing systems.
[0010] The air introduced into the slurry line leading to the dryer immediately after the exit from the water tank is at a very high velocity. It has been found that an air volume of 100 cubic meters (m 3 ) /hour through a valve at a pressure of 8 bar and into a slurry 1.5 inch pipe line produces the requisite air velocity for the present invention. The volume of air introduced into the exiting water and pellet slurry produces an overall gas/slurry mixture in the nature of a mist and is likely to have a gas component of 98%-99% or more by volume of the overall mixture. The air injection into the slurry line dramatically increases the speed of the pellet flow from the water box to the exit of the dryer to a rate less than one second. While air is the preferred gas in view of its inert nature and ready availability, other inert gases such as nitrogen or similar gases could be used.
[0011] It has been found that crystalline PET pellets can be formed in accordance with the method and apparatus of the present invention, with a mean temperature of the PET pellets exiting the dryer above about 145° C., if the residence time of the pellets from the point of formation by the cutter blades at the die face to the exit from the centrifugal dryer is reduced by the injection of high velocity air or other gas into the slurry line. This shortened residence time should assure that the PET pellets will exit the dryer of the underwater pelletizing system at a mean temperature greater than 145° C. and will retain sufficient heat inside the pellets to initiate crystallization and cause the amorphous pellets to form crystalline pellets, if properly stored in a heat insulating container. Hence, the necessity of a secondary heating step is eliminated.
[0012] Accordingly, it is an object of the present invention to provide a method and apparatus for processing PET polymers in an underwater pelletizing system which can produce crystalline PET pellets after exiting from the dryer.
[0013] It is another object of the present invention to provide a method and apparatus for producing crystalline PET polymer pellets utilizing an underwater pelletizing system without the necessity of an expensive secondary heating stage to convert amorphous PET pellets to crystalline PET pellets.
[0014] It is a further object of the present invention to provide a method and apparatus for underwater pelletizing PET pellets in which the pellets are transported through the equipment at a sufficiently rapid speed so that the mean temperature of the pellets exiting the dryer is greater than about 145° C.
[0015] It is yet another object of the present invention to provide a method and apparatus for producing PET polymer pellets using an underwater pelletizing system in which the pellets exiting the dryer have sufficient heat remaining inside the pellets to initiate and complete the crystallization of the PET pellets under proper conditions of storage, if necessary.
[0016] It is still a further object of the present invention to provide an underwater pelletizing method and apparatus for producing PET pellets in which the residence time of the PET pellets from the time of extrusion at the die face until exit from the centrifugal dryer is reduced to less than about 1 second by gas injection into the slurry line from the pelletizer to the dryer.
[0017] These together with other objects and advantages which will become subsequently apparent reside in the details of construction and operation of the invention as more fully hereinafter described and claimed, reference being had to the accompanying drawings forming a part hereof, wherein like numerals refer to like parts throughout.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] FIG. 1 is a schematic illustration of a conventional underwater pelletizing system, including an underwater pelletizer and centrifugal dryer as manufactured and sold by Gala Industries, Inc. (“Gala”) of Eagle Rock, Va., with air injection in accordance with the present invention.
[0019] FIG. 2 illustrates certain components of the underwater pelletizing system shown in FIG. 1 during a bypass mode when the process line has been shut down.
[0020] FIG. 3 is a schematic illustration showing a preferred method and apparatus for air (or gas) injection into the slurry line from the pelletizer to the dryer in accordance with the present invention.
DESCRIPTION OF THE INVENTION
[0021] Although only preferred embodiments of the invention are explained in detail, it is to be understood that the invention is not limited in its scope to the details of construction and arrangement of components set forth in the following description or illustrated in the drawings. The invention is capable of other embodiments and of being practiced or carried out in various ways.
[0022] Also, in describing the preferred embodiments, terminology will be resorted to for the sake of clarity. It is intended that each term contemplates its broadest meaning as understood by those skilled in the art and includes all technical equivalents which operate in a similar manner to accomplish a similar purpose. For example, the term “water” includes not only water itself, but also water with one or more additives included, which are added to the water during the underwater pelletizing step for various purposes used by those skilled in the art of underwater pelletizing.
[0023] An underwater pelletizing system for use in association with the present invention is schematically shown in FIG. 1 and is generally designated by reference number 10 . The system 10 includes an underwater pelletizer 12 , such as a Gala underwater pelletizer, with cutter hub and blades 14 shown separated from the water box 16 and die plate 18 . In the underwater pelletizing system 10 , PET polymer is fed from above from a polymer vat (not shown) into a screen changer 20 which removes any solid particles or other material. The PET polymer is then fed through gear pump 22 to control and maintain a smooth flow of the polymer into the polymer diverter 24 and die plate 18 . The PET polymer is typically extruded through holes in the die plate at a temperature of about 260° C. The PET polymer strands formed by the die holes enter into the water box 16 and are cut by the cutter hub and blades 14 into the desired pellets. Cold water flows into the water box 16 through pipe 26 and the water and cut pellet slurry exits through pipe 28 .
[0024] The water and pellet slurry is then conveyed through the slurry line 30 into a dryer 32 , such as a Gala centrifugal dryer, at inlet 33 . The pellets are dried in the dryer 32 and exit the dryer at 34 . The water removed from the dried pellets exits the dryer 32 through pipe 38 and is conveyed by pump 40 into a fines removal sieve 42 and thence into a water tank 44 through pipe 46 . The recycled water leaves water tank 44 through pipe 48 and pump 50 into a water heat exchanger 52 to reduce the water temperature. The cooled water is recycled through pipe 54 past bypass valve 56 and pipe 58 to inlet pipe 26 and then into the water box 16 .
[0025] In accordance with the present invention, air is injected into the underwater pelletizing system in slurry line 30 at point 70 , preferably near the beginning of the slurry line 30 adjacent the exit from the water box 16 , in order to enhance the transport of PET pellets in the slurry line 30 and keep the PET pellets at a high enough temperature to foster the desired crystallization.
[0026] The air is conveniently injected into the slurry line 30 at point 70 using a conventional compressed air line typically available in most manufacturing facilities, such as with a pneumatic compressor, and a standard ball valve sufficient to produce a high velocity air flow in the slurry line 30 . This is readily achieved by a volume of air in the range of 100 m 3 /hour through a standard ball valve at a pressure of 8 bar into a slurry line comprising a standard 1.5 inch pipe. This high velocity air (or other gas) when contacting the slurry and hot pellets generates a water vapor mist. The pellets tend to disperse to the inside circumference of the pipe as they move rapidly therethrough to the dryer. It is estimated that the volume of air in the overall gas/slurry mixture is on the order of 98%-99% or more by volume of the overall mixture. The air injected into the slurry line 30 at point 70 increases the speed of the pellet flow from the water box 16 to the exit 34 of the dryer 32 to a rate of less than one second.
[0027] The mean temperature of the PET polymer pellets exiting the dryer 32 at 34 in accordance with the present invention should be above about 145° C. At this temperature, the PET pellets will retain sufficient heat inside the pellets to initiate crystallization and cause the PET pellets to fully transform to a crystalline state, without the necessity of a secondary heating step. If desired or necessary, the PET polymer pellets exiting the dryer 32 can be placed in appropriate heat insulating containers so that the retained heat in the PET pellets completes the crystallization process, before the pellets cool below the crystallization temperature.
[0028] In by-pass mode shown in FIG. 2 , the recycled water goes through bypass 56 into pipe 60 and then into slurry line 30 . In the bypass mode, the valve 62 is closed and the water/pellet slurry in line 30 and water box 16 , along with the water in inlet line 26 can drain from the system out of drain valve 64 .
[0029] FIG. 3 schematically illustrates a preferred arrangement for air injection into the slurry line of an underwater pelletizing system in accordance with the present invention and is generally designated by reference numeral 100 . The underwater pelletizer 102 illustrated is a Gala Model No. A5 PAC 6, with water inlet pipe 104 and slurry exit line 106 . The dryer 108 illustrated is a Gala Model No. 12.2 ECLN BF, with the slurry entrance 110 at the top. Inasmuch as the exit from the underwater pelletizer 102 into slurry line 106 is significantly below the entrance 110 to the centrifugal dryer 108 , when both are level on a manufacturing floor, it is necessary to transport the water and pellet slurry upwardly from the pelletizer exit to the dryer entrance. The water and pellet slurry thus moves through valve 112 past angled elbow 114 , through angled slurry line 116 past enlarged elbow 118 and then into the entrance 110 of dryer 108 . The air injection is past nozzle or valve 120 and directly into the angled elbow 114 .
[0030] As shown in FIG. 3 , the angled slurry line 116 is preferably straight and has an enlarged elbow 118 at its exit end. The enlarged elbow facilitates the transition of the high velocity water and pellet slurry from the straight slurry line 116 into the dryer entrance 110 and reduces potential agglomeration into the dryer 108 . Further, the air injection into the angled elbow 114 is preferably in line with the axis of slurry line 116 to maximize the effect of the air injection on the water and pellet slurry and to keep constant aspiration of the air/slurry mixture.
[0031] While the angle ∝ between the vertical axis of slurry line 116 and the longitudinal axis of angle slurry line 116 is most preferably about 45°, as shown in FIG. 3 , a preferred range is 30°-60°. Moreover, the angle ∝ can be varied from 0° to 90°, and even more in the event the water and pellet slurry exit from pelletizer 102 is higher than the entrance 110 to dryer 108 when, for example, the pelletizer and dryer are placed at different levels in the plant or the heights of the components are different than shown in FIG. 3 .
TRIAL EXAMPLES
[0032] Molten PET polymer was continuous extruded into an overall underwater pelletizing system as illustrated in FIG. 1 , using a Gala Underwater Pelletizer Model No. A5 PAC 6 and a Gala Model 12.2 ECLN BF Centrifugal Dryer, in the arrangement shown in FIG. 3 . The melt temperature was about 265° C. and the cutter blade speed in pelletizer 102 was varied between 2500 and 4500 RPM. The die plate was typical for PET polymers and a typical 3.5 mm die plate with elongated lands was used. The melt velocity through the die holes during the trials was constant at 40 kg/hole/hr.
[0033] The pipe for slurry line 116 was a standard 1.5 inch pipe and its length was 4.5 meters. The speed of centrifugal dryer 108 was kept constant during the trials, and the countercurrent air flow through the dryer 108 was also kept constant during the trials.
[0034] The air injection flow rate to nozzle or valve 118 was varied from 0 to a maximum of 100 m 3 /hour, as indicated in Table 1 below, and the water flow and pellet size also varied, again as indicated in Table 1 below.
[0035] The parameters and results of the trials are set forth in Table 1 below.
TABLE 1 Air Weight injec- Crystal- Pellet of a Water- Water tion Pellet linity size pellet temp rate rate temp grade Trial (mm) (g) (° C.) (m 3 /h) (m 3 /h) (° C.) (%) 1 5.5 × 3.0 0.032 76 13 100 155 98 2 4.5 × 3.0 0.0299 74 13 100 152 98 3 4.5 × 3.0 0.0306 71 19 0 105 0 4 4.0 × 2.6 0.0185 64 19 100 130 60 5 3.5 × 3.0 0.0256 69 18 100 136 80 6 4.1 × 3.1 0.0267 73 18 100 146 98
[0036] The pellet temperature and percentage crystallinity as set forth in the last two columns of Table 1 was determined by examining the product coming out of the dryer 108 at the end of each trial.
[0037] It is believed that 135° C. is the minimum temperature for PET polymer pellets to leave the dryer, when the pellets have the sizes used in the above tests. However, a lower exit temperature may be possible for this invention if larger size PET pellets are made.
[0038] While the present invention is particularly applicable to the underwater pelletization of PET polymers, it is believed that other polymers which crystalize at elevated temperatures and which retain heat when subjected to high temperatures may also be appropriate for the present invention. Such polymers include certain grades of thermoplastic polyurethane (TPU), PET copolymers and/or PET blends.
[0039] The foregoing is considered as illustrative only of the principles of the invention. Since numerous modifications and changes will readily occur to those skilled in the art, it is not desired to limit the invention to the exact construction and operation shown and described. Accordingly, all suitable modifications and equivalents may be resorted to, falling within the scope of the invention.
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A method and apparatus for underwater pelletizing and subsequent drying of polyethylene terephthalate (PET) polymers and other high temperature crystallizing polymeric materials to crystallize the polymer pellets without subsequent heating. High velocity air or other inert gas is injected into the water and pellet slurry line to the dryer near the pelletizer exit. The slurry line has a substantially straight component, and air is preferably injected at the end of the straight component nearest the pelletizer exit and in a direction substantially coincident with the axis of the straight component. The air injection significantly increases the speed of the pellets into and out of the dryer such that the PET polymer pellets leave the dryer above at least 135° C., and preferably above 145° C., to self-initiate crystallization.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The present application is a divisional of U.S. patent application Ser. No. 09/500,111, filed Feb. 8, 2000, which, in turn, is a continuation of U.S. patent application Ser. No. 09/425,594 filed Oct. 22, 1999, entitled “System and Method for Controlling Deflection of a Dynamic Surface.” The disclosures set forth in the '111 and '594 applications are hereby incorporated by reference herein.
BACKGROUND OF THE INVENTION
The present invention relates to controlling vibration in surfaces and in particular relates to a system for controlling and/or damping vibration of dynamic surfaces.
In many industries, such as paper making, food processing, and textiles, or any other industry that processes a web of material, rolls are used for various processing functions, and in many instances, the stability of the roll is very important. For example, in a paper making assembly, roll vibration may cause variations in the thickness of the product being produced. Thus, it is desirable for the rolls to be as stable as possible and devoid of any imperfections, deflections or variations so that the paper being formed will be smooth and uniform. In addition to resulting in the production of inferior products, roll vibration may also result in damage to the roll itself or the machinery containing the roll. Thus, various attempts have been made to control vibration of rolls so as to avoid these problems.
One response to this problem has been to lower the rotational speed of the rolls in order to avoid or correct vibration-induced defects.
U.S. Pat. No. 5,961,899 to Rossetti et al. discloses a vibration control apparatus for processing a calendered medium that controls vibration between two or more rolls by controlling vibration induced thickness variations in a medium exiting from a nip. The apparatus includes a frame, first and second rolls relative to the frame and a force generator, such as an electromechanical active actuator, a servo-hydraulic actuator, a controllable semi-damper, and Active Vibration Absorber (AVA), or an Adaptive Tune Vibration Absorber (ATVA), providing canceling forces to control vibration between the first and second rolls, thereby controlling vibration induced thickness variations in the calendered medium. In certain preferred embodiments, the apparatus includes at least one sensor for providing a signal indicating a vibration condition of at least one of the first and second rolls, and a digital controller for controlling the signal representative of the vibration condition according to a feed-forward-control and providing a control signal to a force generator. Vertical and/or lateral vibration of the rolls may thus be controlled simultaneously. In addition, fundamental vibrational frequencies and their harmonics may be controlled individually, or in combination.
U.S. Pat. No. 5,447,001 to Nishimura et al. discloses a vibration control device for buildings. In one preferred embodiment, a building has mounted on its roof a hollow concrete-steel first mast carried on damping rubber supports. Within the hollow of the first mast, a second mast is mounted on anti-friction rollers, which roll on a low coefficient of friction interior floor of the first mast. The first and second masses are interconnected with a single element to vibrate these masses with a period of vibration that can be synchronized with the vibration period of the building to attenuate building vibration.
U.S. Pat. No. 5,403,447 to Jarvinen et al discloses a system in a press section of a paper machine for monitoring and controlling the running of a press felt. The press felts are guided by rolls having axial directions that are altered by means of an actuator so as to control the running of the press felts. The system includes detector devices for detecting one or more alignment stripes on the felts and oscillation detectors for detecting oscillation of the press rolls. The system also includes a microprocessor base controller for monitoring signals fed to the controller from the detectors. The controller analyzes the detector data in order to detect any felt-induced oscillations. The control system then generates signals for regulating the actuators of the guide roll that guide the running of the felts so that when the oscillation levels of the press rolls rise above certain limits, the direction of the guide roll on the felt that causes the oscillation is turned until an acceptable level of oscillation and/or a level of oscillation is reached.
U.S. Pat. No. 4,902,384 to Anstotz et al. discloses a wet press having vibration control. In one preferred embodiment, a wet press of a papermaking machine includes a pair of rolls defining a roll gap through which the paper being treated passes. The felt is guided in a closed loop path by additional rolls, which include a tightening roll. The tightening roll can be tilted to reduce roll vibrations by tightening the felt to set vibratory marks formed in the felt at an angle relative to the transverse width of the felt and the roll gap. A controllable positioning device is provided which includes a motor operated by a controller to automatically vary the tilt angle in response to sensed vibrations.
Vibration is also a problem when using a wet press of a papermaking machine. In such wet presses, as the felt and paper web to be drained are simultaneously conducted through a roll gap, water is pressed out of the paper web and transferred onto the felt web. The absorbed water is removed from the felt at another point along its closed loop path by, for example, a suction roll. The pairs of rolls forming the roll gap, along with their guides which engaged roll journals and the elastically resilient felt, form a vibrating system with a large number of resonance vibrations that can be excited during operation of the web press.
U.S. Pat. No. 5,785,636 to Bonander discloses a roll having an outer surface made of a fabricated fiber matrix for strengthening and reinforcing the roll to maximize roll stability.
U.S. Pat. No. 4,301,582 to Riihinen discloses a system that removes deflections from a roll using magnetic forces. The roll has a non-rotating axle with ends having a load imposed thereat and a cylindrical shell rotatably supported by bearings on the axle. A magnetic core is formed in the axle and a plurality of pole shoes are spaced from the shell by an air gap. A plurality of electromagnetic windings, each wound on the core at one of the pole shoes, produce a magnetic compensating force field between the shell and the core for responding to deflections in the roll.
U.S. Pat. No. 4,357,743 to Hefter, et al., discloses a controlled deflection roll having a roll shell which is radially movable in at least one plane in relation to a roll support. Position feelers or sensors are arranged at the ends of the roll shell for detecting one or more deflections in the roll shell as a function of deviations from a predetermined reference or set point. The position feelers control regulators operatively associated with pressure or support elements positioned between the roll support and the roll shell so that the roll shell is maintained in the reference or set position.
U.S. Pat. No. 4,062,097 to Riinhinen discloses a roll having magnetic deflection compensation that may be used in the calender or press section of a paper machine. The roll has an inner non-rotating axle and an outer shell surrounding and rotatable with respect to the axle, the axle and the shell having a common axis. The axle includes an inner magnetic structure while the shell includes an outer magnetic structure that rotates together with the shell. These inner and outer magnetic structures cooperate to provide attraction between the shell and axle on one side of the above axis and repulsion between the shell and axle on the opposite side of the axis, thereby achieving deflection control and/or compensation.
Other techniques used to reduce the detrimental effects of roll vibration include running process machinery at slower speeds in order to avoid resonance problems, and using back-up roll systems to reduce vibration.
Therefore, there is a need to have a vibration control system for a dynamic surface that damps or eliminates vibrations in the dynamic surface. There is also a need for a vibration control system that enables vibrations to be induced into a dynamic surface for any purpose necessary.
SUMMARY OF THE INVENTION
The present invention addresses the above-identified problems by providing a system and method for controlling vibration of a dynamic surface. In its broadest sense, the present invention may be used to eliminate undesirable vibrations from a dynamic surface or to actively induce vibrations into the dynamic surface. In preferred embodiments, the present invention may be used to control vibration of a dynamic surface on any object that rotates including, but not limited to, a roll that engages a web, a gear, wheels and/or tires. The present invention may also be used to reduce or control vibrations in aerodynamic surfaces or one or more surfaces of a loom. In highly preferred embodiments, the inventive system includes at least one piezoelectric actuator in communication with the dynamic surface of a roll and a mass overlying the piezoelectric actuator so that the piezoelectric actuator is between the mass and the dynamic surface for controlling vibration of the roll and/or actively inducing vibration into the roll.
As is well known to those skilled in the art, piezoelectric elements may be used to covert electrical energy into mechanical energy and vice versa. For nanopositioning, the precise motion that results when an electric field is applied to a piezoelectric material is of great value. Actuators using this effect have changed the world of precision positioning. As used herein, the term “piezoelectric actuator” means a piezoelectric device or element, or any electronic device that operates in a similar fashion to a piezoelectric element such as an electromagnet or a magnetostatic device.
As set forth herein, the term “dynamic surface” means any surface that may change with respect to time, regardless of whether the change occurs over 5-10 seconds or over a time period as small as one microsecond. However, as micro-technology improves and microprocessors operate at faster speeds, it is contemplated that the present invention could be used for dynamic surfaces that change over a period of time as small as 1 nanosecond. The present invention may be used for a broad range of applications whereby the system components move at various speeds. For example, the vibration control system of the present invention can be used when making a paper web moving at approximately 5000 feet/minute, when making textile materials moving at approximately 100-300 feet/minute or when making paper maker's clothing (PMC) moving at approximately 1-30 feet/minute.
In accordance with one aspect of the present invention, there is provided a system for controlling vibration of a dynamic surface, such as the exterior surface of a roll. The system preferably includes at least one sensor in communication with the dynamic surface for measuring vibration of the dynamic surface and generating a feedback signal upon measuring vibration. The feedback signal may be proportional to the velocity, displacement and/or acceleration of the measured vibration. The feedback signal may consist of one or more of these variables. As used herein, the term “vibration” includes any dynamic surface response to any force to which the dynamic surface may be subjected including pressure forces, compressive forces, tensile forces, resonance, thermal action or other process forces. Moreover, the above-listed vibration forces may be applied in any direction with respect to the dynamic surface including directions that are substantially perpendicular to the dynamic surface and directions that are substantially parallel to the dynamic surface. The system also includes at least one piezoelectric actuator in communication with the dynamic surface and at least one mass overlying the at least one piezoelectric actuator so that the at least piezoelectric actuator lies between the mass and the dynamic surface.
The system also preferably includes a controller in communication with the at least one sensor for receiving the feedback signal and sending the output signal to the at least one piezoelectric actuator. If the feedback signal indicates that the dynamic surface is undergoing vibration, the piezoelectric actuator, upon receiving the output signal, applies a counter force between the dynamic surface and the mass upon receiving the output signal for reducing or controlling vibration of the dynamic surface. The at least one piezoelectric actuator may also be activated when no vibration is sensed in order to actively induce vibrations into the dynamic surface.
The application of piezoelectric elements to dynamic surfaces, such as the exterior surface of a roll, resolves vibration problems in a much more efficient manner than is available with the vibration control methods described above. Piezoelectric actuators can apply forces independently in various magnitudes, and in various combinations. This is not possible with most if not all of the existing roll control methodologies. Piezoelectric actuators are extremely precise, allowing repeatable nanometer and sub-nanometer movements. In addition, piezoelectric actuators can produce significant amounts of force over relatively small areas and are capable of moving heavy loads of up to several tons. Moreover, because piezoelectric elements derive their motion through solid state crystal effects and have no moving parts the response time of piezoelectric elements is in the kilohertz range so that they may be activated at very high frequencies. Finally, piezoelectric elements require very little power and require no maintenance.
The at least one piezoelectric actuator preferably includes a plurality of piezoelectric actuators that are provided in contact with the dynamic surface. The piezoelectric actuators are preferably piezoelectric foils having a length of approximately 1 to 5 centimeters, a width of approximately 1 to 5 centimeters and a height of less than 1 centimeter. As such, one piezoelectric actuator preferably covers an area of approximately 1-25 cm 2 . In other preferred embodiments, piezoelectric actuators of any size and/or dimension may be used. Thus, the present invention is not limited to using actuators of the size/type listed above.
The present invention preferably applies a plurality of piezoelectric actuators in contact with the dynamic surface of a roll so that relatively large controlling forces may be applied to the dynamic surface. Because each piezoelectric actuator can be controlled separately by the controller, it is possible to impart virtually any type of vibration or shape in the dynamic surface that is desired, thereby providing for unlimited performance possibilities not available in prior art technologies.
In one preferred embodiment, the dynamic surface is preferably provided on a roll shell secured over a roll support. The roll shell may be a non-coated or a coated roll. The roll shell is preferably flexible and substantially cylindrical, has an interior surface defining an inner diameter of the roll shell and an exterior surface defining an outer diameter of the roll shell. The exterior surface of the roll shell preferably includes the dynamic surface. The sensors and piezoelectric actuators are preferably connected to the interior surface of the roll shell; and one or more masses overlie the piezoelectric actuators so that the piezoelectric actuators lie between the masses and the interior surface of the roll shell. In certain embodiments, the ratio of masses to piezoelectric actuators could be 1:1, however, in other embodiments the number of piezoelectric actuators may greatly exceed the number of masses or the number of masses may greatly exceed the number of piezoelectric actuators. In other embodiments, the sensors and piezoelectric actuators may be connected to either the inner or exterior surface of the roll shell or any combination thereof, so long as the masses overlie the piezoelectric actuators so that the piezoelectric actuators lie between the masses and the dynamic surface. In other embodiments, the sensors are in communication with, but not in contact with, the roll shells.
The roll shell preferably has a longitudinal axis and preferably rotates about a central axis substantially parallel to the longitudinal axis. The roll shell is desirably mounted on a roll shell support that supports rotation of the roll shell about the central axis thereof. The roll shell support may include an axle mounted to an external support structure. The axle may rotate.
In certain embodiments, the counter vibrating force applied by the piezoelectric actuators generates either a compressive force or a tensile force between the mass and the dynamic surface of the roll shell. The compressive and tensile forces are applied through the piezoelectric actuators and directly to the dynamic surface and the corresponding mass surfaces. The compressive and tensile forces are generally opposed to one another. In other words, the compressive forces compress the mass and the dynamic surface toward one another while the tensile forces urge the mass and the dynamic surface away from one another. The piezoelectric actuators may be aligned to exert compressive and tensile forces in directions substantially parallel to or substantially perpendicular to the longitudinal axis of the shell. The piezoelectric actuators may also be aligned to apply compressive and tensile forces to the dynamic surface in a plurality of various directions that are neither perpendicular to nor parallel to the longitudinal axis of the shell.
The vibration control system of the present invention preferably includes a plurality of sensors in communication with the shell. The sensors are designed for detecting and/or measuring the magnitude of the vibration of the dynamic surface of the shell. The sensors are preferably spaced apart from one another and interspersed between the piezoelectric actuators. In certain preferred embodiments, the piezoelectric actuators are aligned in rows over the interior surface of the shell and the sensors are interspersed between the piezoelectric actuators. The rows of aligned piezoelectric actuators may extend in directions substantially parallel to or perpendicular to the longitudinal axis of the shell, or may extend in any number of directions between those that are substantially perpendicular and those that are substantially parallel to the longitudinal axis of the shell. The ratio of piezoelectric actuators to sensors is preferably about 100:1. The sensor may be one of a wide variety of sensors including but not limited to a piezoelectric element, a strain gauge, a laser used in conjunction with a reflective element, an optical device, a capacitive device and/or a magnetic device. In other preferred embodiments, the ratio of piezoelectric actuators to sensors will vary. The ratio may be 1:1, or the number of sensors may outnumber the number of piezoelectric actuators.
The vibration control system of the present invention also preferably includes a controller having a microprocessor and a memory device. The memory may have stored therein look-up tables, a control strategy algorithm and/or an adaptive feedback control strategy algorithm. The controller is preferably designed for receiving feedback signals from the sensors. The controller then processes the feedback signals to determine the presence or absence of a vibration. If an undesirable vibration state is detected at one or more regions of the dynamic surface, the controller transmits output signals to the piezoelectric actuators at those vibrating regions for removing the vibrations. The control system of the present invention may also be used to actively induce vibrations into the dynamic surface.
In certain preferred embodiments, the system for controlling vibration of a dynamic surface may be utilized for a web support structure located between two rolls so as to support the web as it passes by the web support structure. In these particular embodiments, the web support structure includes a supporting element having a web support layer. The web support layer has a top surface including the dynamic surface and a bottom surface remote therefrom. The dynamic surface is designed to engage the web passing thereover, such as a web of partially formed paper moving over the dynamic surface during a paper forming process. The control system of the present invention may also be used for processing textile materials and/or paper maker's clothing felts or any other process involving web handling. In these particular embodiments, the sensors and the piezoelectric actuators are provided in contact with the second surface of the web support layer and one or more masses overlie the piezoelectric actuators so that the piezoelectric actuators lie between the second surface of the web and the masses. However, in other embodiments, the sensors and piezoelectric actuators may be in contact with either the first surface or the second surface or any combination thereof, and the masses overlie the piezoelectric actuators. The dynamic surface of the web support layer may be substantially flat or have an arcuate section. In certain embodiments, the one or more sensors preferably determine the position of the dynamic surface in relation to the supporting element for detecting the presence of a deflecting force upon the dynamic surface.
In these embodiments, at least one of the piezoelectric actuators is sandwiched between the at least one mass and the interior surface of the shell. In certain applications, there is a need to operate rolls at a speed that coincides with the resonance of the roll. When operated at or near resonance, a roll's dynamic response may cause detrimental effects on the roll itself, the machinery containing the roll and the process that the roll is completing. Using piezoelectric devices mounted between the roll (or other machine members) and a mass, and having the piezoelectric actuator connected to and controlled by a properly designed control device, vibrations in the dynamic surface of the roll can be reduced and/or controlled, thereby eliminating or reducing detrimental effects. Similarly, vibrations can be induced into rolls or other machine members for any purposes necessary.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1A is a schematic side view of a prior art roll and mating roll engaging a web at a nip.
FIG. 1B is a schematic side view of another prior art roll engaging a web.
FIG. 2A is a sectional view of the prior art roll of FIG. 1A taken along lines IIA—IIA.
FIG. 2B is a sectional view of the prior art roll of FIG. 1B taken along lines IIB—IIB.
FIG. 3A shows a simplified view of the prior art roll of FIG. 1A during rotation of the roll.
FIG. 3B shows a simplified view of the prior art roll of FIG. 1B during operation of the roll.
FIG. 4A is a schematic cross-sectional view of a roll including a system for controlling vibration of the roll, in accordance with certain preferred embodiments of the present invention.
FIG. 4B is a fragmentary schematic cross-sectional view of a roll, in accordance with further preferred embodiments of the present invention.
FIG. 4C is a fragmentary schematic cross-sectional view of a roll, in accordance with still further preferred embodiments of the present invention.
FIG. 4D is a fragmentary schematic cross-sectional view of a roll, in accordance with yet further preferred embodiments of the present invention.
FIG. 5 is a fragmentary view of a the roll of FIG. 4A taken along lines V—V including a plurality of sensors in contact with the dynamic surface of the roll and a plurality of masses overlying piezoelectric actuators, in accordance with certain preferred embodiments of the present invention.
FIG. 6 shows a fragmentary view, on an enlarged scale, of the dynamic surface of the roll shown in FIG. 5 .
FIG. 7 shows the roll shown in FIG. 4A during operation of the roll.
FIG. 8A is a schematic cross-sectional view of a non-coated roll including a system for controlling vibration of the roll, in accordance with further preferred embodiments of the present invention.
FIG. 8B is a schematic side view of a coated roll including a system for controlling vibration of the roll, in accordance with still further preferred embodiments of the present invention.
FIG. 9 shows a schematic side view of a system for controlling vibration of a dynamic surface, in accordance with further preferred embodiments of the present invention.
FIG. 10A is a sectional view taken along lines X—X of FIG. 9, showing the dynamic surface of a web support layer.
FIG. 10B shows a sectional view of a system for controlling deflection of a dynamic surface including a mating roll for creating nip pressure, in accordance with further preferred embodiments of the present invention.
DETAILED DESCRIPTION
FIGS. 1A-3B show prior art rolls. Referring to FIG. 1A, the roll 20 is a non-coated roll including an axle 22 loaded at its ends. A non-coated roll generally includes rolls having metal tubes, such as a steel roll or tube. In contrast, a coated roll is understood to be a roll that is coated with a layer of flexible material such as rubber, fabric or cloth. The loading forces F are shown in FIG. 1 . The forces F, together with the weight of the roll, provide the required nip pressure at the nip N formed by the interface of roll 20 and a mating roll 24 . The forces shown in FIG. 1 and described above are dependent upon the position of the roll 20 relative to the mating roll 24 . For example, these forces would change if the roll 20 were under the mating roll 24 (i.e., under the nip). The roll 20 includes a roll shell 26 that is secured about axle 22 via bearings 28 . The roll shell has an interior surface 30 and an exterior surface 32 . The longitudinal axis or centerline of the axle 22 is indicated by A—A.
FIG. 1B shows another prior art non-coated roll 20 ′ that does not have an axle extending therethrough as shown in FIG. 1 A. The roll 20 ′ includes a roll shell 26 ′ having an interior surface 30 ′ and an exterior surface 32 ′. The roll 20 ′ includes supports 22 A′ and 22 B′ that support the interior surface 30 ′ of the roll shell 26 ′ as the roll shell rotates about a longitudinal axis A′—A′. The supports 22 A′ and 22 B′ includes extensions 27 ′ supported by bearings 28 ′.
FIG. 2A shows a cross sectional view of the roll 20 and the mating roll 24 of FIG. 1A taken along line IIA—IIA of FIG. 1 A. The roll 20 and mating roll 24 are designed for allowing a web 34 to pass therebetween at the nip N. Mating rolls facilitate the development of nip pressures between two rolls, thereby minimizing deflection of one or more rolls. Mating rolls, such as mating roll 24 , may also be used as backup or support rolls. The roll 20 and the mating roll 24 may typically be incorporated into any assembly that processes a web of material such as a paper making assembly, a textile making assembly, a paper maker's clothing making assembly, a printing assembly, a metal rolling assembly, an embossing assembly or a calendaring assembly.
FIG. 2B shows a cross-sectional view of the roll 20 ′ of FIG. 1B taken along line IIB—IIB of FIG. 1 B. The roll 20 ′ of FIG. 2B is a singular roll that is not in contact with a mating roll for creating nip pressure.
FIG. 3A shows a simplified view of the roll 20 of FIGS. 1A and 2A when the roll is vibrating. The mating roll 24 may also vibrate as indicated by the dashed lines. The vibration of the roll 20 may be the result of vibrating forces applied to the exterior surface 32 of the roll by a web (not shown), or by the resonance frequencies of the rolls or other exciting energies such as vibrational energy transmitted from any other part of a machine that causes a roll to go into resonance or drives a roll into a vibrating state. FIG. 3B shows a simplified view of the roll 20 of FIGS. 1B and 2B when the roll is vibrating. The roll vibration shown in FIGS. 3A and 3B can have detrimental effects on the rolls, the machinery containing the rolls or the products being produced using the rolls. The present invention is directed towards a control system that both detects roll vibration anywhere on a roll and actively corrects the condition for rapidly and efficiently returning the roll to a non-vibrating state. In certain embodiments, it may be preferable to detect and/or correct roll vibration only at the portion of the roll at the nip. To a broader extent, the present invention is directed toward providing a control system for a dynamic surface for detecting the occurrence of a vibration in a dynamic surface, measuring the velocity, acceleration or displacement of the vibration, and then operating actuators to return the dynamic surface to a non-vibrating condition.
FIG. 4A shows a deflection control system 100 for a roll 102 in accordance with certain preferred embodiments of the present invention. The roll 102 includes an axle 104 having bearings 106 for supporting a roll shell 108 . The roll shown in FIG. 4A is commonly referred to as a non-coated roll. A non-coated roll is typically made by providing a roll shell, such as a solid steel shell, that supplies the main support for the roll. The roll shell 108 has a longitudinal axis that is substantially parallel to the longitudinal axis B—B of axle 104 . The roll shell 108 is generally cylindrical or tubular and includes an inner surface 110 defining an inner diameter and an exterior surface 112 defining an outer diameter. The outer diameter (O.D.) of the roll 102 is defined by the exterior surface 112 of roll shell 108 .
The vibration control system also includes a plurality of sensors 114 and a plurality of piezoelectric actuators 116 connected to the interior surface 110 of the roll shell 108 . The sensors 114 and piezoelectric actuators 116 are in signal sending and receiving communication with a controller 118 via conductive traces 120 extending between the sensors 114 and piezoelectric actuators 116 , and the controller 118 . For clarity of illustration, FIG. 4A shows only one sensor 114 and one piezoelectric actuator 116 connected to controller 118 , however, it should be understood that all of the sensors and actuators are preferably in signal sending and receiving communication with the controller. The control system also includes a mass 125 overlying each piezoelectric actuator 116 . As a result, each piezoelectric actuator is positioned between the inner surface 110 of the roll shell 108 and one of the masses 125 overlying the piezoelectric actuators.
In the particular embodiment shown in FIG. 4A, the controller 118 is located within the roll 102 for rotating simultaneously with the roll, the sensors 114 , the piezoelectric actuators 116 and the masses 125 . Power for the controller may be provided from a stationary power source 122 through a power line 123 that extends through axle 104 . The energy is transmitted from the stationary power source to the rotating controller via a connection mechanism, such as a slip ring, that will not twist the power line 123 as the roll rotates. The controller 118 preferably includes a microprocessor 124 and a memory device 126 for storing a deflection control strategy or data related to preferred operating conditions for the roll 102 and roll shell 108 . The controller 118 preferably uses one or more software applications stored therein, the software applications being capable of receiving feedback signals from the sensors 114 , comparing the feedback signals with data stored in the memory device 126 and generating a series of output signals for transmission to the piezoelectric actuators 116 . Upon receiving the output signals, the piezoelectric actuators are actuated for drawing the masses and the dynamic surface toward one another or forcing the masses and the dynamic surface away from one another so as to remove vibrations from the roll shell 108 , as will be described in more detail below.
In operation, a moving web (not shown) passes through a nip N created by roll 102 and mating roll 130 . The roll 102 and mating roll 130 are shown in a generally horizontal orientation, however, the vibration control system of the present invention is also intended for use when the rolls 102 , 130 have a substantially vertical orientation or any other geometric orientation with respect to the ground or one another. For clarity of illustration, FIG. 4A shows two rolls: roll 102 and mating roll 130 . However, the present invention may also be used for controlling vibrations in systems having three or more rolls in contact with one another including a calendar stack of rolls whereby at least one of the rolls in the stack has two or more nip surfaces.
FIG. 4B shows a fragmentary view of a roll having a vibration control system in accordance with further preferred embodiments of the present invention. The FIG. 4B embodiment is substantially similar to the embodiment shown in FIG. 4A, however, the FIG. 4B embodiment includes a coated roll 102 ′ having a roll shell 108 ′. The roll shell 108 ′ includes a flexible coating 108 A′ overlying a structural support member 108 B′. The flexible coating preferably includes a flexible material such as an elastomer (e.g. rubber) or cloth. When the flexible material is an elastomer, the structural support member 108 B′ is preferably a solid tube, such as a steel tube. The outer diameter of the coated roll 102 ′ is defined by the exterior surface 112 ′ of the flexible coating 108 A′. The system includes a plurality of piezoelectric actuators 116 ′ and sensors 114 ′ overlying the inner surface 110 ′ of the roll shell 108 B′ and masses 125 ′ overlying the piezoelectric actuators.
FIG. 4C shows another embodiment of the present invention having the sensors 114 ″ and piezoelectric actuators 116 ″ on the outer diameter 112 ″ of the roll 102 ″. The roll 102 ″ is a coated roll including a roll shell 108 ″ including a flexible coating 108 A″ overlying a structural support member 108 B″. The sensors 114 ″ and piezoelectric actuators 116 ″ are on the exterior surface 112 ″ of the flexible coating 108 A″. Masses 125 ″ are provided over the piezoelectric actuators 116 ″ so that the piezoelectric actuators 116 ″ are sandwiched between the exterior surface 112 ″ of the flexible coating 108 A″ and the masses 125 ″. In further embodiments, the roll may be a non-coated roll and the sensors, actuators and masses are provided on the exterior surface of the roll shell (i.e., the exterior surface of the structural support member).
FIG. 4D shows a fragmentary view of a roll having a vibration control system in accordance with further preferred embodiments of the present invention. In FIG. 4D the ratio of masses 125 ′″ to piezoelectric actuators 116 ′″ may be 1:1, or the number of masses 125 ′″ may exceed or be less than the number of piezoelectric actuators 116 ′″. The left side of the roll has two masses 125 A′″ and 125 B′″ overlying one piezoelectric actuator. In the center of the roll, one mass 125 C′″ overlies three piezoelectric actuators. On the right side of the roll, the ratio of masses to actuators is 1:1 as three masses 125 D′″, 125 E′″ and 125 F′″ overlie three separate piezoelectric actuators.
Although the present specification provides a detailed description of the vibration control system of the present invention when describing the roll 102 embodiment shown in FIG. 4A, the present invention is equally applicable to the coated roll 102 ′ embodiment shown in FIG. 4B, the roll 102 ″ embodiment shown in FIG. 4C, or any other type of dynamic surface.
FIG. 5 shows a fragmentary view of FIG. 4A, taken along lines V—V, showing sensors 114 and masses 125 /piezoelectric actuators 116 connected to the inner surface 110 of the roll shell 108 . The masses 125 overlie the piezoelectric actuators which are not shown. The piezoelectric actuators and the masses overlying the piezoelectric actuators are preferably aligned in rows C, D, E, F, G, H and I that extend substantially parallel to the longitudinal axis B—B of the roll shell 108 . Each mass is preferably in registration with one of the piezoelectric actuators. Each mass 125 preferably has a length of approximately 1 to 5 centimeters, a width of approximately 1 to 5 centimeters, and a height of less than one centimeter. Thus, each mass 125 generally covers an area of approximately 1-25 cm 2 . The piezoelectric actuators generally cover the same area as the masses. The sensors 114 are interspersed between the masses 125 and are preferably spaced so that the controller is able to monitor the entire dynamic surface of the roll. As mentioned above, the sensors are designed for detecting the presence of vibration of the dynamic surface of the roll shell 108 .
The number of piezoelectric actuators 116 and masses 125 generally outnumber the number of sensors 114 by a significant amount. In one preferred embodiment, the ratio of masses and piezoelectric actuators to sensors is approximately 100:1. Preferred sensors include piezoelectric elements, strain gauges, a laser and reflective element sub-assembly, an optical device, a capacitive device, and/or a magnetic device. In the preferred embodiment shown in FIGS. 4A and 5, the sensors are piezoelectric elements capable of detecting a vibration of the dynamic surface of the roll. Such vibration will strain the piezoelectric sensor to stretch or compress. The piezoelectric sensor will then transform the physical movement into an electric feedback signal, whereby the magnitude of the electric feedback signal may be proportional to the magnitude of the physical movement of the sensor. The electric feedback signal is sent to the controller. The electric signal may be either an electric voltage signal or a current signal.
FIG. 6 shows an enlarged fragmentary view of rows D, E and F of FIG. 5 . Each row includes masses 125 overlying piezoelectric actuators (not shown) with sensors 114 interspersed between the masses and piezoelectric actuators. The sensors 114 preferably monitor a specific region of the roll shell 108 to detect whether that region is subjected to vibration. Each sensor 114 operates independently of the other sensors. For example, sensor 114 F in row F may detect a vibration while sensor 114 E of row E detects no vibration. The piezoelectric actuators may also operate independently of one another. For example, piezoelectric actuator 116 F may apply a counter vibrating force to the roll shell while piezoelectric actuator 116 E is not actuated and applies no counter vibrating force to the roll shell. Moreover, piezoelectric actuators adjacent one another may apply counter vibrating forces having different magnitudes; e.g. the piezoelectric actuator underlying mass 125 E applies a counter vibrating force having a greater magnitude that the force applied by the piezoelectric actuator underlying mass 125 E′. The actual magnitude of the counter vibrating force applied by any one piezoelectric actuator is typically proportional to the magnitude of the electric signal received from the controller 118 (FIG. 4 ). Although the masses 125 and the actuators 116 underlying the masses are depicted in rows, the present invention includes embodiments where the masses and actuators are arranged randomly or in a pattern. The sensors 114 may also be arranged in a pattern or randomly.
Referring to FIGS. 4A and 6, during operation or rotation of the roll 102 , the region of the roll shell 108 overlying row D may be in contact with a moving web while regions of the roll shell overlying rows E and F are not in contact with the web. As a result, the moving web vibrates the roll shell overlying row D while rows E and F are not vibrating. Thus, the sensors 114 D in row D will detect vibration while the sensors 114 E and 114 F of respective rows E and F will not detect vibration. In response, output signals sent from the controller to piezoelectric actuators of row D will physically move those piezoelectric actuators for damping vibration of the dynamic surface of the roll shell 108 overlying actuators 116 D. However, no output signals will be sent to the piezoelectric actuators 116 E and 116 F in rows E and F. As such, piezoelectric actuators will only be activated by output signals when necessary to control and/or damp vibration of the roll shell or when it is desirable to actively vibrate the dynamic surface of the roll shell. The force applied by each actuator in any one row may vary. For example, the actuators in the center of a row may apply more force than the actuators adjacent a journal. In addition, in any one row, the actuators adjacent one journal may provide more force than the actuators adjacent an opposed journal.
FIGS. 7 and 8 show the roll 102 of FIG. 4A before activation of the vibration control system of the present invention. During operation of the roll, a web 128 (not shown in FIG. 7) passes between the roll 102 and mating roll 130 . The rotational speed of the roll 102 is dependent upon a number of factors including the speed of the web passing between roll 102 and mating roll 130 and the outer diameter of the roll. Referring to FIG. 8, in response to a number of vibrating forces, including the high rate of rotation of the roll (e.g., 5000 revolutions/minute) web tension, nip pressure and gravity, the roll 102 and the roll shell 108 vibrate. As set forth above, vibration of the roll is undesirable because it will have an adverse effect on the material 128 (e.g., a web) passing between the roll 102 and the mating roll 130 .
Referring to FIG. 7, during operation the sensors 114 are activated for detecting vibration of the dynamic surface of the roll 102 and to send feedback signals back to the controller (FIG. 4) upon sensing vibration. Upon receiving feedback signals from the sensors, the controller will determine the magnitude of the vibration. The controller will then calculate output signals to be sent to each of the piezoelectric actuators 116 connected to the roll shell. The magnitude of the output signals sent to the individual piezoelectric actuators may vary because the amount of damping force or attenuating force required at each particular region of the roll may vary. Upon receiving the output signals from the controller, the piezoelectric actuators 116 will exert tensile and/or compressions forces on the dynamic surface of the roll for damping and/or controlling vibration of the dynamic surface. In certain embodiments, one or more piezoelectric actuators may saturate or “max out”; i.e. a condition where the piezoelectric actuator is exerting a maximum force and this maximum force is not enough to completely damp or control a localized vibration in the dynamic surface. In these instances, piezoelectric actuators located outside the area of the vibration may be actuated to assist the “maxed out” piezoelectric actuators.
FIG. 8A shows a vibration control system 200 for a non-coated roll 202 in accordance with further preferred embodiments of the present invention. The roll 202 includes a roll shell 208 having first and second ends 215 A and 215 B. The system includes first and second supports 217 A and 217 B for supporting the first and second ends 215 A and 215 B of the roll shell 208 . The supports 217 A and 217 B are connected with the interior surface 210 of the roll shell 208 for supporting rotation of the roll 202 . The supports 217 A and 217 B extend beyond the ends 215 A and 215 B of the roll shell 208 to bearings 206 so that the roll 202 may rotate about longitudinal axis C—C. The roll 202 includes a controller 218 for controlling vibration of the roll shell 208 . The controller 218 is in communication with sensors 214 and piezoelectric actuators 216 via traces 220 . FIG. 8A shows only one sensor 214 and one piezoelectric actuator 216 connected to controller 218 , however, it should be understood that all of the sensors and actuators are preferably in signal sending and receiving communication with the controller. Masses 225 overlie the piezoelectric actuators 216 so that the piezoelectric actuators 216 lie between the inner surface 210 of the roll shell 208 and the masses 225 . The controller 218 is preferably located within roll shell 208 for rotating simultaneously with the roll shell, the sensors 214 and the piezoelectric actuators 216 . Power for the controller 218 may be provided from a power source 222 through a power line 223 that extends through one of the structural members 217 . The controller 118 operates in a manner that is substantially similar to that described above in regards to FIG. 4 A.
FIG. 8B shows another embodiment of the present invention that is substantially similar to the FIG. 8A embodiment, however, the FIG. 8B embodiment includes a coated roll 202 ′. The coated roll 202 ′ includes a roll shell 208 ′ having a flexible coating 208 A′ surrounding structural support member 208 B′. The outer diameter of the coated roll 202 ′ is defined by the exterior surface 212 ′ of the flexible coating 208 A′. Both the non-coated roll 202 of FIG. 8 A and the coated roll 202 ′ of FIG. 8B are dynamically flexible and include dynamic surfaces as that term is defined herein. As a result, the non-coated and coated rolls disclosed herein may deflect and/or vibrate during operation.
FIGS. 9 and 10A show a deflection control system in accordance with further preferred embodiments of the present invention. Referring to FIG. 9, a web support element 300 is provided between two rolls 302 and 304 . The web support element 300 supports a web 306 moving between first roll 302 and second roll 304 . Referring to FIG. 10A, the web support element 300 includes a web support layer 308 having a first surface 310 for engaging the web 306 and a second surface 312 remote therefrom. The second surface 312 of the web support layer 308 includes sensors 314 and piezoelectric actuators 316 connected thereto. Masses 325 overlie the piezoelectric actuators for damping vibrational forces on the web support layer 308 .
FIG. 10B shows another embodiment, similar to the embodiment of FIG. 10A, including a mating roll 330 ′, whereby a web 306 ′ passes between the mating roll and the web support layer 308 ′.
Although the invention herein has been described with reference to particular embodiments, it is to be understood that these embodiments are merely illustrative of the principles and applications of the present invention. For example, the present invention may be incorporated into the wing of an airplane or onto a surface of a machine for controlling vibration of these surfaces. It is therefore to be understood that numerous modifications may be made to the illustrative embodiments and that other arrangements may be devised without departing from the spirit and scope of the present invention as defined by the appended claims.
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A method of controlling vibration of a dynamic surface includes providing at least one piezoelectric actuator in communication with the dynamic surface, and providing a mass over the at least one piezoelectric actuator so that the at least one piezoelectric actuator lies between the mass and the dynamic surface. The method includes sensing vibration of the dynamic surface, and activating the at least one piezoelectric actuator after sensing vibration of the dynamic surface for applying a counter force between the dynamic surface and the mass for reducing or controlling vibration of the dynamic surface.
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BACKGROUND OF THE INVENTION
1. Field of the Invention
The invention concerns a floating electrical or fluidic connector, and more particularly a connector intended for use in space and like applications.
2. Description of the Prior Art
In such applications, equipment is subjected to extreme environmental conditions. With particular reference to connectors, there are contradictory requirements: firstly, it is necessary to use floating connectors to allow for assembly tolerances, fluctuations in dimensions due to thermal expansion and variations in alignment on coupling; secondly, it is necessary to hold the device firmly during the launch phase in which it is exposed to levels of vibration typically in a range from 15 g to 30 g (approximately 150 m/s 2 to 300 m/s 2 ).
In the prior art, floating connectors usually comprise a socket floating relative to a fixed frame and relative to which it is centered by resilient return means. Springs are used for this purpose, for example.
The part of the complementary plug which connects to the socket includes a taper which guides the socket when inserted into it and which, in conjunction with the floating mount for the socket, enables re-alignment and effective connection of the fluidic or electrical systems of modules connected to the connector.
Floating connectors are described in the following two patent applications, for example:
DE-A1-3 903 839 (YAZAKI Corp.), and
EP-A1-0 371 835 (AUTOMOBILES PEUGEOT).
In space applications, because of the adverse conditions previously mentioned, there is a serious risk of destruction of the return system or even of the connector itself during launch.
An object of the present invention is a floating connector, for space applications in particular, which does not have the drawbacks of the prior art, some of which are outlined above.
To this end, said connector is provided with a device for temporarily locking the floating member, and this device is automatically disengaged on coupling.
In a preferred embodiment of the invention, this device has two stable states: a first state in which the temporary locking device is active and a second state in which this device releases the floating member.
In a further embodiment of the invention, the temporary locking device has means allowing it to be reset so that tests can be carried out prior to launch.
SUMMARY OF THE INVENTION
The invention consists in a floating connector comprising two parts adapted to be coupled together, namely, a first part comprising at least a floating base supporting at least a first connection member and a fixed second part comprising a second connection member for each first connection member paired therewith, a device for temporarily locking each floating base comprising means for locking the latter prior to coupling, and control means for the locking means having a first stable state or locked state of each base and a second stable state or unlocked state, wherein the second part comprises actuator means operating on the control means during coupling to release each base when coupling of the first and second parts is completed.
By virtue of these provisions, the invention achieves the stated objectives. The connector of the invention has many advantages, including the following:
a small overall size;
the unlocking system is entirely passive: energy is required only for coupling;
as the fixing device can be reset, tests can be carried out prior to launch;
the device is released automatically at the start of coupling;
it has two stable states: it follows that it remains in the released state after coupling.
The invention will be better understood and other features and advantages of the invention will emerge from the following description with reference to the appended drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIGS. 1a, 1b and 1c show one embodiment of a floating connector provided with a temporary fixing device in accordance with the invention, respectively from the front, from the side and from the top.
FIGS. 2a and 2b show one embodiment of the temporary locking device in accordance with the invention respectively from the side and partly in section and from the top.
FIGS. 3a, 3b, 3c and 3d illustrate the operation of the temporary locking device during four successive phases of coupling a plug and a socket of a floating connector in accordance with the invention.
FIGS. 4a and 4b show the connector from the front and the socket of the connector from the top at the start of the coupling phase.
FIGS. 5a and 5b show the connector from the front and the socket of the connector from the top at the end of the coupling phase.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
FIGS. 1a, 1b and 1c show one embodiment of a floating connector 1 in accordance with the invention seen from the front, from the side and from the top, respectively.
The connector 1 has two parts 2 and 3 adapted to be coupled together. The lower part (as shown in the drawings) includes a base 31 floating on a fixed support 6 by means of conventional spring means (not shown). This arrangement, conventional in the prior art, is well known to those skilled in the art and there is no need to describe it further. The base 31 supports a connection member 30. To simplify the following description, without this being in any way limiting on the scope of the invention, it is assumed that the connector is an electrical connector and that the connection member 30 is a plug.
The upper part (as shown in the drawings) includes a support 21 to which is attached a connection member 20, which is a socket in the example shown.
The connection members include respective conventional mutual guide means 200 and 300 which operate when one is inserted in the other for correct alignment with a common axis Δ 1 .
In accordance with an important feature of the invention, the connector 1 is provided with a device 4-5 for temporarily holding the floating base 31. This device includes a pair of jaws 5 or similar members for immobilizing the base 31 and the connection member 30. For practical reasons, it is usually the connection member 30 which is held by the jaws 5. The latter are disposed on opposite sides of the connection member 30 and operate along an axis Δ 2 orthogonal to the axis Δ 1 . The jaws 5 are operated by control means 4 to be described in detail with reference to FIGS. 2a and 2c.
FIGS. 1a through 1c show the connector 1 prior to coupling. In this condition the control means 4 cause the jaws 5 to lock the base 31-30. As explained below, the control means 4 include an unlocking member which, in the example shown, comprises a pedal 42 or like member. This member is accessible from the outside. The support 21 in the upper part 2 of the connector 1 includes rods 22 parallel to the axis Δ 1 . These depress the pedals 42 on insertion and the pedals in turn act on the control means 4 to cause them to release the jaws 5.
FIG. 2a is a more detailed, partly sectioned side view of the device 4-5 for temporarily locking the floating base 30-31. It has a housing 40 in which a piston 41 slides along the axis Δ 2 . To this end, two orifices 400 and 401 are provided in opposite walls of the housing. The housing 40 is fastened to the fixed support 6 (FIG. 1a) supporting the floating base (30-31). The piston 41 drives one of the two jaws 5. To be more precise, in the example shown, the piston 41 has three portions, namely, a first rod 410 inserted in the orifice 400 and whose cross-section allows it to slide in the latter, a second rod 411 inserted in the orifice 401 and whose cross-section allows it to slide in the latter, and a larger cross-section central portion 412. These three portions can be in the form of a single mechanical part. The central part has a central orifice 4120 large enough to receive a drive finger 42. The latter is attached to a shaft 44 which can rotate about an axis Δ 3 orthogonal to the axis Δ 2 . The shaft 44 is rotated about the axis Δ 3 by a pedal 43 or like member normally exposed outside the housing 40. The lower part (as seen in FIG. 2a) of the central member 412 includes two notches or grooves 4121 and 4122 parallel to the axis Δ 2 . A cam 45 is held by a first end of the housing 40, and its free end 450 has a profile complementary to that of the notches 4121 and 4122. The body of the cam 45 is a flexible blade member made from an elastic material.
Referring to FIG. 2a, the position of all the moving parts corresponds to the situation described up to now: the connector 1 is in the uncoupled state. The rods 22 fastened to the support 21 (FIGS. 1a and 1b) are raised and are not in mechanical contact with the pedals 43. These are shown substantially horizontal. The finger 42 is raised and does not apply any pressure to the cam 45. It is assumed that in the state described the jaws 5 immobilize the base 30-31, i.e. that they are pushed to the right (as shown in FIG. 2a) by the piston 41 and in particular by its end 411. The central part 412 abuts against the front wall of the housing 40. The free end or head 450 of the cam 45 is engaged in the notch 4121, the leftmost notch in the figure, and therefore locks the piston in the position shown, butted up against the front wall of the housing 40.
FIG. 2b is a top plan view of the temporary locking device 4-5 just described. Note in particular from this figure the shape of the jaw 5. The side 50 in contact with the connection member 30 must naturally mate as closely as possible with its exterior shape, to enhance the quality of locking. In most cases it is cylindrical. The jaw 5 is therefore advantageously semi-cylindrical in this case.
A knurled wheel 46 at the end of the shaft 44 is fixed to the latter by any appropriate means, such as screwing or welding. It is used to reset the temporary locking device 4-5, as explained further below.
FIGS. 3a through 3b illustrate the operation of the temporary locking device 4-5 by means of four successive states it assumes.
FIG. 3a shows the state in which the jaws 5 immobilize the connection member 30, i.e., that shown in FIG. 1b through 1c. In this state, the piston 41 is pushed to the right (in the example shown) and held against the front wall of the housing 40. To this end, the end 450 of the cam 45 is engaged in the notch 4121. The finger 42 is engaged in the central opening 4120 in the central area 412 of the piston 41, but does not displace the latter.
This state constitutes a first stable state of the temporary locking device 4-5.
During coupling of the connector, the rods 22 move towards the base as shown in FIG. 3b by the downward-pointing arrow. The bottom end of the rod 22 bears on the pedal 43 which rotates the shaft 44 about the axis Δ 3 and therefore displaces the finger 42, which begins to apply pressure to the rear wall 4123 of the central opening 4120 and to the body of the cam 45. The wall 4123 advantageously has a rounded profile. Trapped at one end in the rear wall of the housing 40, the cam 45, by virtue of its elasticity, curves downwards and its head begins to disengage from the notch 4121. The piston 41 begins to move to the left and the jaws 5 begin to release.
The rods 22 continue to move down as coupling proceeds. The pressure on the pedal 43 increases and the finger 42 continues to move the piston 41 towards the left. The end 450 of the cam disengages entirely from the notch 4122.
Finally, when coupling of the two parts of the connector 1 is about to be completed, as shown in FIG. 3d, the piston 41 is pushed towards the rear wall of the housing 40. Again by virtue of its elasticity, the body of the cam 45 pushes the finger towards the rear and the head 450 is engaged in the second notch 4122. Accordingly, the piston 41 is held in the new position, in which the jaws 5 are released.
This state constitutes a second stable state of the temporary locking device 4-5.
It will be readily understood from the foregoing description that the only energy input required by the temporary locking device 4-5 equipping the floating connector 1 in accordance with the invention is supplied by conventional coupling actuation means (not shown). The device is therefore entirely passive.
Referring again to FIG. 2a, it is entirely reversible and it can be tested in a non-destructive manner to see that it is operating correctly before the operational launch phase. It is only necessary to operate the knurled wheel 46 to move the finger 42 in the required direction to change from the second stable state to the first or vice versa, an extremely simple operation.
As already mentioned, FIGS. 1a through 1c show the first stable state or locked state of the jaws 5.
For a more comprehensive illustration of how the floating connector 1 of the invention operates, FIGS. 4a, 4b, 5a and 5b will now be described.
FIGS. 4a and 4b show the floating connector 1 respectively from the side and from the top during an intermediate phase of coupling the two parts 2 and 3 of the connector. FIG. 4a shows more particularly the action of the rods 22 on the pedals 43 which, in the intermediate state shown in the figure, begin to push the latter down. The jaws 5 begin to open and release the connection member 30. This state corresponds to that shown in FIGS. 3b and 3c for the temporary locking device 4-5.
FIGS. 5a and 5b show the floating connector 1, respectively from the side and from the top, on completion of coupling of the two parts of the connector 1. FIG. 5a shows more particularly the position reached by the rods 22 and the pedals 43. The latter are totally depressed. The jaws 5 are open and the connection member 30 has been released, i.e., is floating. This state corresponds to that shown in FIG. 3d for the temporary locking device 4-5.
It should be clear that the invention applies equally to electrical and fluidic connectors.
Although particularly well suited to space applications, the invention is not restricted to this type of application. It applies to any floating connector where it is necessary to provide temporary locking before coupling of the two parts constituting the connector.
Finally, it is implicitly assumed in the description that there is only one pair of male and female connection members. In one embodiment of floating connector in accordance with the invention, a plurality of connection members is provided. A temporary locking device similar to that previously described can then be associated with each floating connection member or a single locking device can operate one pair of jaws gripping all the connection members. All that is required in this case is for the wall of each jaw facing the connection members to be locked to have an appropriate profile mating with the external sections of the connection members. In most cases this wall will have semicircular cavities which fit around the connection members.
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A temporary locking device for locking the base of a floating base type connector comprises a pair of jaws, each actuated by a control member. The latter comprises a pedal operating through the intermediary of a finger on a drive piston having two notches defining locked and unlocked stable positions of the jaws. The finger operates also on a cam whose head engages in the notches. The device also comprises a manual resetting knurled wheel. Applications include space applications.
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CROSS-REFERENCE TO RELATED APPLICATIONS
The following U.S. Patents disclose the inking apparatus disclosed herein: U.S. Pat. No. 4,945,831, titled "INK TRAY DRIVE".
The following U.S. Patents disclose a tape apparatus with which the inking apparatus disclosed herein may be utilized: U.S. Pat. No. 4,935,078, titled "TAPE DRIVE"; U.S. Pat. No. 4,953,782, titled "REELED TAPE SUPPLY"; U.S. Pat. No. 4,007,370, titled "TAPE TAKE-AWAY AND MOISTENING SYSTEM"; U.S. Pat. No. 5,016,511, titled "TAPE CUTTER"; and U.S. Pat. No. 4,991,268, titled "TORQUE OR FORCE LINEARIZING DEVICE"; all filed on the same data as this application, and all assigned to the assignee of this application.
U.S. Pat. No. 4,935,078, titled "HIGH THROUGHPUT MAILING MACHINE TIMING", filed on the same data as this application and assigned to the assignee of this application, discloses a timing and control system for a mailing machine in which the inking apparatus disclosed herein may be utilized.
A modular mailing machine, tape apparatus and inking apparatus are disclosed in the following U.S. Patents which are assigned to the assignee of this application: U.S. Pat. No. 4,852,786, titled "TAPE MODULE FOR A MODULAR MAILING MACHINE".
The disclosures of all of the foregoing applications are incorporated herein by reference.
BACKGROUND OF THE INVENTION
The invention disclosed herein relates to an ink pad device, particularly for inking a printing device, particularly a printing device of a mailing machine.
In the mail processing field, it is highly desirable to imprint postage and other indicia on envelopes, packages, tapes, etc., at high speed. With such high speed operation, particularly where high volume is involved, it is important to maintain the quality of imprinted postage and other indicia.
SUMMARY OF THE INVENTION
It is an object of the invention disclosed herein to provide improved ink pad devices, particularly for inking a printing device.
It is another object of the present invention to provide ink pad devices incorporating a substantial supply of ink therein in addition to any ink already contained in an ink pad of the particular device.
It is another object of the invention to provide ink pad devices which are capable of imparting ink to a printing device quickly so as to permit high speed operation of the printing device.
It is another object of the invention to provide ink pad devices for inking a printing device which may be replenished with ink during operation of the printing device.
It is an another object of the invention to provide improved ink pad devices and ink pumps and/or ink reservoirs therefor, particularly for inking a printing device.
It is another object of the invention to provide ink pad devices which incorporate an ink reservoir and/or an ink pump.
It is another object of the invention to provide such ink pad devices in which all or part of the devices are disposable.
It is another object of the invention to provide such ink pad devices for inking postage meter printing devices, particularly at high speed.
It is another object of the invention to provide such ink pad devices which may be mounted to drive apparatus, particularly high speed drive apparatus, for moving the ink pad device or parts thereof including an ink pad from a home position to an inking position in which the ink pad of the ink pad device is tamped against a printing device.
It is another object of the invention to provide ink pad devices described in the preceding paragraph which are capable of being replenished with ink while mounted to the drive therefor during operation thereof.
It is another object of the invention to provide such ink pad devices which may be mounted to drive apparatus, particularly high speed drive apparatus, for moving the inking device or parts thereof including an ink pad in two directions, for example horizontal and vertical, from a home position to an inking position in which the ink pad of the ink pad device is tamped against a printing device.
The above and other objects are achieved by the invention disclosed herein which provides an ink pad device that includes an ink pad and an ink chamber for holding ink to be transferred to the ink pad i.e., the ink chamber holds ink in addition to any ink already contained in the ink pad. The ink chamber and the ink pad are configured such that the ink pad when mounted in the ink pad device is at least partially disposed in the ink chamber adjacent a layer of ink held in the ink chamber to obtain ink directly from the layer.
In a specific embodiment, the ink chamber includes therein a plurality of partitions defining a plurality of channels for holding ink, and the ink pad is at least partially disposed in the ink chamber contacting the partitions adjacent the channels to obtain ink disposed in the channels. The ink chamber may comprise structure defining a manifold extending adjacent an end of the ink channels in communication therewith.
In a specific embodiment, the ink pad comprises one or more layers of a material which sorbs ink from a layer of ink which the material is in contact.
According to an embodiment of the invention, an inlet is provided to the ink chamber for supplying ink thereto. Preferably, an outlet is also provided from the ink chamber for removing excess ink accumulated in the ink chamber.
According to an embodiment of the invention, the ink pad device includes an ink reservoir. In a specific embodiment, the ink chamber and reservoir are attached so as to form a unit. Thus, the ink pad, the ink chamber and the reservoir may be moved as a unit from the home position referred to above to the inking position referred to above when mounted to an ink device drive. Preferably, the ink pad/ink chamber/ink reservoir unit is a disposable unit, i.e., is constructed so as to make disposability practical. In another embodiment, the ink pad and ink chamber are attached as a unit, preferably a disposable unit, and the ink reservoir is separate therefrom.
According to an embodiment of the invention, the ink pad device includes an ink pump. In a specific embodiment, the ink chamber and the ink pump are attached so as to form a unit. Thus, the ink pad, the ink chamber and the ink pump may be moved as a unit from the home position referred to above to the inking position referred to above when mounted to an ink device drive. Preferably, the ink pad/ink chamber/ink pump unit is a disposable unit. In another embodiment, the ink reservoir and the pump are attached as a unit, preferably to be reused after the reservoir is emptied, and the ink chamber is separate therefrom. In that embodiment, only the ink chamber (and the ink pad) are moved from a home position to an inking position. Preferably, the ink chamber and ink pad are a disposable unit.
According to another embodiment of the invention, the ink pad device includes the ink reservoir and the ink pump, and in a specific embodiment, the ink chamber, the ink reservoir and the ink pump are attached so as to form a unit. Thus, the ink pad, the ink chamber, the ink reservoir and the ink pump may be moved as a unit from the home position referred to above to the inking position referred to above when mounted to an ink device drive. Preferably, the ink pad/ink chamber/ink reservoir/ink pump unit is a disposable unit.
In one embodiment, the ink pad device includes a cartridge with which the reservoir forms an integral or unitary part, and a tray which incorporates the ink chamber and which is attached to the cartridge. In another embodiment, the ink reservoir is a separate part from the ink chamber.
BRIEF DESCRIPTION OF THE DRAWINGS
The invention is illustrated by way of example and not limitation in the figures of the accompanying drawings in which like references denote the same elements, and in which:
FIG. 1 is a front perspective view of a drive according to the invention for moving an ink pad tray from a home position to an inking position in a mailing machine;
FIG. 2 is a sectional view of the drive of FIG. 1, also showing the ink pad tray in its home position, and a pump for the ink pad, a printing device and a platen device in its home position;
FIG. 3 is a front prospective view of the drive depicted in FIG. 1;
FIG. 4 is a simplified side view partially broken away of the drive, ink pad, ink pad tray, platen device and printer device depicted in FIG. 3 with the ink pad tray and the platen device in their home positions;
FIGS. 5-7 are views similar to that of FIG. 4 showing the motion of the ink pad tray in stages from its rest position depicted in FIG. 4 to its inking position depicted in FIG. 7 with the ink pad tamped against the printing device, the platen device being shown in its home position;
FIG. 8 is a view similar to that of FIG. 4 showing the ink pad tray back in its home position and the platen device in its printing position tamping an envelope or tape against the printing device for imprinting the envelope;
FIG. 9 consisting of FIGS. 9a, 9b and 9c is a series of plots showing the relationship between the horizontal and vertical positions of the ink pad tray and the angle of the ink pad drive camshaft with respect to movement of the ink pad tray from its home to its inking position;
FIG. 10 consisting of FIGS. 10a, 10b, and 10c is a series of plots showing the relationship between the horizontal and vertical positions of the ink pad tray and the angle of the ink pad drive camshaft with respect to movement of the ink pad tray shortly before, during and shortly after tamping thereof against the printing device;
FIGS. 11-17 are stick diagrams illustrating the relative positions of drive linkages, the ink pump linkages and the drive camshaft and showing the percentage completed of the inking cycle in moving the ink tray from its home position to its inking position;
FIG. 18 is a perspective view of an ink pad, ink pad tray and pump according to the invention;
FIG. 19 is an exploded perspective view of the ink pad, ink pad tray and pump depicted in FIG. 18;
FIG. 20 is a side sectional view of another embodiment of an ink pad, ink pad tray and pump, this embodiment including an ink reservoir, and this figure also showing portions of the ink tray drive which also actuate the pump; and
FIG. 21 is a sectional view of the reservoir and pump depicted in FIG. 20 taken along line 21--21 of FIG. 20.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
Referring to FIGS. 1 and 2, inker module 25 includes a chassis 30 which houses drive 32 that (a) moves an ink pad tray 34 (FIG. 2) from a home position (FIG. 2) to an inking position (FIG. 7) in which an ink pad 36 (FIG. 2) is tamped against a printing device 38 (FIG. 2) to ink the printing device; and (b) actuates a pump 40 (FIG. 2) to pump ink from a reservoir 41 in ink pad tray 34 to ink pad 36. Chassis 30 also houses drive 42 which moves platen device 44 (FIG. 2) upwardly from a home position (FIG. 2) to a printing position (FIG. 8) in which an envelope or strip of tape 46 is pressed against printing device 38 to imprint postage indicia thereon. Printing device 38 is part of a flat-bed postage meter referenced generally by 47 (FIG. 2) which is pivotally mounted by a counterbalance mechanism 48 in a system including inker module 25.
Ink tray 34 at opposed sides 50 (FIG. 2) adjacent its rear 52 is pivotally connected to ends 54, 55 (FIG. 1) of links 56, 57, respectively, by inwardly projecting pins 59 from links 56, 57 snap fitted in receptacles 61 (FIG. 18) of ink tray 34. The forward part 63 of ink tray 34 is supported by pins 65, (FIG. 1) inwardly projecting from ends 67, 68 of links 70, 71, respectively. That snap-fit arrangement facilitates replacement of ink tray 34 as described in more detail below. Platform 72 is fixed to chassis 30 so that links 56 and 57 move relative to platform 72. Pins 65 extend into slots or cut-outs 73 in sides 50 of ink tray 34 (FIG. 18) so that ink tray 34 may be moved by links 56 and 57 relative to platform 72 riding on pins 65. Platform 72 is attached to opposed sides 73, 74 (FIG. 1) of chassis 30 by screws 75 so that it may be removed for ease of assembling, disassembling and servicing of drives 32 and 42. Links 70 and 71 are pivotally attached in a central region 77 thereof to platform 72 by pins 79 so that ends 67 and 68 of links 70 and 71 pivot upwardly (clockwise) relative to platform 72. Movement of links 56 and 57 to the left in FIG. 1 move ink tray 34 horizontally to the left relative to platform 72, and clockwise pivoting of links 70 and 71 moves ink tray 34 vertically upwardly.
Drive 32 first moves links 56 and 57 to the left, as illustrated by the sequence of FIGS. 4-6, to move ink tray 34 horizontally to the left from its rest position (FIG. 4) to a position registered with printing device 38 (FIG. 6). Drive 32 then pivots links 70 and 71 (FIG. 7) to move ink tray 34 vertically and tamp it against printing device 38 to ink it. After drive 42 raises platen device 44 to press an envelope or tape strip 46 against printing device 38, drive 32 moves links 70 and 71, and links 56 and 57 move in reverse to the movements that brought ink tray 34 into its inking position, and return ink tray 34 to its home position.
Drive 32 (FIG. 3) includes drive motor 85, cam wheels 87, 88 fixed to camshaft 90 journaled to sides 72 and 73 of chassis 30, and pulley system 92 coupling motor shaft 93 and camshaft 90. Links 70 and 71 have respective rollers 94 rotatably connected to respective ends 96 thereof and are supported from chassis sides 72 and 73 such that respective rollers 94 ride on cam wheels 87 and 88, respectively. Springs 95 urge links 72 and 73 towards cam wheels 87, 88, and urge rollers 94 thereof into engagement with cam wheels 87, 88. Links 56 and 57 are pivotally connected at respective ends 100 thereof to respective ends 102 of links 104 and 105, respectively. Links 104 and 105 are pivotally connected at respective ends 107 to chassis sides 73 and 74, respectively, and have respective rollers 109 rotatably connected to a respective central part 110 thereof. Links 56 and 57 have rotatably connected to a respective central part 111 (FIG. 2) thereof respective rollers 112. Springs 113 urge links 56 and 57 towards cam wheels 87, 88, and urge rollers 112 thereof into engagement with cam wheels 87, 88. Cam wheels 87 and 88 each include a cam surface 114 on which a respective roller 94 rides, a cam surface 115 on which a respective roller 109 rides, and a cam surface 116 on which a respective roller 112 rides. Links 56 and 104, and links 57 and 105 are interconnected and supported such that respective rollers ride on respective cam surfaces of cam wheels 87 and 88, respectively, as respective cam followers. The cam surfaces are contoured to move the various links upon a given rotation of camshaft 90 to provide the motion of ink tray 34 described above and defined by FIG. 9, and the cam surfaces are aligned axially offset, as shown, or may be circumferentially aligned along the respective outer peripheries of cam wheels 87, 88. Cam wheels 87, 88 may be rotated through a cycle, with constant velocity or continuously with variable velocity, or cam wheels 87, 88 may be oscillated through a cycle.
Referring to FIGS. 1-3, drive 42 includes motor 118 having motor shaft 119, supported from sides 73, 74 of chassis 30 by bearing 120 (FIG. 3), gear 122 fixed to shaft 119, gear 123 meshing with and driven by gear 119, shaft 124 fixed to gear 123 and supported from chassis 30 by bearings 125, pinion gears 126 fixed to shaft 124, and racks 127 (FIG. 2) fixed to opposed sides of platten device 44 meshed with respective pinion gears 126. Actuation of motor 118 causes pinion gears 126 to rotate, engaging and elevating respective racks 127 and with them platten device 44. FIGS. 4-8 show elevation of platten device 44 with respect to movement of ink pad tray 34.
In order to produce straight line (e.g. generally horizontal) and parallel motion (e.g., parallel to the indicia surface of printing device 38), links 57 must experience some orthogonal motion (e.g., generally vertical). Links 105 and the corresponding cam surfaces cooperate with links 57 to provide that motion. Additionally, links 105 and the corresponding cam surfaces provide the orthogonal (vertical) motion during tamping.
The relationship between ink tray movement and camshaft 90 rotation is given in FIG. 9. FIG. 9(a) shows horizontal ink tray movement versus time; FIG. 9(b) shows vertical ink tray movement versus time; and FIG. 9(c) shows camshaft angle rotation versus time. The ordinate axes time scales in FIGS. 9(a), (b) and (c) are identical, so that viewing FIG. 9(a) and/or FIG. 9(b) with FIG. 9(c) gives horizontal and/or vertical displacement versus camshaft angle.
The plots in FIGS. 10(a), (b), and (c) are similar to the corresponding plots in FIG. 9 and give the relationship between ink pad tray movement and camshaft angle on an expanded side shortly before, during and shortly after the ink tray is tamped against the printing device, and include additional information. The cam profiles are configured to ensure that there is a bounceless strike of ink pad 36 against printing device 38, i.e., once ink pad 36 has been tamped against printing device 38 and it starts its downward movement, it is prevented from restriking printing device 38. FIG. 10 also gives ranges for acceptable ink tray vertical heights and indicia heights. The cam profiles are further configured to provide smooth acceleration and deceleration.
As mentioned above, drive 32 also actuates a pump 40 which pumps ink from reservoir 41 to ink pad 36. Referring to FIG. 2, link 130 is pivotally supported in its central part 132 from bracket 134 of chassis 30 with link end 136 adjacent cam wheel 88 and link end 138 adjacent pump 40. Roller 140 is rotatably connected to end 136 of link 130, and link 130 is configured and supported so that roller 140 rides on cam surface 142 as a cam follower. Rotation of cam wheel 88 pivots link 130 so that end 138 compresses pump 40 to create a pumping action therein as described below. Pump 40 is compressed once for each tamping of ink pad 36 against printing device 38, or less than once or more than once depending upon the amount of ink required. In the disclosed embodiment, pump 40 is compressed once for each ink pad tamping. It is preferred that pump 40 be compressed starting shortly before and during a substantial portion of the time that ink pad 36 is tamped against printing device 38. At high speed operation, it is preferred to pump only once per inking cycle to allow enough time for the pump material to relax to its original shape before compressing it again.
FIGS. 11-17 show the relative positions of links 57, 71, 105 and 130, rollers 96, 109, 112 and 140, cam wheel 88, ink tray 34, printing device 38, platen device 44 and pump 40 for different times of the inking cycle indicated in each figure as a percentage of the inking cycle. FIG. 11 shows the various parts in the home position of ink tray 34 (100% or 0% of the cycle), and FIG. 17 shows the various parts at the inking position of ink tray 34 when ink tray 34 is at its maximum height (about 30% of the cycle) and tamped against printing device 38. A time is indicated on each figure corresponding to times on the ordinate axis in FIGS. 9 and 10. A Cartesian coordinate system is referenced in the upper part of FIGS. 11-17 with the ordinate axis 175 representing the horizontal or "x" position of ink tray 34 and the coordinate axis 179 representing the vertical or "y" position of ink tray 34, with the origin of the coordinate system designated 183. The links and rollers (followers) are designated in FIG. 11 with respect to the axis along which they control movement. Diametric line 90 through the circle representing cam wheel 88 and diametric line 93 through the circle representing shaft 93 of motor 85 indicate in FIGS. 11-17 rotational relationship of cam wheel 88 and motor shaft 93 and the positional relationship of the various links and rollers at the indicated times in the cycle. Ink pad 36 also moves along the x-axis at the same time it is rising at the last 0.060 inch of vertical rise (total rise is 0.210) to provide a wiping action against the printing drive, which improves ink transfer. This is referred to in the drawings as "alpha-scrub". The alphascrub ratio is 4:1, that is 0.015 inch x-motion for the 0.060 inch y-motion. Various references locations are represented by cross hatches.
Referring to FIGS. 18 and 19, ink cartridge 200 includes ink reservoir 41 and ink tray 34 which holds ink pad 36 in an ink distribution chamber 204. Ink pad 36 is made of a resilient sorbent material which sorbs (i.e., absorbs) ink contained in ink distribution chamber 204. Ink pad 36 is compressed slightly during tamping thereof against inking device 38 to transfer ink thereto. Releasing of compression causes additional ink to be sorbed to the upper portion of ink pad 36. Preferably, ink pad 36 also sorbs ink through capillary action.
For use in a high speed mailing machine environment, ink tray 34 is constructed to transfer ink up to four times or more per second to the printing device 38, which imposes restraints on the amount of time in which ink must be sorbed by ink pad 36 and the amount of time in which ink must be transferred to printing device 38. Referring to FIGS. 9 and 10, each inking cycle is about 0.25 seconds (250 ms) including rest time, and is about 160 ms excluding rest time. Tamping takes up about 25 ms. Therefore, ink release to printing device 38 must take place within 25 ms, and a resupply of ink must be sorbed to the upper part of ink pad 36 in about 225 ms. Pump 40 must be compressed in about 80 ms and recover in about 80 ms. The design of ink tray 34 and pump 40 disclosed herein takes those restraints into consideration.
Ink pad 36 disclosed herein (FIGS. 18 and 19) includes a single layer or multi-layers. In the disclosed embodiment, two layers are shown, upper layer 36a and lower layer 36b. Upper layer 36a functions as a metering layer to release a metered amount of ink during tamping thereof against printing device 38, and lower layer 36b functions as a supply layer to the upper metering layer 36a to replenish ink released by the upper layer. Typically, upper layer 36a has a smaller average pore diameter than lower layer 36b, and ink transfer from ink distribution chamber 204 to lower layer 36b, and from lower layer 36b to upper layer 36a is by capillary action and negative internal pad pressures. During tamping, upper layer 36a is compressed slightly so that some ink transfer also occurs from lower layer 36b to upper layer 36a as a result, and upon release, of compression of upper layer 36a. The particular material used for ink pad 36 may depend upon the particular ink used. For example, when a dispersion ink is used, upper layer 36a and lower layer 36b may be a Scotfelt foam laminate (polyurethane) which consists of a firmness of 20 (upper) over 8 (lower), and when a solution ink is used, upper layer 36a may be in the so-called "Porex" media (sintered polyethylene), i.e., a polyethylene laminated with a heat-activated adhesive extending in a spider web pattern, and lower layer 36b may be an olefinic material such as Neoprene.
Referring to FIGS. 18 and 19, ink distribution chamber 204 has an inlet 206, an optional outlet 208, a number of channels 210 formed therein by partitions 212 and a manifold 214 in communication with partitions 210. Ink pad 36 is supported on partitions 212 in communication with channels 210 and manifold 214 so as to sorb ink present in channels 210 and manifold 214. The height of partitions 212 is selected to properly deliver the required amount of ink at highest possible usage while printing. For the specific ink used in the mailing machine referred to above, the height is about 0.030 inch.
Although channels 210 are shown to extend parallel to each other and to be of equal size, they need not be, and other designs may be suitable for supplying ink to ink pad 36.
Tubing 216 represented schematically in FIG. 18 communicates the output 218 of pump 40 with the inlet 206 of ink distribution chamber 204. In some applications it is preferable to provide for the removal of excess ink to avoid overflow and splashing during high speed operation, and to insure adequate ink supply. Ink usage is variable depending on the printing area (with or without ad slogan; variation in the ad slogan design, etc.). For use of ink tray 34 in such applications, ink distribution chamber 204 may optionally have an outlet 208, and reservoir 41 may have an inlet 220. Ink distribution chamber outlet 208 and reservoir inlet 220 are communicated via tubing 222 (represented schematically), or may be blocked, depending on the particular application, etc. Reservoir 41 has an outlet (not shown in FIGS. 18 and 19) within support 226 in direct communication, without valving, etc., with the input 224 of pump 40.
Ink flow is as follows. Pump 40 injects ink into ink distribution chamber 204 from reservoir 41 via pump output 218, tubing 216 and ink distribution chamber inlet 206. Optionally, excess ink in ink distribution chamber 204 not sorbed by ink pad 36 is returned to reservoir 41 via ink distribution chamber outlet 208, tubing 222 and reservoir inlet 220. Outlet 208 is communicated with ink distribution chamber 204 at an appropriate height so that excess ink flows back to reservoir 41 primarily by gravity force and to some extent by the pumping action of pump 40. If desired, a second pump (not shown) may be used to pump excess ink back to reservoir 41.
Pump 40 (FIG. 21) comprises an elastic sleeve or tube 230 capable of repeatedly being compressed and recovering to its original shape. Within sleeve 230 are disposed an input valve 232 and an output valve 234. Valves 232 and 234 are one-way valves which permit liquid to flow from the reservoir (41 in FIG. 18) into sleeve 230, and from sleeve 230 into ink pad distribution chamber 204. Ink reservoir 41 (FIGS. 18 and 19) includes a bearing surface 235 against which sleeve 230 is compressed by end 138 of link 130 (FIG. 2). Compression of sleeve 230 by link 130 closes valve 232 and opens valve 234, and expels ink from sleeve 230 through open valve 234. Upon release of the compression, a partial vacuum is created within sleeve 230 which closes valve 234 and opens valve 232, and which draws additional ink into sleeve 230. Valves 234 and 232 operate in the nature of ball valves, but are disposed entirely within sleeve 230. In the preferred embodiment valves 232 and 234 are duck bill valves which not only allow valves 232 and 234 to be placed entirely within sleeve 230, but also permit pump 40 to be operated at any attitude. In the embodiments illustrated in the drawings, pump 40 is disposed horizontally. In the presently preferred embodiment, the diameter of sleeve 230 is about 5/8 inch and its length about 2 inches, and is compressed by about 1/8 inch.
The particular application in which pump 40 will be used requires a consideration of the fluid to be pumped, the nature of the service environment, service life, cost, serviceability, etc. In the specific embodiments disclosed herein, sleeve 230 is made of an elastic material which is (a) non-reactive with the particular ink being used, (b) can withstand repeated compression cycles in the thousands to millions and recover to substantially its original shape to thereby perform the pumping action described above over the desired service life of the pump, and (c) can recover to substantially its original shape in a fraction of a second, more specifically within a time permitting at least four full pumping cycles per second. The wall thickness of sleeve 230 has an effect on service life and recovery time. A thicker wall thickness provides a faster recovery time, but also subjects sleeve 230 to more stress which reduces service life. For example, sleeve 40 may be made of an olefinic material such as Neoprene, silicone rubber, polyethylene or polypropylene which may have a preferred wall thickness of about 1/16 inch, and the duck bill valves may be made of olefinic material such as Neoprene (for ink capability). Similarly, other parts which come into contact with ink are made of a material which is not reactive with the particular ink used. Sleeve 230 may be connected to reservoir 41 by fitting the ends thereof tightly over conical fittings 236, 238 (FIG. 21), and sealing the sleeve to the fittings by means of an adhesive, heat shrinking, etc.
Referring to FIGS. 18 and 19, ink cartridge 200 (including ink tray 34) and ink pump 40 may be supplied as a disposable cartridge unit comprising ink reservoir 41, ink pad holder 202 including ink distribution chamber 204 and ink pad 36, and pump 40. Such a cartridge may be supplied tightly covered in foil or plastic to preserve product integrity during shipment, storage and handling, and ready for installation, which is facilitated by virtue of the snap-fit construction of ink tray 34 described above. Ink cartridge 200 includes a finger grasp 240 which may be engaged to un-snap ink cartridge 200 from and snap ink cartridge 200 into inker module 25. If desired individual parts of ink tray 34 and ink cartridge 200 may be replaced, although replacement as a unit is preferred.
FIGS. 20 and 21 depict an alternate embodiment in which ink cartridge 200 includes ink tray 34A, and ink pad holder 202A including ink distribution chamber 204A. Ink cartridge 200 does not include an ink reservoir, rather a separate larger reservoir 250 is provided. Ink pad holder 202A is constructed and mounted similar to ink pad holder 202, and ink distribution chamber 204A is similar to ink distribution chamber 204. Platform 72A is constructed and mounted similar to platform 72 except that reservoir 250 is disposed transversely to the plane of platform 72A, i.e., vertically, protruding through hole 252 thereof. Ink pad holder 202A moves relative to platform 72A as generally described for ink tray 34 and platform 72. Ink reservoir 250 is received in receptacle 254 mounted to the bottom 256 of chassis 30A by flanges 257. With tray 34A removed, reservoir 250 is simply dropped in or lifted out of receptacle 254. Pump 40 is affixed to the bottom 260 of reservoir 250 projecting through hole 261 of receptacle 254. Pump 40 extends horizontally as in the embodiment of FIGS. 18 and 19.
Drive 32A includes a link 130A supported to be cammed by cam wheel 87A similar to link 130 and cam wheel 87 so that its end 138A compresses sleeve 230 of pump 40, as described above for drive 32, link 130 and cam wheel 87. The output of pump 40 is communicated with the inlet 206A of ink distribution chamber 204A by tubing 216A, and the outlet of ink distribution chamber 204A is communicated with port 262 of reservoir 250 by tubing 222A. Port 262 communicates with the input 224 of pump 40.
Ink tray 34A and reservoir 250 and pump 40 operate to pump ink from reservoir 250 to ink distribution chamber 204A as described for the embodiment depicted in FIGS. 18 and 19, except that excess from ink distribution chamber 204A tends to be recirculated rather than returned to reservoir 250.
In the embodiment depicted in FIGS. 20 and 21, ink reservoir 250 and pump 40 are replaceable separately from ink tray 34A. Tray 34A may easily be replaced, as described for tray 34, by a new tray. After un-snapping tray 34A, and disconnecting tubing 216A and 222A, reservoir 250 is exposed and may easily be lifted out of receptacle 254 for removal and replacement, and thereafter replaced by connecting tubing 216A and 222A, and dropping reservoir 250 back into receptacle 254. If necessary, receptacle 254, reservoir 250 and pump 40 may be replaced by a new unit.
For those embodiments which include an ink pump 40, it may be necessary to initialize the system each time an ink tray is changed to pump a predetermined amount of ink into the ink distribution chamber 204, 204A before commencing actual printing operations.
The control system described in U.S. Pat. No. 4,935,078, referenced above, may be used to accomplish and synchronize the foregoing operation of drives 32 (32A) and 42, and pump 40.
Certain changes and modifications of the embodiments of the invention herein disclosed will be readily apparent to those of skill in the art. Moreover, uses of the invention other than in mailing apparatus will also be readily apparent to those of skill in the art. It is the applicants' intention to cover by the claims all such uses and all those changes and modifications which could be made to the embodiments of the invention herein chosen for the purposes of disclosure which do not depart from the spirit and scope of the invention.
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An ink pad device for a high speed mailing machine is disclosed. The ink pad device includes an ink pad and an ink chamber in which the ink pad is at least partially disposed to sorb ink therefrom. The ink pad device may also comprise an ink reservoir and/or a pump for pumping ink from the reservoir to the ink chamber. The ink pad device is attachable to a drive for moving the ink pad horizontally and vertically from a horizontal home position to a horizontal inking position in which the ink pad is tamped against a printing device which imprints postage indicia. The ink pump comprises a deformable chamber which is compressed to pump ink from the reservoir to the ink chamber. In one embodiment, the ink pad and the ink chamber are provided as a disposable, non-replenishable, non-refillable unit containing a limited amount of ink for limited use. In another embodiment, the ink chamber, the ink pad, the reservoir and the pump form a unit in which ink is replenished from the reservoir to the ink chamber. In that embodiment, the entire unit may be made disposable and may be moved by the drive to the inking position. In still another embodiment, the ink pad and the ink chamber form a disposable, replenishable unit, and the reservoir is replaceable. In that embodiment, only the ink pad and the ink chamber are movable by the drive to the inking position.
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This application claims benefit of Provisional Application 60/115,906 filed Jan. 14, 1999.
FIELD OF THE INVENTION
This invention relates to phase shift masks, specifically photomask blanks and the patterned photomasks made therefrom, in optical lithography with short wavelength, i.e., <200 nm, light. More specifically this invention relates to phase shift masks that attenuate and change the phase of transmitted light by 180° relative to light propagating the same path length in air. Such masks are commonly known in the art as attenuating (embedded) phase shift masks or half-tone phase shift masks. Still more particularly, this invention discloses novel attenuating embedded phase-shift masks, whose optical properties can be engineered at any wavelength by multilayering ultrathin UV transparent layers with ultrathin UV absorbing layers.
BACKGROUND OF THE INVENTION
Optical lithography is one of the key enabling technologies in semiconductor microcircuit fabrication. Photomasks, which are high purity quartz or glass plates containing precision microscopic images of intergrated circuits, are used to transfer precise design patterns on to silicon wafers. Deposition and etching techniques create actual circuits on the wafers, which are then cut into hundreds of individual chips. Making a complex chip, such as a microprocessor, can involve more than 20 layers. And each requires a different, precise, reusable mask.
As the demand for devices with higher performance and speed continue, the need for patterning circuits with finer features is driving optical micro-lithography to shorter and shorter wavelengths (248 nm→193 nm→157 nm). This is because the resolution achieved with traditional Cr masks, that either block or pass light for imaging, is limited by optical diffraction effects. At any wavelength, however, phase-shift masks can extend resolution beyond the wavelength-imposed diffraction limit Phase-shift masks work by employing destructive optical interference to enhance contrast. Current projections are that optical lithography with 193 nm light and phase-shift masks will support designs with minimum feature size of 120 nm. But sub 100 nm features will require moving to 157 nm and phase-shifting, if optical lithography is to be used.
Phase-shift masks for optical lithography, and attenuating phase-shift masks in particular, have been the subject of numerous publications, e.g., Marc D. Levenson, “Wavefront engineering for photolithography,” Physics Today, 28, Jul. 1993, and Y.-C. Ku, E. H. Anderson, M. Schattenburg, and H. I. Smith, “Use of pi-phase shifting x-ray mask to increase intensity slope at feature edges,” J. Vac. Sci. Technol. B6(1) 150 (1988). Nearly all of the prior art of attenuating phase-shift masks falls into two categories: (1) nonstoichiometric materials, that is, materials that are chemically deficient in one or more elements to be considered proper compounds and (2) bi-layers comprised of one absorber and one phase-shift layer. Commonly assigned, copending application Ser. No. 08/797,443, filed Feb. 10, 1997, now U.S. Pat. No. 5,897, 977 discloses optical multilayer structures as a novel approach to systematically designing attenuating phase-shift masks. They consist of alternating, ultrathin (<10 nm) layers of an optically transparent material , multilayered with an optically absorbing material at the optical wavelength of use. Both the optically transparent and absorbing layers can be stable compounds. Non-stoichiometric materials, such as SiN x , K. K. Shih and D. B. Dove, “Thin film materials for the preparation of attenuating phase shift masks,” J. Vac. Sci. Technol. B 12(1) 32 (1994), are less attractive because their optical properties depend critically on synthesis conditions, so that, for example, a small fluctuation in the partial pressure of the reactive gas concentration during sputtering can cause large excursions in optical properties such as transmission as well as phase-shift. Non-stoichiometric materials also tend to be less stable, especially thermally, than the corresponding stoichiometric compound.
Bilayer designs usually consist of a thin metal such as Cr, which is optically absorbing and a transparent layer such as SiO2. The disadvantages of this structure include the need to interrupt the manufacturing process, because each layer requires very different synthesis conditions. In fact, transfer of the partially made mask blank to a separate deposition chamber may be required Mask-making is also made difficult by the requirement for distinctly different etch processes for each layer and also by potential problems such as delaminating of the separate layers that can occur because of significant differences in their thermal, mechanical, and chemical properties.
In contrast, control of optical properties of optical multilayers is by layer thickness, which can be precisely controlled in the sputtering process, usually preferred for manufacturing. Also the layers are kept ultra-thin, compared to the optical lithographic wavelength—thus optical properties are less sensitive to interfacial roughness and this promotes uniform etching of the separate layers. Also, both layers of the multilayer can be chosen to be stable nitride or oxide compounds. Thus, systematic tailoring of optical properties (i.e., chemistry) is by layer thickness; and this approach is tunable for multiple optical wavelengths. Further, sputtering conditions can be chosen with broad process latitude with the simplicity of elemental sputtering targets. Chemically stable layers can be selected with attractive etch properties. And the layers can be thin, leading to uniform dry etching and improved radiation stability.
While there are disclosures in the literature to SiO 2 /Si 3 N 4 multilayers for application as “dielectric mirrors ” or equivalently as “Bragg reflectors”, e.g., A. Scherer, M. Walther, L. M. Schiavone, B. P. Vander Gaag, and E. D. Beebe, “Thigh reflectivity dielectric mirror deposition by reactive magnetron sputtering,” J. Vac. Sci. Technol. A 10(5) 3305 (1992) and D. J. Stephens, S. S. He, G. Lucovsky, H. Mikkelsen, K. Leo, and H. Kurz, “Effects of thin film deposition rates, and process-induced interfacial layers on the optical properties of plasma-deposited SiO 2 /Si 3 N 4 Bragg reflectors, J. Vac. Sci. Technol. A 11(4) 893 (1993), their structure and properties at the operating wavelength are very different than what is required for phase-shift masks at wavelengths below 200 nm. The application of multilayered stacks as dielectric mirrors is disclosed in “The Materials Science of Thin Films”, M. Ohring, Academic Press, San Diego 1992 in Chapter 11, pp. 534-536. One requirement is that one material in the stack have a high index of refraction relative to the other material. And each layer in the stack must be a quarter wavelength thick at the reflector or operating wavelength. It is also desirable that both layers be transparent, i.e., have negligible extinction coefficient, at the reflector wavelength for maximum reflectivity. By comparison application as a phase-shift mask does not require that separate layers have contrast in their indices of refraction, although they may. However, one layer should be absorbing for application as a tenuating phase-shift masks, so that the optical transmission of the stack can be adjusted by the thickness ratio of the two layers. Further, there is no restriction of layer thickness for phase-shift masks as there is for a dielectric mirror, where each layer must have a thickness corresponding to a quarter wavelength. In fact layer thicknesses much less than the operating wavelength are preferred in application as phase-shift masks. The optical design for a dielectric mirror is unrelated to the design criteria for an attenuating, phase-shift mask, and these design equations are distinctly different Thus, there is no way to anticipate whether a particular multilayer stack can be designed to be an attractive attenuating, phase-shift mask, solely based on its satisfactory performance as a dielectric mirror.
Commonly assigned, copending application Ser. No. 08/797,443, filed Feb. 10, 1997, now U.S. Pat. No. 5,897,977, granted Apr. 27, 1999, discloses a novel, systematic materials approach involving optical multilayer structures to design attenuating phase-shift masks, the most versatile and common type phase-shift mask, applicable at any optical wavelength, with particular emphasis on wavelengths below 400 nm. These multilayers are comprised of alternating, ultrathin (<10 nm) layers of an optically transparent material, multilayered with an optically absorbing one, e.g., Si 3 N 4 and TiN, respectively. While the multilayered structures of this disclosure fill a wide variety of applications, the need remains for simpler multilayered system which are more easily manufactured.
This invention provides for two particularly simple optical multilayer masks, specifically, silicon oxide multilayered with silicon nitride and aluminum oxide layered with aluminum nitride. The masks provided for by this invention have attractive properties as phase-shift masks with application at wavelengths below 200 nm, and in particular near 157 nm, as discussed in T. M. Bloomstein, M. W. Horn, M. Rothschild, R. R. Kunz, S. T. Palmacci, and R. B. Goodman, “Lithography with 157 nm lasers,” J. Vac. Sci. Technol. B15(6) 2112, 1997 and T. M. Bloomstein, M. Rothschild, R. R. Kunz, D. E. Hardy, R. B. Goodman, and S. T. Palmacci, “Critical issues in 157 nm lithography, J. Vac. Sci. Technol. B16(6) 3154, 1998 [1,2], targeted for optical lithography following the 193 nm generation.
SUMMARY OF THE INVENTION
This invention provides for an attenuating embedded phase shift mask capable of producing a phase shift of 180° with an optical transmissivity of at least 0.001 at a selected lithographic wavelength <200 nm, said mask comprising distinct alternating contiguous layers of an optically transparent material consisting essentially of an oxide selected from the group consisting of oxides of Al and Si and layers of an optically absorbing material consisting essentially of a nitride selected from the group consisting of nitrides of Al and Si. It is preferred for ease of manufacture that the distinct layers contain the same cation, i.e., either an oxide of silicon on a nitride of silicon or an oxide of aluminum on a nitride of aluminum.
As used hereinunder the term “mask” is intended to include both photomask blanks, i.e., unpattemed photomasks prior to imagewise exposure to imaging radiation, and patterned photomasks, i.e., photomasks containing an imagewise pattern resulting from imagewise exposure to imaging radiation.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a graph showing the dependence of the index of refraction (n) at 157 nm on the fraction (f) of Si 3 N 4 in SiO 2 /Si 3 N 4 multilayers.
FIG. 2 is a graph showing the dependence of the extinction coefficient (k) at 157 nm on the fraction (f) of Si 3 N 4 in SiO 2 /Si 3 N 4 multilayers.
FIG. 3 is a graph showing the dependence of the index of refraction (n) at 157 nm on the fraction (f) of AlN in Al 2 O 3 /AlN multilayers.
FIG. 4 is a graph showing the dependence of the extinction coefficient (k) at 157 nm on the fraction (f) of AlN in Al 2 O 3 /AlN multilayers.
FIG. 5 is a graph showing the dependence of the optical transmission (T) for SiO 2 /Si 3 N 4 multilayers with 180° phase-shift on the fraction (f) of Si 3 N 4.
FIG. 6 is a graph showing the dependence of the total film thickness (d) for SiO 2 /Si 3 N 4 multilayers with 180° phase-shift on the fraction (f) of Si 3 N 4.
FIG. 7 is a graph showing the dependence of the optical transmission (T) for Al 2 O 3 /AlN multilayers with 180° phase-shift on the fraction (f) of AlN.
FIG. 8 is a graph showing the dependence of the total film thickness (d) for Al 2 O 3 /AlN multilayers with 180° phase-shift on the fraction (f) of AlN.
DETAILED DESCRIPTION OF THE INVENTION
This invention relates to attenuating phase-shift masks based on novel Si-based and Al-based optical multilayer structures for optical lithography at wavelengths below 200 nm. Preferably, the phase-shift masks are comprised of either Si-nitride layered with Si-oxide or Al-oxide layered with Al-nitride. At wavelengths below about 200 nm Si-oxide is more transparent than Si-nitride, and Al-oxide is more transparent than Al-nitride. At about 157 nm, which is a candidate wavelength for the next generation optical lithography, Al-oxide and Si-oxide films of thicknesses less than 200 nm have negligible optical absorption for application as photomasks. At this same wavelength Al-nitride and Si-nitride are optically absorbing with extinction coefficients close to but less than one (1.0), providing a gradual dependence of multilayer optical properties on the oxide to nitride thickness ratio. Precise tailoring of optical properties and phase-shift of the corresponding multilayer structures can be achieved by layering Al-nitride with Al-oxide or layering Si-nitride with Si-oxide.
Because each layer in the structure consists of either Si or Al, synthesis is greatly simplified and can be accomplished by techniques well known in the art. In the case of sputtering, only one target, either Si or Al, is needed. Sputtering, because of its excellent control and reproducibility, is usually preferred for manufacture of lithographic masks. For sputtering, the transition from oxide to nitride layer, or vice versa, is accomplished by changing the reactive gas from oxygen to nitrogen. For example, multilayers of Si-oxide/Si-nitride can be made by ion-beam sputtering, using one ion gun to sputter Si atoms from the Si target and a secondary ion gun to alternately bombard the substrate with oxygen and then nitrogen ions to form alternating layers of Si-oxide and Si-nitide. Of course, alternating layers of oxide and nitride can also be made by chemical vapor deposition, using appropriate individual precursor chemicals for each layer, as well known to those skilled in the art of chemical vapor deposition. For example, Si-nitride layers can be synthesized from silane plus ammonia (SiH 4 +NH 3 ), while Si-oxide layers can be grown from hexamethyldisiloxane (C 6 H 18 Si 2 O).
The art of preparing patterned photomasks from unpatterned photomasks, known as photomask blanks, is well know and the various techniques for so doing are completely described in L. F. Thompson et al., “Introduction to Microlithography”, Second Edition, ACS Professional Reference Book, American Chemical Society, Washington, D.C., 1994. Typically, to pattern photomask blanks made of Si-oxide/Si-nitride or Al-oxide/Al-nitride multilayers of this invention dry etching is preferred. For both Al-based and Si-based multilayers, because of the similar layer chemistries, e.g. Si-oxide and Si-nitride, the same dry etch protocol can be used for both layers, effectively etching the multilayer as a chemically homogeneous material. For example, CF 4 can be used to dry etch Si-oxide and Si nitride layers.
From a knowledge of the index of refraction and extinction coefficients for the oxide and nitrides of Si and Al, one can calculate the thicknesses of individual oxide and nitride layers in a multilayer structure with 180 degrees phase-shift and a particular optical transmission at a specified wavelength. The equations relating phase-shift, optical transmission (T s ) for a multilayer film with optical coefficients, n s and k s and total thickness d s at an optical wavelength λ are:
( n s −1)d s ≈λ/ 2
T s ≈(1−R) 2 exp(−4π k s d s /λ)
(K. K. Shih and D. B. Dove J. Vac. Sci. Technol. B 12(1), Jan/Feb 1994, pp. 32-38).
Here, R is the reflection coefficient for the multilayer film. R can calculated from n s and k s (O. S. Heavens, Optical Properties of Thin Solid Films, Dover, New York, 1991, Chapter 4, pp 46-95).
The optical coefficients for the multilayer can be calculated from the coefficients for individual oxide and nitride layers (a and b) using the effective medium approximation, when the oxide and nitride layers are thin compared to optical wavelength, that is, d a , d b <<1/10λ. Hunderi and K. Johannessen, Superlattices and Microstructures, Vol. 3, No. 2, 1987, pp. 193-198):
e s =fe a +(1 −f ) e b ; f=fraction of metal (3)
where the dielectric coefficients e are related to the corresponding optical coefficients by
e =( n−ik ) 2 (4)
In the above expression, f corresponds to the fractional thickness of the absorbing nitride layer in the multilayer structure, and thus (1−f) corresponds to the factional thickness of the more optically transparent oxide layer.
At about 157 nm, the index of refraction and extinction coefficients for SiO 2 are n=1.69 and k=1×1 −5 , respectively; for Si 3 N 4 n=2.65 and k=0.962 (Handbook of Optical Constants of Solids, ed. E. Palik, Academic Press, Orlando, 1985, pp. 719-763). Using Equations 3 and 4, the optical coefficients for the Si-oxide/Si-nitride multilayer can be calculated as a function of the fractional nitride thickness. These dependence of the optical coefficients for Si-oxide/Si-nitride multilayers is shown in FIGS. 1 and 2.
For Al 2 O 3 with n=2.09 and k=0 at about 157 nm (Handbook of Optical Constants of Solids II, ed. E. Palik, Acadernic Press, San Diego, 1991, pp. 719-763) and for AIN with k=3.02 and k=0.81 at the same wavelength (Handbook of Optical Constants of Solids III, ed. E. Palik, Academic Press, San Diego, 1998, pp. 373-401), the dependence of the optical coefficients of Al-oxide/Al-nitride multilayers is shown in FIGS. 3 and 4.
From the dependence of the optical coefficients on the fractional nitride thickness, design graphs of the optical trans mission and the corresponding multilayer thickness with 180 degrees phase-shift can determined, using Equations 1 and 2, for both Si-oxide/Si-nitride and Al-oxide/Al-nitride multilayers versus the fractional nitride thickness. These graphs are shown in FIGS. 5 and 6 for Si-oxide/Si-nitride multilayers and in FIGS. 7 and 8 for Al-oxide/Al-nitride multilayers. FIGS. 5 and 6 indicate that to design an attenuating phase-shift mask with 180 degrees phase-shift and optical transmission between 5% and 15% requires fractional Si-nitride thicknesses of between about 0.37 and 0.17, respectively, corresponding to multilayer film thicknesses in the range of about 74 nm to 91 nm. Al-oxide/Al-nitride multilayers with 180 degrees phase-shift and optical transmisson between about 5% and 15% require fractional Al-nitride thicknesses of about 0.2 to 0.1, and multilayer thicknesses corresponding to about 58 nm to 65 nm. In the next section, FIGS. 5 and 6 for Si-oxide/Si-nitride and FIGS. 7 and 8 for Al-oxide/Al-nitride will be used to develop specific examples of multilayer designs for attenuating phase-shift masks.
EXAMPLES
Example 1
Si-oxide/Si-nitride multilayer phase-shift mask with T=15% at 157 nm
From FIGS. 5 and 6, T=15% requires a fractional Si-nitride thickness of 0.169, and 180 degrees phase-shift corresponds to a multilayer thickness of 91.3 nm at this fractional nitride thickness. If we choose a multilayer structure which is periodic with a periodicity of 7.6 nm, much less than the optical wavelength of 157 nm, then the multilayer structure will consist of 12 layers of Si-nitride, each 1.284 nm thick alternating with 12 layers of Si-oxide, each 6.316 nm thick. This can be expressed as:
12×(1.284 nm Si 3 N 4 +6.316 nm SiO 2 )
Example 2
Si-oxide/Si-nitride multilayer phase-shift mask with T=10% at 157 nm
From FIGS. 5 and 6, T=10% requires a fractional Si-nitride thickness of 0.230, and 180 degrees phase-shift corresponds to a multilayer thickness of 85 nm at this fractional nitride thickness. If we choose a multilayer structure which is periodic with a periodicity of 8.5 nm, much less than the optical wavelength of 157 nm, then the multilayer structure will consist of 10 layers of Si-nitride, each 1.96 nm thick alternating with 10 layers of Si-oxide, each 6.54 nm thick. This can be expressed as:
10×( 1.96 nm Si 3 N 4 +6.54 nm SiO 2 )
Example 3
Si-oxide/Si-nitride multilayer phase-shift mask with T=5% at 157 nm
From FIGS. 5 and 6, T=5% requires a fractional Si-nitride thickness of 0.37, and 180 degrees phase-shift corresponds to a multilayer thickness of 73.7 nm at this fractional nitride thickness. If we choose a multilayer structure which is periodic with a periodicity of 6.7 nm, much less than the optical wavelength of 157 nm, then the multilayer structure will consist of 11 layers of Si-nitride, each 2.48 nm thick alternating with 11 layers of Si-oxide, each 4.22 nm thick. This can be expressed as:
11×(2.48 nm Si 3 N 4 +4.22 nm SiO 2 )
Example 4
Al-oxide/Al-nitride multilayer phase-shift mask with T=15.3% at 157 nm
From FIGS. 7 and 8, T=15.3% requires a fractional Al-nitride thickness of 0.105, and 180 degrees phase-shift corresponds to a multilayer thickness of 64.8 nm at this fractional nitride thickness. If we choose a multilayer structure which is periodic with a periodicity of 7.2 nm, much less than the optical wavelength of 157 nm, then the multilayer structure will consist of 9 layers of Al-nitride, each 0.76 nm thick alternating with 9 layers of Al-oxide, each 6.44 nm thick. This can be expressed as:
9×(0.76 nm AlN+4.22 nm Al 2 O 3 )
Example 5
Al-oxide/Al-nitride multilayer phase-shift mask with T=10.4% at 157 nm
From FIGS. 7 and 8, T=10.4% requires a fractional Al-nitride thickness of 0.136, and 180 degrees phase-shift corresponds to a multilayer thickness of 62.7 nm at this fractional nitride thickness. If we choose a multilayer structure which is periodic with a periodicity of 5.7 nm, much less than the optical wavelength of 157 nm, then the multilayer structure will consist of 11 layers of Al-nitride, each 0.775 nm thick alternating with 11 layers of Al-oxide, each 4.925 nm thick. This can be expressed as:
11×(0.775 nm AIN+4.925 tn Al 2 O 3 )
Example 6
Al-oxide/Al-nitride multilayer phase-shift mask with T=5.3% at 157 nm
From FIGS. 7 and 8, T=5.3% requires a fractional Al-nitride thickness of 0.20, and 180 degrees phase-shift corresponds to a multilayer thickness of 58.6 nm at this fractional nitride thickness. If we choose a multilayer structure which is periodic with a periodicity of 5.86 nm, much less than the optical wavelength of 157 nm, then the multilayer structure will consist of 10 layers of Al-nitride, each 1.17 nm thick alternating with 10 layers of Al-oxide, each 4.69 nm thick. This can be expressed as:
10×(1.17 nm AlN+4.69 nm Al 2 O 3 )
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Disclosed are attenuating embedded phase shift masks capable of producing a phase shift of 180° with an optical transitivity of at least 0.001 at a selected lithographic wavelength less than 200 nm. The masks are comprised of distinct contiguous alternating contiguous layers of an optically transparent material consisting essentially of an oxide selected from the group consisting of oxides of Al and Si and layers. of an optically absorbing material consisting essentially of a nitride selected from the group consisting of nitrides of Al and Si. Such masks are commonly known in the art as attenuating (embedded) phase shift masks or half-tone phase shift masks.
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FIELD OF THE INVENTION
[0001] This invention relates to materials, particularly polymeric materials, which absorb and dissipate energy and/or selectively allow energy to be transmitted, methods of making same, and articles comprising such materials.
BACKGROUND OF THE INVENTION
[0002] Included in the concept of energy absorption are the ability to absorb mechanical vibration, shock, and impulse such as with engine mounts and other shock absorbing devices, as well as absorb acoustical energy. By way of example only, the latter may include conventional sound waves as well as sonar at both sonic and ultrasonic frequencies. Energy absorption can occur in the form of mechanical transmission loss and echo reduction or insertion loss, for example in the field of sonic or ultrasonic sonar. Material is formulated such that the energy from mechanical or acoustic waves is attenuated therein, thereby reducing the energy in the wave as it traverses the material.
[0003] Energy-absorbing polymeric materials in general are known in the art. For example, U.S. Pat. No. 4,980,386 to Tiao et al. discloses polyurethane from polyol and polyisocyanate having shock-attenuating and low rebound attributes. U.S. Pat. No. 6,100,363 to Sampara et al. discloses polyurethane-based energy-absorbing elastomers comprising a water scavenger and exhibiting low resilience. U.S. Pat. No. 4,476,258 to Hiles discloses polyurethane elastomer compositions comprising a urethane-forming component and a diisocyanate exhibiting a compression set of less than about five percent and a recovery time of about 10 to about 100 milliseconds. Many materials, including that disclosed in U.S. Pat. No. 4,346,205 to Hiles, are composites which include, for example, hollow glass spheres (U.S. Pat. No. 4,079,162 to Metzger) or, gas bubbles as in a foam (U.S. Pat. No. 4,097,633 to Focht). Finally, perhaps the most well-known damper or isolator material is Sorbothane® from Sorbothane, Inc. of Kent, Ohio. Sorbothane® is a proprietary polyurethane which converts mechanical energy into heat.
[0004] Sonar-absorbing materials are also known in the art. U.S. Pat. No. 4,628,490 to Kramer et al. discloses a plurality of non-conducting elastomeric matrix layers having piezoelectric or magnetostrictive particles disposed therein. U.S. Pat. No. 5,444,668 to Sevik discloses an elastomeric matrix containing sealed air-filled cavities and random labyrinths of small water-filled passages. Finally, specialized syntactic foams for underwater acoustic applications (Syntactic Acoustic Damping Material—SADM) are offered by Syntech Materials, Inc. of Springfield, Va. The latter, however, contain lead, a potential environmental hazard.
[0005] Despite the wide variety of materials available for various energy-absorbent applications, there remain multiple needs for materials with improved properties which are, at the same time, less burdensome to the environment. For example, acoustic/sonar reduction materials which exhibit high insertion loss per inch, large and tailored echo reduction with relatively thin layers, tailored impedance, and mechanical integrity under deep ocean conditions can provide benefits not available with conventional materials. For mechanical applications, there is a need for materials which exhibit high internal loss and suitable mechanical properties such as hardness and toughness which may be tailored to the application for shock and vibration control.
SUMMARY OF THE INVENTION
[0006] A polymeric material is provided with inherently high internal energy loss for mechanical waves propagating through the material. Mechanical waves can be compression or shear waves within the material, variously described in the literature as mechanical waves or, in some contexts, described as acoustic plane waves or higher order acoustic waves. The material formulation is such that mechanical or acoustic waves are attenuated thereby reducing the energy in the wave as it traverses the material in any of several possible waveforms and/or modes of propagation. The energy dissipation within the material is presumed to occur from a variety of internal conditions, including, but not limited to, point relaxation, thermo-elastic effects, interactions between molecules, and interactions between various aspects of polymer chain. These conditions within a material are difficult to measure and to evaluate; therefore, the exact mechanisms are always somewhat speculative in nature and the contribution of each of the various mechanisms to the total energy dissipated. The energy dissipation typically will depend on measurable quantities such as temperature, frequency, and strain amplitude. The energy loss is oftentimes described and measured as hysteresis within the material. A common method to mathematically describe the hysteresis within a material is with the use of complex arithmetic with real and complex portions of the mathematical equation that is a representation of phase differences in the vector components of the physical parameters used to describe the material behavior.
[0007] The bulk material performs in a similar manner to dissipate mechanical and/or acoustic energy as gross deflections are imposed on the bulk material as in the case of a machinery mount, shock isolator, vibration isolator mount, noise pad, unconstrained damping material, or as a constrained damping material. The mechanical energy is imposed in a manner to result in tension-compression strain, shear strain, or a combination of tension-compression and shear strain within the bulk material. Similar mechanisms as described above are considered to be the method of energy dissipation.
[0008] It has been unexpectedly and surprisingly found that materials comprising a formulation comprising a polyol, preferably a polyol selected from the group consisting of polyether, polyester, polyether/ester, acrylic, and mixtures thereof; a polybutadiene, preferably a hydroxyl-terminated polybutadiene; a polyisocyanate; a silicone; and preferably a suitable catalyst, more preferably an organometallic catalyst, and even more preferably dibutyl tin dilaurate (DBTDL), exhibit improved energy-absorbent properties. Optionally, additives may be functionally (fillers or extenders) or cosmetically (color contributors) added.
[0009] It is, therefore, an object of the present invention to provide formulations which form energy-absorbent materials which offer improved acoustic, vibration, and shock attenuating properties over conventional materials. It is also an object of the invention to provide materials whose acoustic impedance matches closely the impedance of water, and especially sea water.
[0010] It is further an object of the present invention to provide devices made from or comprising the energy-absorbent materials disclosed herein which offer improved acoustic, vibration, and shock attenuating properties over devices made from conventional materials. Such devices include, without limitation, hydrophone mounts and covers, sub-marine-related coatings and other devices, both passive and active, which operate underwater, composite propellers and thrusters, sonar domes, acoustic panels, sound-reduction mats or blankets, composite hatches and covers, composite fairings and baffles, remote undersea operations vehicles, sound deadening and other sound reduction devices, ear muff components for noise reduction, molded noise-reducing ear plugs, machinery mounts, enclosures, and isolators, and mechanical snubbers, bumpers, stops, impact absorbing structures, vibration and shock reduction materials in sporting equipment and hand tools, and shock absorption in shoes.
[0011] It is yet a further object of the present invention to provide methods of preparing such energy-absorbent materials and to further prepare devices made from or comprising such materials.
[0012] In one embodiment, an energy-absorbent composition is provided which comprises the result of the combination of a polyol, a polybutadiene, an isocyanate, and a silicone. Preferably, the energy-absorbent composition further comprises a suitable catalyst, more preferably an organotin catalyst, and even more preferably dibutyl tin dilaurate (DBTDL). Preferably, the polyol is chosen from the group consisting of polyether, polyester, polyether/ester, acrylic, and mixtures thereof. For example, the polyether may be Desmophen 1920 D® (Bayer Corp., Pittsburgh, Pa.) polyether. For example, the polyester may be chosen from the group consisting of Desmodur 670A-80® (Bayer) polyester and Desmophen 631A-75® (Bayer) polyester and mixtures thereof. For example, the polyether/ester may be Desmophen 1150® (Bayer) polyether/ester. For example, the acrylic may be Joncryl 492® (Johnson Polymer, Sturtevant, Wis.) acrylic. Preferably, the polybutadiene is a hydroxyl-terminated polybutadiene, for example, Poly bd R-45M® (Startomer, Exton, Pa.). Preferably, the isocyanate is a hexamethylene diisocyanate-based isocyanate, for example, Bayhydur 302® (Bayer) polyisocyanate. Preferably, the silicone is an RTV silicone, for example, RTV 3140® (Dow Corning, Midland, Mich.) silicone rubber. Preferably, the polyol content, on a solvent-free basis, is between ten and 50 weight percent, more preferably between 20 and 45 weight percent, and even more preferably between 25 and 40 weight percent. Preferably, the polybutadiene content, on a solvent-free basis, is less than 50 weight percent, more preferably between ten and 22 weight percent, and even more preferably between 14 and 22 weight percent. Preferably, the isocyanate content, on a solvent-free basis, is between 25 and 60 percent, more preferably between 25 and 45 weight percent, and even more preferably between 28 and 45 weight percent. Preferably, the silicone content, on a solvent-free basis, is between one and 40 weight percent, more preferably between five and 30 weight percent, and even more preferably between ten and 22 weight percent. Preferably, the DBTDL catalyst content, on a solvent-free basis, is between 0.1 and 0.2 weight percent and more preferably between 0.14 and 0.17 weight percent.
[0013] In another embodiment, a method of making an energy-absorbent material is provided comprising the steps of combining a polyisocyanate, a polybutadiene, a polyol, a silicone rubber, and, optionally adding a suitable catalyst. Preferably, the polyisocyanate and the polybutadiene are combined, the polyol is mixed therein, and the silicone rubber subsequently mixed therein. A suitable catalyst is preferably added last and mixed therein just prior to casting. The complete mixture may then be introduced into a suitable mold for final curing. Blowing and other preparation procedures may also be employed. In addition, composites, including the inclusion of non-polymeric materials such as solid additives to form a non-homogeneous material, may be formed. Finally, multiple layers of material may be combined to provide additional properties.
[0014] Optionally, additives, principally color contributors (prime pigments), may be added. Examples include, carbon black, iron oxide red, black, yellow; lithos red, para red, toluidine red, bon red, hansa yellow, diarylide yellow, benzidine yellow, quinacridone maroon, phthalocyanine blue and green, Chinese blue, and iron blue. Other additives include inert pigments such as calcium carbonate, magnesium carbonate, talcs or aluminum and magnesium silicate, barium sulfate, silicas, mica, and wollastonite (calcium silicate). Finally, additives for, e.g., UV protection, flame retardants, and fillers may be added.
[0015] In yet another embodiment, an energy-absorbent material is provided that exhibits improved sound (sonic and ultrasonic) reflectance and attenuation coefficients.
[0016] In yet another embodiment, articles comprising the energy-absorbent material disclosed herein are provided. As will be appreciated by one skilled in the art, a virtually unlimited variety of shapes and sizes may be produced, limited only by the materials processing variables.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a table of compositions and test results for several compositions according to the present invention.
[0018] FIG. 2 is a graph showing the reflection loss of material according to the present invention.
[0019] FIG. 2 is a graph showing the insertion loss of material according to the present invention.
DETAILED DESCRIPTION OF THE INVENTION
[0020] It has been surprisingly found that a polyol, a polybutadiene, an isocyanate, and a silicone may be combined to produce material with improved energy-absorbent properties
[0021] Preferred polyols include branched polyethers, branched polyethers having an —OH content of 0.85 percent, branched polyethers having a hydroxyl number between 26 and 30, and branched polyethers having an average equivalent weight of 2,000; linear saturated polyesters, linear saturated polyesters having a hydroxyl number of between 200 and 220, linear saturated polyesters having an —OH content of 6.4 percent, and linear saturated polyesters having an average equivalent weight of 267; polyether/esters having an —OH content of five percent, polyether/esters having a hydroxyl number of 165, and polyether/esters having an average equivalent weight of 340.
[0022] Exemplary polyethers include, but are not limited to, Desmophen 1920 D®, a branched, dispersion-grade polyether soluble in esters, ether esters, ketones, and aromatics, but insoluble in aliphatic hydrocarbons. Preferably, between ten and 30 weight percent and more preferably between ten and 25 weight percent.
[0023] Exemplary polyesters include, but are not limited to, Desmodur 670A-80® and Desmophen 631A-75®, the latter a saturated polyester resin supplied in propylene glycol monomethyl ether acetate (PMA) soluble in urethane-grade solvents such as ethyl and butyl acetate and in methyl ethyl ketone and methyl isobutyl ketone, but insoluble in aromatic and aliphatic hydrocarbons. Preferably, between five and 35 weight percent, more preferably between ten and 30 weight percent, and even more preferably between 11 and 17 weight percent.
[0024] Mixtures of polyether and polyester include, preferably, polyether between 14 and 30 weight percent and polyester between five and 20 weight percent and more preferably polyether between 14 and 25 weight percent and polyester between 11 and 17 percent.
[0025] Exemplary polyether/esters include, but are not limited to, Desmophen 1150®, a solvent-free, branched polyol with ether and ester groups soluble in esters, ketones, aromatic hydrocarbons and ether esters, but insoluble in aliphatic hydrocarbons. Preferably, between 15 and 25 weight percent.
[0026] Mixtures of polyester and polyether/ester include, preferably, polyester between ten and 20 weight percent and polyether/ester between 15 and 25 weight percent.
[0027] Exemplary acrylics include, but are not limited to, Joncryl 942®. Preferably, between ten and 20 weight percent and more preferably between 14 and 16 weight percent.
[0028] Preferred polybutadienes include hydroxyl-terminated polybutadienes having a number average molecular weight of 2,800 and hydroxyl-terminated polybutadienes having a hydroxyl functionality of between 2.2 and 2.4.
[0029] Exemplary polybutadienes include, but are not limited to, Poly bd R-45M®, a low molecular weight, hydroxyl-terminated homopolymer of butadiene having primary, allylic alcohol groups.
[0030] Preferred isocyanates include those based upon hexamethylene diisocyanate (HDI) such as, by way of example only, the biuret of HDI, the isocyanurate ring of HDI, and the copolymer of toluene diisocyanate (TDI) and HDI, isocyanates having an —NCO content of 17 percent, isocyanates having an average equivalent weight of 243, isocyanates comprising an aromatic polyisocyanate, and isocyanates having an —NCO content of between 31 and 33 percent.
[0031] Exemplary isocyantes include, but are not limited to, Bayhydur 302®, a solvent-free, water-dispersible polyisocyanate based on hexamethylene diisocyanate (HDI)
[0032] Preferred silicones include silicones comprising a polyorganosiloxane silicone and a polyorganosiloxane silicone having a methyltrimethoxysilane proportion of between one and ten percent.
[0033] Exemplary silicones include, but are not limited to, RTV 3140®, a one-part, high viscosity, clear, non-corrosive cure, self-leveling, solventless RTV (room temperature vulcanizing) silicone.
[0034] In practice, the components of the compositions should be blended and mixed just prior to casting. There are several important factors in the blending of the material. For example, the order of addition can be important. Specifically, adding the materials in the preferred order appears to minimize air entrapment and improve workability prior to casting. For example, the isocyanate, the polybutadiene, and the at least one polyol are preferably blended together as a first step. More preferably, the polybutadiene is first blended with the isocyanate and a first polyol blended into the isocyanate-polybutadiene blend. Preferably, at least one organic solvent is next blended into the isocyanate-polybutadiene-polyol blend. More preferably, the at least one organic solvent comprises a mixture of, first, a solvent suitable for thinning the isocyanate-polybutadiene-polyol blend and, second, a solvent suitable for thinning the silicone. Even more preferably, the first organic solvent comprises cyclohexanone and the second organic solvent comprises xylene. Preferably, the silicone is next blended into the instant mixture. Preferably, an additional portion of organic solvents are added and the entire mixture allowed to become homogeneous. Preferably, and finally, a suitable catalyst is added. Preferably, the suitable catalyst is DBTDL. Other catalysts suitable for catalyzing a reaction between an —OH functionality and an —NCO functionality may be employed. For example, the catalyst may be selected from the group consisting of organometallic, a bismuth-based, a morpholine-based, an amine-based, and mixtures thereof. Upon sufficient blending, the entire mixture may be cast or applied as required.
[0035] Mixing must be relatively slow—approximately 250 RPM for prototype tests—to further avoid air entrapment. As will be appreciated by one skilled in the art, the time during which the batch may be allowed to mix subsequent to the addition of any catalyst determines whether the batch sets up prematurely or flows out into a smooth, homogeneous form. For prototype tests, times in the order of a maximum of 30 seconds were expected. While the non-catalyzed components will eventually cure, the inclusion of a suitable catalyst is important to the overall integrity of the cured polymeric matrix as tensile and tear strength, flexibility, and resiliency are affected.
[0036] Batch size can also be important. The components in a too-large batch with insufficient mixing may begin to quickly cure before the catalyst is sufficiently disbursed resulting in non-homogeneous material.
[0037] While selected compositions are shown herein on a solvent-free basis, it will be recognized by those skilled in the art that many compounds are more practically delivered and worked in a suitable solvent. This is also true during the compounding stage when additional solvents may be added to promote handling and mixing.
[0038] Numerous tests were performed on prototype materials. One test procedure involved measuring the sound reflectance and attenuation coefficient. Prototype test panels were subjected to a 1.4 MHz signal through water at ambient temperature and pressure and the reflectance (R) and the transmittance measured. To account for variations in the thickness of the test panels, the attenuation coefficient (α) was calculated as follows:
α=−ln( P ts /P t )/ X s , where:
[0039] P ts =received peak-to-peak amplitude of wave propagated through test panel,
[0040] P t =received peak-to-peak amplitude of wave propagated between transmitter and receiver and
[0041] Xs=panel thickness.
[0042] The reflectance (R) was calculated as follows:
R=P rs /P t , where:
[0043] P rs =received peak-to-peak amplitude of wave reflected from sample and
[0044] P t =received peak-to-peak amplitude of wave propagated between transmitter and receiver.
[0045] The prototype test panels were prepared as shown in Table 1, below.
TABLE 1 I. Blend, in order shown, under agitation: 1. Isocyanate. 2. Polybutadiene. 3. Polyol. 4. A first solvent and optionally, a second solvent. 5. Optionally, a second polyol. 6. Silicone. 7. Optionally, carbon black. II. Blend, in order shown, under agitation: 1. A first solvent and optionally, a second solvent. 2. DBTDL III. Blend the solvent-DBTDL mixture of Step II into the resultant mixture from Step I for a maximum of 30 seconds. IV. Pour the resultant mixture from Step III into a suitable mold and allow to cure.
[0046] The prototype test panels were prepared using the component formulations as shown in FIG. 1 (Table 2). Component proportions are given in weight percent on a volatiles-included basis. In addition, Table 2 shows the measured reflectance (R) and attenuation coefficient (α) for the tested prototype panels.
[0047] A second test procedure involved measuring the reflectance loss and insertion loss of a signal varying from 20 kHz to 220 kHz through sea water at five deg. C. and varying pressures from 15 psig to 1800 psig. Measurements of reflection loss (R) and insertion loss (I) were made. Where:
I=P ts /P t .
[0048] The formulation is shown in Table 3, below.
TABLE 3 Component Weight Percent Desmophen 1920 D ® (100%) 20.86 Desmodur 670A-80 ® (80%) 17.78 Poly bd R-45M ® (100%) 17.78 Bayhydur 302 ® (100%) 26.38 RTV 3140 ® (100%) 8.86 DBTDL 0.17 Carbon Black Tr MEK 4.08 Xylene 4.09
[0049] Test results for the material resulting from the formulation shown in Table 3 are shown in FIGS. 2 and 3 .
[0050] Referred to herein are trade names for materials. Applicants do not intend to be limited by materials under a certain trade name. Equivalent materials (e.g., those obtained from a different source under a different name or catalog (reference) number to those referenced by trade name may be substituted and utilized in the compositions herein.
[0051] It will be understood that the embodiments of the present invention which have been described herein are illustrative of some of the applications of the principles of the present invention. Various modifications may be made by those skilled in the art without departing from the true spirit and scope of the invention.
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This invention relates to materials which absorb and dissipate energy and/or selectively allow energy to be transmitted, methods of making same, and articles comprising such materials. In particular, polymeric materials which include polyol(s) such as, but not limited to, polyethers, polyesters, polyether/esters, acrylics, and combinations thereof, plus other formulary components such as hydroxyl-terminated polybutadienes, polyisocyanates, silicone, preferably RTV (room temperature vulcanizing) silicone, and, preferably, suitable catalysts, preferably organometallic catalysts such as DBTDL (dibutyl tin dilaurate). Included are such polymeric materials which are resilient and which resist compression and compression set while exhibiting energy absorbing properties. Optionally, additives may be functionally or cosmetically added.
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FIELD OF THE INVENTION
[0001] The present invention relates to rotational sensors. More particularly, the invention relates to a rotational sensor that may be used in, for example but not limited to, a training aid which simulates movement of a virtual endoscope in a virtual human or animal body passageway or cavity, and which preferably provides for improved realism and/or accuracy in the simulated path in the virtual space when compared to the movements of the user.
BACKGROUND OF THE INVENTION
[0002] Endoscopy is a minimally invasive diagnostic medical procedure used to view interior parts of the body, such as the interior or exterior surfaces of organs, joints or cavities. It enables physicians to peer through the body's passageways. An endoscope typically uses two fibre optic lines. The first, a “light fibre”, carries light to the region of the body to be viewed. The second, an “image fibre”, carries the image of the region back to the physician's viewing lens or, where desired, to a camera so that the image may be displayed on a screen.
[0003] There are also other endoscopes that rely on camera technology at the end of the scope, and are sometimes referred to as are videoendoscopes. These have small digital cameras rather than optical fibre bundles. The video bronchoscope has a built in camera which is transmitted to a viewing screen.
[0004] The portion of the endoscope inserted into the body may be sheathed in a rigid or flexible tube, depending upon the medical procedure. One or more lenses may be provided at the end of the endoscope to enhance image capture and/or illumination of the body region. Ports may be provided to for administering drugs, suction, irrigation, and introducing small instruments.
[0005] For applications such as bronchoscopy, the tube must be sufficiently flexible to allow it to be accommodated in body passageways without undue discomfort or injury to patients under examination, but must be rigid enough to cause it to move through passageways without bunching up. Physicians operate an endoscope by controlling how far the tube is inserted in the body cavity, the rotation of the tube and also the bending of the tube along its length.
[0006] The tips of endoscopes may be selectively bendable in at least one direction so that the tip may be pointed in a desired direction. Through control of the bend of the tip and rotation of the endoscope tube, the tip of the endoscope may pass through bends in the interior passageways without the tip directly impinging on the walls. This also facilitates the desired path to be selected at a junction, e.g. where the trachea meets the left and right bronchi.
[0007] A physician may practice procedures on a patient but this is not desired, at least during early stages of training as inexperienced operators may injure a patient or damage the equipment (endoscopes are fragile, complex and expensive to replace).
[0008] Physical models of passageways or “airway mannequins” may be used in place of patients but these suffer from difficulty in accurately mimicking the contour and surface characteristics of the passageways. It is generally necessary to use genuine endoscopes with mannequins and so they do not prevent the endoscopes being damaged and the associated cost. Also, they remove endoscopes from clinical use and raise sterility concerns. The mannequins themselves are expensive and limited in that each mannequin is modelled on a particular type of patient (e.g. paediatric versus adult). Thus, it is necessary to obtain a variety of mannequins or for physicians to practice in an environment which differs from that of a patient to be operated on. To overcome these problems, simulators have been created which avoid the use of an actual endoscope. For example simulators of varying types are shown in GB-A-2,252,656, WO-A-96/30885, WO 2009/008750 and the simulation software High Techsplantations' Telios. The physically based simulators generally rely on use of an endoscope, or a close facsimile thereof, which is slid into an aperture in a simulation box. Within the box are sensors to detect rotation and movement of the endoscope. These then feed the sensor outputs via a cable or wireless connection to a computer. The computer then translates these sensor outputs into movements on screen which the operator can then use to control the endoscope and practice.
[0009] Physical models of passageways or “airway mannequins” may be used in place of patients but these suffer from difficulty in accurately mimicking the contour and surface characteristics of the passageways. It is generally necessary to use genuine endoscopes with mannequins and so they do not prevent the endoscopes being damaged and the associated cost. Also, they remove endoscopes from clinical use and raise sterility concerns. The mannequins themselves are expensive and limited in that each mannequin is modelled on a particular type of patient (e.g. paediatric versus adult). Thus, it is necessary to obtain a variety of mannequins or for physicians to practice in an environment which differs from that of a patient to be operated on.
[0010] To overcome these problems, simulators have been created which avoid the use of an actual endoscope. For example simulators of varying types are shown in GB-A-2,252,656, WO-A-96/30885, WO 2009/008750 and the simulation software High Techsplantations' Telios. The physically based simulators generally rely on use of an endoscope, or a close facsimile thereof, which is slid into an aperture in a simulation box. Within the box are sensors to detect rotation and movement of the endoscope. These then feed the sensor outputs via a cable or wireless connection to a computer. The computer then translates these sensor outputs into movements on screen which the operator can then use to control the endoscope and practice.
[0011] In this specification where reference has been made to patent specifications, other external documents, or other sources of information, this is generally for the purpose of providing a context for discussing the features of the invention. Unless specifically stated otherwise, reference to such external documents is not to be construed as an admission that such documents, or such sources of information, in any jurisdiction, are prior art, or form part of the common general knowledge in the art.
OBJECTS OF THE INVENTION
[0012] It is an object of the present invention to provide an improved rotational sensor which may be able to overcome or at least ameliorate the above problems or at least will provide the public with a useful choice.
[0013] Further objects of the invention will become apparent from the following description.
SUMMARY OF THE INVENTION
[0014] It is an object of the present invention to provide an improved rotational sensor which may be able to overcome or at least ameliorate the above problems or at least will provide the public with a useful choice.
[0015] Further objects of the invention will become apparent from the following description.
[0016] Preferred and alternative examples of the present invention are described in detail below with reference to the following drawings:
[0017] In a first aspect the present invention may be said to broadly consist in a rotational sensor to sense an angle of an object located nearby said sensor, said sensor comprising or including,
a. At least one first emitting source, to either emit onto, or from said object, b. At least one first receiving sensor, to receive emissions from said at least one first emitting source, either directly or indirectly, said emissions received dependent on said angle, said at least one first receiving sensor outputting a first signal, proportionate to said emissions, as a course measurement of said angle, c. At least one second emitting source, to emit onto, or from said object, d. At least one second receiving sensor, to receive emissions from said at least one second emitting source, either directly or indirectly, said emissions received dependent on said angle, said at least one second receiving sensor outputting a second signal, proportionate to said emissions, as a fine measurement of said angle,
[0022] Wherein said first signal and said second signal are capable of being combined to determine said angle.
[0023] Preferably said at least one first emitting source and said at least one first receiving sensor measure absolute rotation of said object.
[0024] Preferably said at least one second emitting source, and said at least one second receiving sensor measure relative rotation of said object.
[0025] Preferably there is a plurality of said first emitting sources.
[0026] Preferably said plurality of first emitting sources is arranged in an array about said object.
[0027] Preferably there is a plurality of said first receiving sensors.
[0028] Preferably said plurality of first receiving sensors is arranged in an array about said object.
[0029] Preferably said array is a circular array, through which said object can pass.
[0030] Preferably each said first receiving sensor is tuned to its first emitting source, or vice versa.
[0031] Preferably said rotational sensor has a course measurement resolution of 360 degrees divided by twice the number of said first receiving sensors.
[0032] Preferably there are between two and fifteen first receiving sensors.
[0033] Preferably there are seven said first emitting sources.
[0034] Preferably there is a one to one matching of a said first emitting source to a said first receiving sensor.
[0035] Preferably the output of said first and second light receiving sensors is analysed by the method as herein described.
[0036] Preferably said object is an elongate object.
[0037] Preferably said object has a substantially constant external shape.
[0038] Preferably said object is circular in cross-section.
[0039] Preferably said sensor can detect said object having a first emissive property over one surface arc of said object, and a second emissive property over a remainder surface arc of said object, because of said at least one first emitting source, said first and second emissive properties detectable by said at least one first receiving sensor.
[0040] Preferably said first emissive property over said one surface arc runs as a stripe of said first emissive property in a longitudinal direction along said object.
[0041] Preferably said stripe is continuous over said one surface arc and has substantially the same beginning and end angle along said object.
[0042] Preferably said stripe of said first emissive property is over substantially a 90 degree arc of said surface.
[0043] Preferably said first receiving sensor receives light from said first emitting source, either indirectly as a reflection or directly as an emission.
[0044] Preferably said second receiving sensor receives light from said second emitting source, either indirectly as a reflection or directly as an emission.
[0045] Preferably said first emitting source illuminates at least part of a surface of said object and said first receiving source receives said illumination as a reflection from said surface.
[0046] Preferably said second emitting source illuminates at least part of a surface of said object and said second receiving source receives said illumination as a reflection from said surface.
[0047] Preferably said at least one emitting source is a light emitting diode.
[0048] Preferably said at least one first emitting source emits in the infra-red spectrum.
[0049] Preferably said at least one first receiving sensor is a photo-transistor.
[0050] Preferably said at least one first receiving sensor receives in the infra-red spectrum.
[0051] Preferably said at least one second emitting source is a laser based light emitting source.
[0052] Preferably said at least one second receiving sensor has a resolution in excess of 1,000 dots per inch.
[0053] Preferably said at least one second receiving sensor has a resolution of 2,000 dots per inch.
[0054] Preferably said object has an outward presenting or visible surface comprised primarily of two colors, one color over one arc of said surface as said stripe, and the other color over the remainder arc of said surface.
[0055] Preferably said stripe is white and said other color is black.
[0056] Preferably said sensor has at least one connector to transmit said signals.
[0057] Preferably said connector is an electrical connector.
[0058] According to a further aspect the present invention consists in a rotational sensor to sense a rotation of an object located nearby said sensor, said sensor comprising or including,
[0059] At least one first light emitting source, to illuminate at least part of a surface of said object,
[0060] At least one first light receiving sensor, to receive light from said at least one light emitting source, at least some of which is reflected from said object when in front of said light emitting source, wherein the output of said at least first one light receiving sensor is dependent on a change in color of said object,
[0061] At least one second light emitting source, to illuminate at least part of a surface of said object,
[0062] At least one second light receiving sensor to receive at least light from said at least one second light emitting source,
[0063] Wherein said first light receiving sensor receives and outputs a signal proportionate to a first measurement of an angle of said object, and said second light receiving sensor receives and outputs a signal proportionate to a second measurement of an angle of said object.
[0064] Preferably said first measurement is a course measure of the rotation of said object.
[0065] Preferably said second measurement is a fine measure of the rotation of said object.
[0066] Preferably said at least one first light emitting source and said at least one first light receiving sensor measure absolute rotation of said object.
[0067] Preferably said at least one second light emitting source, and said at least one second light emitting sensor measure relative rotation of said object.
[0068] Preferably said at least one light emitting source is a light emitting diode.
[0069] Preferably said at least one first light emitting source emits in the infra-red spectrum.
[0070] Preferably there is a plurality of said first light emitting sources.
[0071] Preferably said plurality of first light emitting sources is arranged in an array about said object.
[0072] Preferably said array is a circular array.
[0073] Preferably said at least one first light receiving sensor is a photo-transistor.
[0074] Preferably said at least one first light receiving sensor receives in the infra-red spectrum.
[0075] Preferably there is a plurality of said first light receiving sensors.
[0076] Preferably said plurality of first light receiving sensors is arranged in an array about said object.
[0077] Preferably said array is a circular array.
[0078] Preferably there is a one to one matching of a said first light emitting source to a said first light receiving sensor.
[0079] Preferably each said first light receiving sensor is tuned to its first light emitting source.
[0080] Preferably said rotational sensor has a course resolution of 360 degrees divided by twice the number of said first light receiving sensors.
[0081] Preferably there are between two and fifteen first light receiving sensors.
[0082] Preferably there are seven said first light emitting sources and seven said first light receiving sensors.
[0083] Preferably said at least one second light emitting source is a laser based light emitting source.
[0084] Preferably said at least one second light receiving sensor has a resolution in excess of 1,000 dots per inch.
[0085] Preferably said at least one second light receiving sensor has a resolution of 2,000 dots per inch.
[0086] Preferably the output of said first and second light receiving sensors is analysed by the method as herein described.
[0087] Preferably said object is an elongate object.
[0088] Preferably said object has a substantially constant external shape.
[0089] Preferably said object is circular in cross-section.
[0090] Preferably said object has an outward presenting or visible surface comprised primarily of two colors, one color over one arc of said surface, and the other color over the remainder arc of said surface.
[0091] Preferably said one color as an arc runs as a stripe in a longitudinal direction on said object.
[0092] Preferably said stripe is continuous over said surface and has substantially the same beginning and end angle along said object.
[0093] Preferably said one color is over substantially a 90 degree arc of said surface.
[0094] In another aspect the present invention consists in a method of sensing an angle of an object comprising or including the steps of,
a. Providing at least one first emitting source, to either emit onto, or from said object, b. Providing at least one first receiving sensor, to receive emissions from said at least one first emitting source, either directly or indirectly, said emissions received dependent on said angle, said at least one first receiving sensor outputting a first signal, proportionate to said emissions, as a course measurement of said angle, c. Providing at least one second emitting source, to emit onto, or from said object, d. Providing at least one second receiving sensor, to receive emissions from said at least one second emitting source, either directly or indirectly, said emissions received dependent on said angle, said at least one second receiving sensor outputting a second signal, proportionate to said emissions, as a fine measurement of said angle,
[0099] Wherein said first signal and said second signal are capable of being combined to determine said angle.
[0100] In yet another aspect the present invention consists in a method of sensing rotation using a rotational sensor having a plurality of first sensors to measure the absolute rotation of an object, and at least one second sensor to measure the relative rotation of said object, the method comprising or including the steps of,
e. Receiving the sensor absolute angle signal from the first sensors, f. Receiving the sensor relative angle signal from the second sensors, g. Calculating a current absolute angle if not known, by setting this and a current derived angle to the sensor absolute angle, h. Calculating the current absolute angle, if not equal to the sensor absolute angle by setting this to be equal to the sensor absolute angle, and calculating a current offset error equal to the current absolute angle minus the current derived angle, i. If this error is zero then stepping to step i, j. If this error is not zero then calculating an angle adjustment equal to the minimum of a percentage of the sensor relative angle or the current offset error, k. Comparing the sign of the sensor relative angle and the current offset error, and
i. If the sign is the same then calculating a new sensor relative angle equal to the sensor relative angle plus the angle adjustment, or ii. If the sign is not the same then calculating a new sensor relative angle equal to the sensor relative angle minus the angle adjustment,
l. Calculating a new current offset error equal to the old current offset error minus the angle adjustment, m. Calculating a new current derived angle equal to the old current derived angle plus the sensor relative angle,
[0112] Wherein the new current derived angle is then used as a signal, readout, display or similar of the actual rotational angle of said object.
[0113] Preferably the percentage is in a range of 10% to 90%.
[0114] Preferably the percentage is 50%.
[0115] Preferably said method is used in an endoscope simulator to provide a virtual readout of position and angle of an endoscope or facsimile thereof.
[0116] Preferably said first sensor is a light based sensor.
[0117] Preferably said second sensor is a light based sensor.
[0118] In yet another aspect the present invention consists in a system including a rotational sensor as herein described, using a method as herein described with reference to any one or more of the accompanying drawings.
[0119] In yet still another aspect the present invention consists in a rotational sensor as herein described with reference to any one or more of the accompanying drawings.
[0120] In a further aspect the present invention consists in method as herein described with reference to any one or more of the accompanying drawings.
[0121] In a further aspect still the present invention consists in a system as herein described with reference to any one or more of the accompanying drawings.
[0122] Further aspects of this invention which should be considered in all its novel aspects will become apparent from the following description given by way of example of a possible embodiment thereof.
[0123] Where in the foregoing description, reference has been made to specific components or integers of the invention having known equivalents then such equivalents are herein incorporated as if individually set forth.
[0124] As used herein the term “and/or” means “and” or “or”, or both.
[0125] As used herein “(s)” following a noun means the plural and/or singular forms of the noun.
[0126] Unless the context clearly requires otherwise, throughout the description and the claims, the words “comprise”, “comprising”, and the like, are to be construed in an inclusive sense as opposed to an exclusive or exhaustive sense, that is to say, in the sense of “including but not limited to”.
[0127] It is intended that reference to a range of numbers disclosed herein (for example, 1 to 10) also incorporates reference to all rational numbers within that range (for example, 1, 1.1, 2, 3, 3.9, 4, 5, 6, 6.5, 7, 8, 9 and 10) and also any range of rational numbers within that range (for example, 2 to 8, 1.5 to 5.5 and 3.1 to 4.7).
[0128] The entire disclosures of all applications, patents and publications, cited above and below, if any, are hereby incorporated by reference.
[0129] To those skilled in the art to which the invention relates, many changes in construction and widely differing embodiments and application of the invention will suggest themselves without departing from the scope of the invention as defined in the appended claims. The disclosures and the descriptions herein are purely illustrative and are not intended to be in any sense limiting.
[0130] Other aspects of the invention may become apparent from the following description which is given by way of example only and with reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0131] Preferred forms of the present invention will now be described with reference to the accompanying drawings in which;
[0132] FIG. 1 : is a schematic diagram of an example use of the present invention in an endoscope simulator,
[0133] FIG. 2 : is a side view of location of the sensors in one application, for an endoscopy simulator,
[0134] FIG. 3 : is a schematic showing the locations of the fine resolution sensors,
[0135] FIG. 4 : is a printed circuit board containing the circular array of first light emitting sources and first light receiving sensors for course resolution sensing,
[0136] FIG. 5 : shows in isometric view a length of object, in this case circular in nature, with a stripe along its longitudinal axis over 90 degrees of arc,
[0137] FIG. 6A : is a close up schematic of the first light sensing array (shown with 7 sensors) showing the object in cross-section, with the stripe across an odd (3) number of sensors, and therefore the angle sensed, and
[0138] FIG. 6B : is a close up schematic of the first light sensing array (shown with 7 sensors) showing the object in cross-section, with the stripe across an even (2) number of sensors, and therefore the angle sensed, and
[0139] FIG. 7 : is a flow chart of the method of the present invention used to analyse the outputs from the light based sensors.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0140] Preferred embodiments will now be described with reference to FIGS. 1 through 7B .
[0141] FIG. 1 is a schematic diagram of a system 10 , according to one embodiment (in this case an endoscopy simulator) that may use the present invention of a rotational sensor 18 . System 10 includes display 11 , processor 12 , memory 13 , bus 14 , handset 15 , tube (object) 16 , housing 17 , sensor 18 , control 19 (as will be appreciated, multiple controls may be provided and positioned as desired), wire 20 and circuit 21 .
[0142] Display 11 , processor 12 , memory 13 and bus 14 are preferably embodied by a conventional personal computer but purpose-built devices with more specific functionality are within the scope of the invention. Any display may be used such as monitors, projectors and viewing lenses adapted to provide images therethrough and mimic those used for real endoscopic procedures. While a single display is shown, any number of displays may be used to enable others to view the user's operation. The displayed images are preferably created by processor 12 using information stored in memory 13 . Due to the virtual nature of the environment, parameters for additional/alternative environments may be obtained or generated as required, such as via the internet or any computer readable memory. Processor 12 may include or be couplable to a 3D graphics accelerator card to assist in displaying images. Bus 14 enables the transfer of data between display 11 , processor 12 and memory 13 .
[0143] The display 11 may show simply numbers of the current derived angle, or may show an image from which the operator can discern the angle, for example a virtual image of the orientation of the object 16 .
[0144] Handset 15 is preferably configured to feel and operate in a similar manner to a genuine handset for an endoscope. Similarly, object 16 (in this instance a tube) is preferably selected to have structural properties (e.g., flexibility/rigidity, thickness, etc.) similar to that of a genuine tube for an endoscope. According to one embodiment, tube 16 is selectively couplable or engageable to handset 15 to enable different tubes to be used for different procedures so as to better mimic the actual equipment used for a particular procedure.
[0145] In operation, a user inserts the tip of object 16 into an opening in housing 17 . The opening may be provided with a funnel to guide insertion. Alternatively, the wall of the opening may be configured to imitate an opening into which an endoscope may be inserted (e.g. a mouth/throat). Sensors 18 may be provided at the opening to monitor movement of object 16 . Preferably, there is at least two sensors, course resolution sensor 18 A and fine resolution sensor 18 B (shown in FIG. 2 ) to monitor rotational movement of object 16 as it passes through the opening. There may also be further sensors (not shown) to measure translational movement of the object.
[0146] The invention relies on a fine resolution sensor 18 B having a second emitting source 28 and a second receiving sensor 29 for fine measurement, and a course resolution sensor 18 B having a first emitting source 22 and first receiving sensor 25 and analysis of the signals from these two sensors to determine the actual angle of the object 16 . The second source and sensor measure fine movements of angle, and typically are relative in their measurement. That is, they have very fine resolution, but only report, movement by this much in a direction, they do not report relative to a baseline or zero measurement. The first source and sensor measure course movement in angle and report as a variation in angle from a baseline or known zero measuring.
[0147] The sensors rely on emission of light, magnetism or other property from their respective emission source. The source and sensors could be mounted separate to the object and rely on reflectivity from the object surface or other property. Alternatively one of either the sensor or source could be on the object and the other of the source or sensor could be mounted off the object. Also the first source/receivers could be of one such mounting (e.g. one on the object and one off the object) and the second source/receivers could be of the other such mounting (e.g. both off the object) or vice versa.
[0148] The use of the first and second sources and their respective sensors will be described herein as the sources being light based and the sensors receiving that light by reflection off the surface 23 of the object. A person skilled in the art will understand that alternative emissions could be used as described such magnetism, other radiation sources or other near field emissions that may be detectable and the invention should not be limited as such.
[0149] It is preferred the fine resolution sensor 18 B is a laser-based sensor, the invention is not limited thereto. Where a laser-based sensor is used, it is preferably capable of tracking the tube rotation and displacement at a resolution of 2000 dpi.
[0150] The fine resolution sensor 18 B used in one embodiment is preferably an infrared (or laser) sensor 18 B of a type commonly used for computer mice. This second light receiving sensor 29 , receiving light reflected from the object surface 23 from the second light emitting source 28 is able to report changes in position of an object in front of it in an X and Y axis. In the preferred form the source 28 and the sensor 29 are placed alongside the guides 61 which the object 16 runs through and reports fine resolution changes in rotation (by reading movement in one axis). It can also report changes in insertion (by reading changes in the other axis). In other embodiments, through less preferred the source 28 and sensor 29 are separate. These values are reported back to the software simulation. This fine resolution sensing is also relative to the position last time a change was reported, (potentially hundreds of times per second).
[0151] FIG. 3 shows a preferred arrangement for the fine resolution sensor 18 B, including guides 61 and detector 62 . Detector 62 is preferably the laser based sensor as discussed above and preferably incorporates a second light emitting source 28 and second light receiving sensor 29 . In the embodiment shown these are incorporated in the one unit, however separate emitter and receiver may be used and still perform the same function. Guides 61 hold object 16 a fixed distance from detector 62 so that detector 62 is able to detect movement of tube 16 and the extent of movement thereof.
[0152] Detector 62 is preferably a fine laser as the second light emitting source 28 and is projected onto the object surface 23 upon which an optical sensor (second light receiving sensor 29 ) is focused. Consecutive images from the detector 62 , preferably captured at a rate of 7000 pictures per second, are analysed to detect changes corresponding with movement of the object 16 . Displacement values corresponding to rotational movement of the object are calculated in real time by a digital signal processor (DSP), preferably at a rate of 120 times per second and transmitted to processor 12 via USB or any other suitable interface so that the movement is reflected in the simulated display. The sensed displacement resolution is preferably at least 2000 dpi or 0.0127 mm.
[0153] A problem occurs when sensing the rotation of an object, for example a tube, that relates to compounding rotation errors due to rounding or minor sensor inaccuracies. Relative rotation changes can be sensed with a very high degree of accuracy but because these rotation changes happen so frequently any minor error builds into a very obvious absolute rotation error very quickly. To the user of for example the simulator system 10 , this may present itself for example as them holding the handset 15 upright and the simulated view on the screen 11 showing the camera rotated by 90 degrees.
[0154] Sensors for determining absolute rotation instead could be used, but they have a comparatively very coarse granularity and so do not produce the smooth rotational movements required by the simulator.
[0155] This problem therefore is resolved by making use of both relative (fine) 18 B and absolute (course) sensors 18 A and combining the results to produce very smooth absolute rotational movement.
[0156] Therefore a course resolution sensor 18 A is also used to act as a base measurement for the fine resolution sensor 18 B. The relative locations in one preferred embodiment of 18 A and 18 B are shown in FIG. 3 . This shows selected features of a preferred arrangement of housing 17 which may use rotational sensor 18 . In this arrangement, funnel 71 is provided to aid insertion of the object 16 into housing 17 and through sensors 18 A and 18 B. Sensor 18 A and 18 B, or a separate, additional sensor, may be configured to monitor lengthwise movement of object 16 .
[0157] In the preferred embodiment the fine resolution sensor 18 B is located before the course resolution sensor 18 A, as shown in FIG. 2 . The fine resolution sensor 18 B is positioned about 1.5 cm down the guide path from the entrance or funnel 71 . The course resolution sensor 18 A is about 1 cm after that.
[0158] The course resolution sensor arrangement in one preferred embodiment is described with reference to FIGS. 4 through 6B . For the course resolution sensor 18 A, a circuit board 36 is constructed with a hole 37 in the centre for the object 16 to pass through (shown in FIG. 6 A/ 6 B). Arranged in an array about the hole 37 is at least one, and preferably a plurality, of first light emitting sources 22 and first light receiving sensors 25 . Shown in FIGS. 6A and 6B in a preferable embodiment there are seven sources 22 and sensors 25 . Persons skilled in the art will understand there may be more or less of these as necessary. The first light emitting source 22 in the preferred embodiment is a light emitting diode (“LED”), and emits some light at least in the infrared (“IR”) spectrum. In the preferred embodiment substantially all the light is in the IR spectrum. The first light receiving sensors 25 in the preferred embodiment are photo transistors. As shown in FIGS. 6A and 6B the sources 22 and sensors 25 are equally spaced around the hole 37 . The photo transistors are optimized for IR light and are thus less sensitive to any ambient light which may enter the device. Between each pair of photo transistors is an IR LED 22 which is positioned and angled so that when the object 16 is present the light from a single LED 22 will reflect off the object surface 23 into a single photo transistor 25 .
[0159] The object 16 in the preferred embodiment has a first emissive property over one arc of its surface as a stripe running the length of the object. The object also has a second emissive property over a remainder arc of the object. For example the first emissive property may be confined to constant a 90 degree arc down the length of the object, and the remaining object surface has the second emissive property on the remaining 270 degrees. The course sensor 18 A second receiving sensor can pick the difference from each of these emissive properties to provide a course angle reading. The first emitting source and thus also the first and second emissive properties could also be an inherent material property of the object 16 , such as reflectivity (possibly also from natural light), radiation, magnetism or other.
[0160] In one embodiment using light based emission and sensing the object presents surface 23 which is predominantly of one colour and has a stripe 38 running down the longitudinal axis, of a contrasting colour as shown in FIG. 5 . In the preferred embodiment the surface 23 is predominantly black and the stripe 38 is white. The stripe 38 in the preferred embodiment covers the same arc over the length of the object 16 this is it that starts and finishes on the same angles all the way along the object 16 . The stripe 38 is preferably one quarter of the circumference of the object 16 . However in other embodiments the stripe and sheath may be of different colours, normally contrasting and the stripe 38 may cover a different angle, so long as this is known. The contrast is important so the sensors can pick up the change from one colour to the other.
[0161] Each photo transistor 25 as stated is calibrated separately to account for the variance in sensitively between individual sensors. Due to this variance in sensitively only “primarily black” or “primarily white” are checked for, rather than attempting to detect various shades which may be present as the edge of the stripe 38 passes the sensor.
[0162] When the object 16 passes through the hole 37 in the circuit board 36 , a number of adjacent sensors 25 will report they are primarily seeing the stripe 38 , as shown in FIGS. 6A and 6B . Seen in FIG. 6A an odd number of sensors 25 one, two and three are seeing the stripe 38 (counted clock wise from the zero degree line). In FIG. 6B an even number of sensors two and three are seeing the strip 38 .
[0163] Based on which sensors 25 are primarily seeing the stripe 38 along the object 16 , the firmware in the device will calculate and report the sensor absolute angle 39 ( FIG. 6A ) of the stripe 38 . If an odd number of sensors 25 (as in FIG. 6A ) are able to see the stripe 38 then the angle 39 is reported as the angle which relates to the middle sensor which is able to see it. In this instance the middle sensor 25 is number two and for an array of seven sensors this is at approximately 50 degrees (360 degrees divided by 7 (the number of sensors)).
[0164] In FIG. 6B there is an even number of sensors 25 , sensors two and three able to see the stripe 38 . The angle 39 therefore is reported as the angle between the middle pair of sensor able to see it, in this case 75 degrees. This gives a total of 14 possible absolute angles which can be reported, approximately 25 degrees apart, for a 7 sensor array.
[0165] Because it may be possible for light to travel around the edge of the object 16 and cause a sensor 25 to falsely report that it is seeing the stripe 38 , sensors 25 along with their corresponding LED 22 may be turned on in rapid succession, either individually or in groups to avoid “false positive” results. If all of the sensors 25 report that they are able to see the strip 38 at the same time then the system it is assumes the object is not inserted and each sensor 25 is actually seeing light from other LEDs 22 .
[0166] Referring to FIG. 7 the analysis method of reducing the error between the actual angle of the object and the sensed or displayed angle will now be described. The outputs from the rotational sensor 18 (comprising fine sensor 18 B and course sensor 18 A) are passed via bus 14 or other communication link to the processor 12 . Contained in the processor 12 (there may be more than one) is software that runs the algorithm.
[0167] The software retrieves the course resolution sensor 18 A (course) signal and the fine resolution sensor 18 B (relative) from the sensor 18 as the sensor absolute angle and sensor relative angle respectively as shown in FIG. 7 .
[0168] The software then uses these to determine the current derived angle as shown in FIG. 7 and explained below.
[0169] When a new sensor absolute angle is reported, that is, different to the previous sensor absolute angle reported by the sensing device 18 from sensors 18 B, the software records this as the “current absolute angle”. The current absolute angle is compared to the current derived angle and a “current offset error” is calculated, being the signed difference between the current absolute angle and the current derived angle.
[0170] The software then tries to drive this error to zero by adjusting any relative movements toward the direction indicated by this error amount. Alternatively if the current offset error is zero then the software immediately calculates a new current derived angle as described shortly.
[0171] Each time a relative movement is reported by the fine sensor 18 A as a new sensor relative angle, this sensor relative angle will have an angle adjustment applied as the minimum of a percentage adjusted sensor relative angle, or the current offset error (this value of percentage can be adjusted to tune how quickly errors are resolved). In the preferred embodiment this percentage may be in the range of 1% to 99%, but is preferably in the range of 10% to 90%. In the preferred embodiment this percentage is 50%.
[0172] A check is made to see whether the sensor relative angle and the angle adjustment have the same sign, that is both positive, or both negative, or have a differing sign, that is negative and positive.
[0173] If they are the same sign then the sensor relative angle is increased by adding the angle adjustment because it is in favour of the current offset error (that is, turning toward the current absolute angle). If they are of differing sign then the sensor relative angle is decreased by subtracting the angle adjustment percentage because it is turning away from the current absolute angle.
[0174] The adjustment to the relative reported angle change will never be more than the current offset error so that the derived angle doesn't overshoot the current absolute angle.
[0175] Each time an adjustment is made to derive a new or adjusted sensor relative angle relative change the current offset error is also reduced by this same amount (that is the angle adjustment), and when this error amount reaches zero then no more adjustments will be made to the relative rotational movement.
[0176] The current derived angle is then updated from the old current derived angle plus the sensor relative angle and the display 11 (or other output using the angle) is updated accordingly.
[0177] Whenever the current absolute angle reported by the sensing device changes a new current offset error is calculated and the process starts again, even if the previous offset error had not yet been resolved. In this way the simulated bronchoscope always rotates in the direction indicated by the user, but is always “pulled” in the direction of the current absolute angle reported by the device avoiding any compounding rotation errors due to rounding or minor sensor inaccuracies.
[0178] Although this invention has been described by way of example and with reference to possible embodiments thereof, it is to be understood that modifications or improvements may be made thereto without departing from the scope or spirit of the invention as defined in the appended claims.
[0179] While the preferred embodiment of the invention has been illustrated and described, as noted above, many changes can be made without departing from the spirit and scope of the invention. Accordingly, the scope of the invention is not limited by the disclosure of the preferred embodiment. Instead, the invention should be determined entirely by reference to the claims that follow.
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The invention is a rotational sensor to sense an object's angle and methods to analyse the sensor output. The sensor has a first emitting source, to either emit onto, or from the object, a first receiving sensor, to receive emissions from the first emitting source, either directly or indirectly, the emissions received dependent on said angle, first receiving sensor outputting a first signal a course measurement of the angle. Also present is a second emitting source, to emit onto, or from the object and a second receiving sensor, to receive emissions from the second emitting source, either directly or indirectly the emissions received again dependent on said angle, second receiving sensor outputting a second signal, as a fine measurement of the angle. A method of use of the sensor is disclosed together with a method of combining the fine and course measurements to output a signal with zero error.
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FIELD OF THE INVENTION
The pharmaceutical packaging industry is constantly changing and improving to try to meet the needs of patients requiring a wide range of medications. Patient non-compliance with medications prescribed by physicians, however, results in up to 15 percent of all hospital admissions. This problem of non-compliance increases as the number of prescriptions and doses for a patient increases. The present invention relates to a multiple dose compliance package and method for manufacturing the same. In addition to increasing patient compliance, the present invention provides for customized prescription packaging to be economically handled by a patient's pharmacist.
BACKGROUND OF THE INVENTION
The pharmaceutical packaging industry offers a wide array of dispensers and containers for all types of medications. These packages include conventional pill vials, as well as the now popular blister cards. The present prescription vial, however, offers no checks to either remind a patient of when to take the medicine, or whether the medication has in fact been taken. In those cases where a patient is on multiple medications, a number of different vials only serves to confuse a patient.
Recently, blister cards have overcome a number of the shortcomings of prescription vials and become increasingly popular. Exemplary patents discussing various advantages of blister packaging include the following: U.S. Pat. Nos. 4,429,792; 4,125,190; 3,856,144; and 3,780,856. Most of the blister packages of this type require specialized packaging machinery for assembly. Thus, such packages have the serious economic drawback that they are difficult and expensive to manufacture on a small or customized scale. The primary drawbacks with the prior art blister packages are the sealing material and the methods of sealing the plastic blister sheets to the lidding sheets. Typically, the blister sheets are sealed to the lidding sheets with the use of pressure-sensitive or heat-activated adhesives. The sticky nature of pressure-sensitive adhesives requires that the adhesive be carefully placed on a blister sheet and backing sheet in a specific pattern. The blister sheet and backing sheet are then carefully aligned and registered to seal in any medications. If the registration is not accurate, the adhesive may attach to the medications and possibly spoil the enclosed medications. Further, incomplete or inaccurate registration does not offer a sufficiently hermetic seal. Likewise, heat-activated adhesives require clumsy and inconvenient sealing devices. Further, the heat may have an adverse effect on medications being sealed in the package.
SUMMARY OF THE INVENTION
The present invention overcomes the drawbacks of these prior art packages and methods by the provision of a package assembly which comprises a blister sheet having a plurality of medication receiving blister recesses formed therein, with the sheet having substantially planar shoulder portions coated with a first cohesive composition, and a lidding sheet having one surface coated with a second cohesive composition having affinity for the first cohesive that is coated on the shoulders of the blister sheet but has no affinity for pharmaceutical medications. Therefore, the lidding sheet can be sealed to the shoulder portions of the blister sheet to encapsulate medications which are positioned within the blister recesses, without the demanding registration problems of prior art blister packages.
In a preferred embodiment, a backing sheet is adhered to the rear surface of the lidding sheet, and the backing sheet includes printed information arranged in registry with the blister recesses to identify the contents of each respective recess. Also, a supporting outer frame may be provided, with the outer frame having front and back panels positioned on opposite sides of the package, and with the front panel having apertures through which respective ones of the blister recesses protrude. The back panel preferably also includes apertures which are in registry with the blister recesses and the printed information, so as to permit the information to be visible.
Other features and advantages of the present invention will become apparent upon reading the following detailed description and appended claims, and upon reference to the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
For a more complete understanding of this invention, reference should now be had to the embodiment illustrated in greater detail in the accompanying drawings and described below by way of an example of the invention.
In the drawings:
FIG. 1 is a perspective view of a blister package assembly embodying the present invention.
FIG. 2 is a fragmentary sectional side view of the blister package assembly taken along line 2--2 in FIG. 1.
FIG. 3 is an exploded view of the blister sheet and lidding sheet embodying the present invention.
FIG. 4 is a fragmentary sectional side view taken along line 4--4 in FIG. 3.
FIG. 5 is a perspective view of the blister sheet, lidding sheet and backing sheet embodying the present invention.
FIG. 6 is a fragmentary sectional view of the package and taken along line 6--6 of FIG. 5.
FIG. 7 is a fragmentary sectional view of the interengaging means of the outer frame and taken along the line 7--7 of FIG. 1.
FIG. 8 is a perspective view of the outer frame of the assembly.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
Turning first to FIG. 1, there is shown a preferred embodiment of a complete package assembly 10 which embodies the present invention. The package assembly is made up of a number of different components including a blister package 22 which comprises a blister sheet 11, an overlying lidding sheet 16, and a backing sheet 14 overlying the rear surface of the lidding sheet 16. The blister sheet 11 has a plurality of blister recesses 23 formed therein, and the assembly further includes an outer frame 12 having front and back panels positioned to overlie the opposite sides of the package 22.
The blister recesses 23 of the blister sheet are arranged in a pattern, and the front panel of the frame 12 has apertures or openings 27 that correspond to and receive respective ones of the blister recesses, note FIG. 8. Each blister recess is fully supported by the stiff outer frame because the frame encases the package and is positioned on both sides of the package in a sandwich relationship. Preferably, the blister recesses are arranged in a matrix of rows and columns that correspond to a calendar or some other schedule convenient for a particular patient. The frame also has windows 21, see also FIG. 8, that allow portions of the backing sheet of the blister package to be visible. Writing appears on this visible portion of the backing sheet that preferably gives all of the information or labeling requirements of the pharmaceutical medications 13 that are sealed in each of the blisters of the package.
Turning now to FIG. 2, there is shown the sandwich relationship of the frame 12 and the package 22. The stiff frame 12, which is preferably formed of a single molded plastic sheet, is shown positioned on either side of the blister package. The top and bottom panels of the frame 12 are hingedly connected to each other by a hinge 20 formed of a flexible integral piece of plastic along one side edge of the overlying panels. On the side edge of the panels opposite the edge hingedly interconnecting the panels and along both side edges, there are snaps 26 or other releasable interengaging means that hold the panels together and sandwiched around the package 22, note FIG. 7. Thus, the stiff frame 12 is positioned on opposite sides of the blister package and offers support to the entire package.
Referring again to FIG. 2, the frame 12 has apertures through which the blister recesses of the blister package 22 protrude Likewise, on the opposite panel or side of the frame, there are also apertures which make the back of the package 22 visible. Printed information relating to the specific medications in each blister, therefore, appears on the package in a general corresponding relationship to each blister.
As best seen in FIG. 3, the blister package 22 includes the blister sheet 11 and the lidding sheet 16. The blister sheet 11 is formed from a flat, clear plastic sheet of a suitable transparent thermoplastic polymer such as polyvinyl chloride or polyethyleneterepthalate which has been thermoformed or die molded to form the pattern of blister recesses 23. The blister recesses are arranged in a plurality of columns and rows and are separated by substantially planar shoulder portions 15. The peripheral portions of the sheet 11 adjacent the edges of the sheet are also substantially flat and planar. As illustrated, score lines 24 are provided in the shoulder portions of the blister sheet 11 to form preweakened areas to facilitate separating the individual blisters from the package. This allows a patient's unused medications or blister recesses to be separated easily from the package and recycled or reused in other package assemblies.
The thermoplastic polymer that makes up the plastic sheet 11 must have sufficient barrier properties to prevent the diffusion of unwanted moisture and oxygen into the blister recesses of the package 22 that may spoil or deactivate the packaged medications. This barrier property may be formed by including a barrier layer in a plastic sheet before it is thermoformed or pressed into the blister sheet 11 form. The method of forming the sheet and the various compositions of the sheet are well known in the industry. The lidding sheet 16 is made of frangible material, typically relatively thin and flexible metal foil or plastic, that has barrier properties like those discussed above to insure the hermetic preservation of medications sealed in the package.
As best seen in FIGS. 3 and 4, the upper surface of the shoulder portions 15, including the peripheral portions 25, of the plastic blister sheet 11 contain a coating 17 of a cohesive material. The coating can be applied by conventional methods and, alternatively, may be applied to the entire surface of the blister sheet. Also, the coating can be applied before or after a plastic sheet is formed or molded into the blister sheet 11. One entire surface of the lidding sheet 16 also bears a coating 18 of a cohesive material. The cohesive coating 18 on the lidding sheet and the cohesive coating 17 on the blister sheet can be of the same or of different compositions.
The cohesive coatings 17 and 18 serve to securely bond the blister sheet 11 to the lidding sheet 16 when the coated surfaces are positioned next to each other in the assembly of the package. Thus, the lidding sheet serves to close the blister recesses and encapsulate the medications therein. As used herein, the term "cohesive" refers to the ability of the coating to securely attach to and adhere to other surfaces coated with the same material or compatible cohesive material, yet have no bonding or adherent properties with other surfaces. Unlike conventional pressure sensitive adhesives, a cohesive is not inherently sticky or tacky and adherent to virtually any surface. The presence of cohesive on the entire surface of the lidding sheet does not affect the packaged medications or make them stick to the lidding sheet or blister sheet. Suitable cohesives include copolymers of vinyl acetate ethylene.
An advantage to using a cohesive is that the lidding sheets and blister sheets can be stored by stacking or rolling on each other as long as the cohesive-coated surface is not in contact with another cohesive-coated surface. This is particularly convenient for pharmacists storage and assembly of the packages. It alleviates the need for release sheets normally required with pressure sensitive adhesives. Further, a cohesive is advantageous over aqueous or solvent based adhesives that require drying delays in package assembly. A cohesive is also advantageous over thermally activated adhesives because specialized equipment is required to activate the adhesive and the heat that is applied may degrade or deactivate or otherwise adversely affect the packaged medications.
Referring now to FIGS. 5 and 6, a backing sheet 14 can be applied to the rear surface of the lidding sheet 16 of the blister package 22. The backing sheet 14 is preferably coated with an adhesive or glue material 19 for adhering the backing sheet to the lidding sheet 16. The backing sheet is preferably made of paper, because it is desirable to print information on the side of the backing sheet opposite the side having the adhesive and that relates to the packaged medications. The printed information, that can be written, typed or generated by a computer printer, sets forth required pharmaceutical labeling information, and the printed information is in registry with respective ones of the blister recesses Thus, the specific contents of each blister recess may be set forth in matrix form that corresponds to the blister recesses of the package when the backing sheet 14 is applied to the lidding sheet 16.
In practice, a pharmacist will be provided with a kit to prepare and assemble the package assembly on an individual basis pursuant to an individual's prescription. The kit includes plastic blister sheets having the previously-described coating of cohesive, and a supply of lidding sheets already coated with a cohesive material. The kit may also include a supply of backing sheets to be adhered to the back of the lidding sheet to identify the contents of the blisters. The kit may further include a supply of plastic frames to give the finished package assembly support and rigidity.
Contrary to earlier pharmaceutical packaging systems, the present invention allows the package to be assembled quickly and easily by a pharmacist. A pharmacist simply takes an empty blister sheet, positions it so that the blister recesses are oriented downwardly, and deposits pharmaceutical medications into the blister recesses. Once the medications are in the blisters, the lidding sheet is positioned over the blister sheet and the cohesive material on the lidding sheet is brought into contact with the cohesive material on the shoulders and periphery of the blister sheet. Enough pressure is applied to bring the entire surface of the shoulders and periphery into contact with the lidding sheet. A backing sheet may then be adhered to the lidding sheet. Alternatively, the backing sheet may be adhered to the lidding sheet before the lidding sheet is sealed to the blister sheet. The backing sheet may include printed information that corresponds to the medications in each blister that is in corresponding relationship to the printed information. The blister sheet, lidding sheet and backing sheet are then encased in a stiff outer frame having front and back panels or portions, one panel having apertures through which protrude the blisters and the other panel having apertures allowing the printed information corresponding to the medications in the blister to be visible. Also, the relatively thin and frangible nature of the lidding sheet and the overlying backing sheet permit the medications to be pushed therethrough and thus dispensed, by collapsing the associated blister recess.
From the foregoing, it can be seen that the package of the disclosed invention may be easily assembled without cumbersome apparatus otherwise necessary for pressure-sensitive or heat-activated sealing materials.
Once a patient receives a prescription in the package assembly, it is very easy and convenient to take the prescribed medications and keep track of medications already taken. The patient is able to look at the specific medications in the blister recesses to determine which blister contains the appropriate medications for a given time. Alternatively, or in addition to looking in the blister recesses, a patient can read the information printed on the backing sheet of the assembly that corresponds to the content of the specific blisters. Once the blister recess containing the appropriate medications is chosen, the patient merely presses against the blister recess, thus forcing the medications to puncture and dispense through the lidding sheet and backing sheet.
While a particular embodiment of the invention has been shown, it will be understood, of course, that the invention is not limited thereto since modifications may be made by those skilled in the art, particularly in light of the foregoing teachings. It is, therefore, contemplated by the appended claims to cover any such modifications as incorporate those features which constitute the essential features of these improvements within the true spirit and the scope of the invention.
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The present invention includes a package assembly for dispensing pharmaceutical medications, and a method of manufacturing the same. The package assembly comprises a blister sheet having blister recesses and substantially planar shoulder portions located between the recesses and coated with a cohesive composition, and a lidding sheet having one surface entirely coated with a cohesive composition having affinity for the cohesive that is coated on the shoulder portions of the blister sheet, but having no affinity for pharmaceutical medications positioned in the blister recesses. A relatively stiff plastic frame having top and bottom panels is positioned on opposite sides of the blister sheet and lidding sheet in a sandwich relationship, thereby giving support to the entire package assembly. The present invention, therefore, allows for customized prescription packaging to be economically handled by a patient's pharmacist.
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BACKGROUND OF THE INVENTION
The present invention relates to a power earth auger, which can be driven from either end. If one end becomes worn or damaged the auger can be inverted, and inverting a pilot bit that is normally used with an auger charged from one end of the auger tube to the other to extend the useful life of the auger.
Powered earth augers mounted on a skid steer loader, a backhoe boom or an excavator boom are used quite widely. The augers are generally driven by a power unit that will couple to a number of different auger sizes and lengths. Reversible hydraulic motors are used conventionally for powering the auger. This permits the auger to be driven in either direction of rotation. Different horse power hydraulic motors can be utilized for different sized augers as needed.
SUMMARY OF THE INVENTION
The present invention provides a powered earth auger that has a central tube or shaft with either single or double helix flight, used for boring holes in the ground. The center tube has identically constructed opposite ends to permit the auger to be driven from either end, and conversely permit either end to be used as the earth penetrating end.
The central tube or shaft has a drive connection at either end. The end of the helix that engages the ground is provided with a shank plate, that is, a reinforcing bar at the leading end of the helical flight used to support teeth that will rip into the ground as the auger rotates, to aid in penetration.
Additionally, the augers normally include a pilot bit at the end that enters the ground. The pilot bit mounts on the center shaft and extends out axially farther than the auger helical flights, and holds the auger at an entry location as the auger flights first engage the ground.
The auger shaft is adapted to have a drive connection for the auger bit and the power unit drive shaft at each end.
The helical flights also are provided with a shank plate at each end. The end that is coupled to the power unit has removable teeth removed from the shank plate. The teeth for the shank plate will be added when the auger has been inverted and the pilot bit inserted at the end to be used for boring.
The ability to use both ends for boring extends the life of the augers because the end that enters the ground is subject to greater wear, and also can be damaged more frequently by rocks or obstructions that it might strike.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevational view of an earth auger made according to the present invention;
FIG. 2 is an enlarged side view of the auger of FIG. 1 showing the lower end of the auger;
FIG. 3 is a view taken on line 3--3 in FIG. 2;
FIG. 4 is an enlarged view of the drive end of the auger of FIG. 1, with parts in section and parts broken away; and
FIG 5 is a sectional view taken along 5--5 in FIG. 4.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
In FIG. 1 a hydraulic motor drive unit indicated generally at 10 is mounted onto a suitable boom or arm 11 of a backhoe or excavator. A link 12 is used for controlling the pivoting of the power unit 10 through a pin 14 that slides in a slot 16. The link 12 is of the type shown in U.S. Pat. No. 5,556,217, and the mounting bracket 18 can be the same as that shown in U.S. Pat. No. '217.
The hydraulic motor 10 is connected in a hydraulic circuit including an operator controlled valve 20 and that receives hydraulic fluid from a pump 22 in a conventional manner. The pump and valve are positioned to be accessible to an operator of the excavator, backhoe or other machine that is being utilized.
The hydraulic motor has an output drive shaft 24 (See FIG. 4), which in this form of the invention has a hexagon cross section as shown in FIG. 5. The drive shaft 24 is made to drive an earth boring auger shown generally at 26, which includes a center tubular shaft 28 and a helical flighting 30 fixed to the center tube. In this instance, the flighting 30 is single helix, but many earth augers will use a double helix for added capacity.
The helix 30 forms an auger flight that is welded to the tubular shaft 28, and when the power unit 10 is powered, tubular shaft 28 will be rotated and will bore into the earth in a known manner. The auger flight has a rotationally leading edge at the lower end of the auger.
In FIG. 2, the lower end of the auger is illustrated, and it includes a pilot bit 32 that also has a shaft section 34 which fits into the hexagon cross-section bore of the tubular auger shaft 28 and can be pinned in place with a suitable bolt 36. The drive shaft 24 of the power unit also is pinned in place with a suitable bolt 25. The location of the bolt hole measured from the end of the auger tubular shaft is the same at both ends of the auger. The leading edge 38 of the ground engaging end of the auger flight shown in FIG. 3, is provided with a shank plate or reinforcing bar 40. The shank plate 40 is placed in relation to the leading edge of the auger flight so that the shank plate will tilt downwardly slightly. A plurality of digging teeth 42 are removably mounted (bolted) in place onto the shank plate 40. The upper end of the auger flight shown in FIG. 4 at 44 is provided with a shank plate 46 which is identical to the shank plate 40, and is mounted in the same manner so that when the auger is inverted end for end the upper shank plate 46 is oriented to engage the ground. While the removable teeth 42 are not illustrated at the upper end of the auger, they can be bolted to the shank plate 46 in the same manner as shown in FIG. 3.
The opposite ends 44 and 38 of the auger are identically constructed, and both include a socket or drive portion for receiving either the power shaft 24 or the shaft 34 for the pilot bit 32. The pins 25 and 36 are positioned at the same location relative to the end surface of the auger and are made so that they will pass through provided openings in either the drive shaft 24 or the shaft 34 for the pilot bit 32. The auger can be turned end for end and driven from either of the two ends, with the other end, opposite from the power unit or drive unit, receiving the pilot bit 32 and being the first end that will bore into the ground when the unit is used.
The useful life of an auger is extended because if damage occurs to the end that engages the ground, as sometimes happens, the auger can be inverted, the pilot bit removed from the previously used end and the drive shaft 24 inserted for driving the auger. The removable teeth can be placed onto the shank plate from the previously driven end and the unit is ready to run when the pivot bit is also reinserted.
Although the present invention has been described with reference to preferred embodiments, workers skilled in the art will recognize that changes may be made in form and detail without departing from the spirit and scope of the invention.
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An earth auger has a center shaft and a helical flighting extending along the axis of the shaft. The flighting and the center shaft have opposite ends that are identical in construction, so that the auger can be driven from either end by a power unit.
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CLAIM OF PRIORITY
The present invention claims priority to U.S. Provisional patent application no. 60/128,433, filed on Mar. 30, 1999.
FIELD OF INVENTION
The present invention relates to a pad that provides hypo/hyperthermia properties to a person using the pad.
BACKGROUND OF THE INVENTION
In U.S. Pat. No. 5,336,708, Chen discloses a gelatinous elastomer composite article. These articles, as disclosed by Chen, “include: GMG, MGM, MG 1 G 2 M, M 1 M 2 G 1 G 2 , M 2 M 1 G 1 G 2 , G 1 MG 1 G 2 , MG 1 G 2 M, G 1 G 2 M, GM 1 M 2 G, G 1 M 1 G 2 M 2 M 1 , M 1 GM 2 GM 3 GM 4 , [sic] ect, where G = gel and M = material The subscript 1, 2, 3, and 4 are different and are represented by n which is a positive number. The material (M) suitable for forming composite articles with the gelatinous elastomer compositions can include foam, plastic fabric, metal, concrete, wood, wire screen, refractory material, glass, synthetic resin, synthetic fibers, and the like. Sandwiches of gel/material . . . are ideal for use as shock absorbers, acoustical isolators, vibration dampers, vibration isolators and wrappers. For example the vibration isolators can be [sic] use under research microscopes, office equipment, tables, and the like to remove background vibrations.” U.S. Pat. No. 5,336,708, col. 3, lines 35-51. Chen further discloses, “generally the molten gelatinous elastomer composition will adhere sufficiently to certain plastics (e.g., acrylic, ethylene copolymers, nylon, polybutylene, polycarbonate, polystyrene, polyester, polyethylene, polypropylene, styrene copolymers, and the like) provided the temperature of the molten gelatinous elastomer composition is [sic] sufficient high to fuse or nearly fuse with the plastic. In order to obtain sufficient adhesion to glass, ceramics, or certain metals, sufficient temperature is also required (e.g., above 250° F. [121° C. ]” U.S. Pat. No. 5,336,708, col. 9, lines 8-18 (brackets added for consistency of temperature comparison).
Elkins in U.S. Pat. No. 4,884,304 describes a bedding system with selective heating and cooling of a person. That system has, from top to bottom, in order: a top mattress cover, a gas envelope and a multiplicity of liquid flow channels. The multiplicity of liquid flow channels is accomplished by a conventional hypo/hyperthermia blanket. The details of this conventional blanket are set forth in this patent. A problem with this system occurs when a person is on the mattress cover. When the person is on that mattress cover, the person has two sides: (1) a “contacting side” that touches the mattress cover and (2) the “exposed side” that does not touch the mattress cover. The person disperses the gas envelope and only certain portions of the contacting side contact the flow channels. As shown in FIG. 5 of that patent, the shoulders and other peripheral points of the contacting side of the person, such as arms, do not contact the flow channels. Thereby, that bedding system fails to transfer the desired temperature of the flow channels uniformly to all,sections of the contacting side of the person.
M. Figman in U.S. Pat. No. 3,266,064, and von der Heyde in U.S. Pat. No. 5,887,304 illustrate conventional convective medium mattress system which essentially has a lower “box spring” and a mattress made of rubber, foam, or conventional mattress materials that an individual or object lies thereon. In each embodiment, the lower box spring has a cavity that the medium enters and distributes throughout. The medium then escapes from the cavity through apertures of the mattress.
A problem with these apertures 89 is that they kink 90 when an adult lies 22 thereon, as shown in FIG. 8 . Please note that von der Heyde's system is designed for an infant, not an adult. And an infant is of such low weight that kinking is essentially nonexistent.
When kinking occurs, the medium is prevented from contacting the body. And when the medium does not contact the body, the medium is unable to treat the hypothermia or hyperthermia portions of the patient that contact the mattress, or even cool or heat the portions of the patient that contact the mattress.
The present invention solves this problem.
SUMMARY OF THE INVENTION
The present invention relates to a first conformable material having a three-dimensional shape and a first hypothermia and/or hyperthermia device.
BRIEF DESCRIPTION OF THE FIGURES
A preferred embodiment of the present invention is described in detail hereinafter with reference to the accompanying drawing, in which:
FIG. 1 is a cross-sectional view of the present invention; and
FIGS. 2-7 are alternative embodiments of FIG. 1 .
FIG. 8 is prior art of an adult patient on a conventional mattress system with apertures.
FIG. 9 is the present invention of an adult patient on a gelatinous elastomeric material with apertures.
FIG. 10 is an alternative embodiment of the present invention with a conventional blanket.
FIG. 11 is an alternative embodiment of FIG. 10 with a convective blanket.
FIG. 12 is an alternative embodiment of FIG. 7 .
FIG. 13 is an alternative embodiment of FIG. 7 .
DETAILED DESCRIPTION OF THE INVENTION
FIG. 1 illustrates a pad 10 having a first sealable bag 12 , a first hypothermia and/or hyperthermia device 14 , and a pad cover 16 . The bag 12 contains at least a first conformable material 18 , and a thermally conductive medium 20 . The thermal conductive medium 20 is any liquid or viscous gel that transfers energy generated by the device 14 to a patient (not shown). Examples of this liquid include water, water-based solutions, oil-based solutions, oils, alcohols, mixtures thereof, and viscous gels.
The conformable material 18 is any material having apertures that do not easily kink, preferably, a gelatinous elastomeric material. Examples of types of gelatinous materials, which are heat formable and heat reversible, are fully described in U.S. Pat. Nos. 4,369,284, 4,618,213, 5,262,468, 5,336,708, and 5,508,334, which are hereby incorporated by reference herein, and those made by Pittsburgh Plastic. The gelatinous materials manufactured by Pittsburgh Plastic are allegedly distinct from the patented types. This conformable material can be of any shape or design, so long as it has a three-dimensional shape that supports a patient or object on the pad 10 .
The hypothermia and/or hyperthermia device 14 is any conventional hypo/hyperthermia blanket—an example of this blanket is the MUL-T-PAD® or the THERMACARE® blanket by Gaymar Industries, Inc. of Orchard Park, N.Y.—and its corresponding pump—the MEDI-THERM II® temperature regulator by Gaymar Industries, Inc. of Orchard Park, N.Y.—, an electric blanket, a cold compress, and a convective device. The convective device pumps or blows air or other gaseous medium (collectively “Air”) having a predetermined temperature. The Air obtains the desired temperature in a conventional Air temperature regulator (for example, an air conditioner, a heat pump, a ThermaCare® blower unit, or the MEDI-THERM II® temperature regulator) and then circulates through a mesh screen like the Air Queen by Teijin, Inc. or a non-woven polymeric device having a plurality, of tubes with numerous apertures therein. The Air is then distributed throughout the entire pad 10 . In any embodiment of device 14 , the device 14 affects the temperature that a patient (not shown) or object (not shown) is exposed to, and, in some embodiments, the medium 20 that encompasses the conformable material 18 .
The bag 12 is any sealable instrument that contains at least the thermally conductive medium 20 and conformable material 18 in place. Preferably, the bag 12 is plastic, and it can be sealed thermally, acoustically, by a zipper, zip locked, or even by Velcro®.
The pad cover 16 is any conventional material used to cover a pad 10 . The pad cover 16 can encompass the entire pad 10 , the preferred embodiment as shown, or cover the pad 10 like a conventional mattress sheet. In either embodiment the pad cover 16 can be cloth, leather, plastic or conventional cover material. The materials of the pad cover 16 allow the patient or object, on the pad 10 , to feel the desired temperature of the pad 10 (Air or medium 20 ). The pad cover 16 can also allow moisture to pass through it. Thereby, it helps control the patient's temperature and prevents overcooling or overheating.
Turning to FIG. 2, a patient 22 disperses a portion of the thermal conductive medium 20 in the bag 12 and contacts at least a portion of the conformable material 18 when the patient 22 lies on the pad 10 . The conformable material 18 provides support to the patient 22 , increases the effective surface contact of the pad 10 to the patient 22 to ensure greater desired thermal conductivity to the patient 22 , maintains the stability of the bag 12 , and reduces the pressure to the patient 22 . By maintaining the stability of the bag 12 , the conformable material 18 ensures the patient (or object) 22 , on the pad 10 , from directly contacting the hypothermia and/or hyperthermia device 14 . In other words, the patient 22 does not “bottom out” to or directly contact the device 14 .
In a preferred embodiment, the conformable material 18 has apertures 24 . The apertures 24 , in this embodiment, go from the bottom to the top of the material 18 and ensure the thermal conductive medium 20 is between the patient 22 and the hypothermia and/or hyperthermia device 14 . However, in order to decrease, and essentially avoid, kinking— which is discussed above and, as a reminder, inhibits the medium 20 or the Air from contacting the patient— and which is common in many mattress materials, the preferred embodiment of the conformable material 18 is a gelantinous elastomer material. The gelantinous elastomer material has a structure design that admittedly bends and indents, as shown in FIG. 9, when a patient lies thereon, but does not kink. Thereby, the Air or medium can go through the apertures 24 .
The hypothermia and/or hyperthermia device 14 heats or cools the thermal conductive material 20 and the patient 22 to a predetermined temperature. Since the thermal conductive material 20 contacts most, if not all, portions of the contacting side 23 of the patient 22 , the material 20 ensures a uniform, or nearly uniform application of the predetermined temperature to the contacting side 23 .
Turning to FIG. 3, the pad 10 contains at least a second bag 12 a . The second bag 12 a has at least a second conformable material 18 a and a second thermal conductive material 20 a . The second thermal conductive material 20 a , the second bag 12 a , and the second conformable material 18 a can be the same or different materials as the previously listed corresponding elements 12 , 18 , 20 .
Turning to FIG. 4, an alternative embodiment of FIG. 3 is shown. A second hypothermia and/or hyperthermia device 14 a is positioned under the second bag 12 a . The second hypothermia and/or hyperthermia device 14 a can be set at the same or different temperature as the hypothermia and/or hyperthermia device 14 . Thereby, the first thermally conductive material 20 can apply one temperature to one portion of the contacting side 23 b of the patient 22 and the second thermally conductive material 20 a can apply the same or a different predetermined temperature to another portion contacting side 23 c.
Turning to FIG. 5, an alternative embodiment of FIG. 4 is shown. A third conformable material 18 b underlies the hypothermia and/or hyperthermia devices 14 , 14 a . This material 18 b offers further support to the patient 22 , maintains the stability of the bags 12 , 12 a , and further reduces the pressure to the patient 22 . Obviously, this third material 18 b can underlie, or alternatively be over. (not shown), the hypothermia and/or hyperthermia device(s) 14 , 14 a of FIGS. 1-4.
Turning to FIG. 6, an alternative embodiment of FIG. 1 is shown. The hyperthermia and/or hypothermia device 14 is within the bag 12 under, or alternatively be over (not shown), the conformable material 18 and surrounded by the thermal conductive medium 20 . In this embodiment, the conventional inlet-outlet 77 of the device 14 , i.e., the pump hoses of the MEDI-THERM II® system, protrudes from the sealed bag 12 . Obviously this embodiment can be used in the other embodiments illustrated in FIGS. 3 and 4.
FIG. 7 illustrates an alternative embodiment of FIG. 1, wherein the conformable material is not inserted in a bag 12 or surrounded by a medium 20 . In this embodiment, the hypothermia and/or hyperthermia device 14 is a convective unit and the Air goes through the apertures 24 of the gelatinous elastomer material 18 .
FIG. 12 illustrates an alternative embodiment of FIG. 7 . Along with the apertures 24 , the conformable material 18 has a plurality of side apertures 24 a interspaced between the upper wall and a lower wall of the material 18 . Side apertures 24 a receive Air and then distribute the Air throughout the conformable material 18 .
In one embodiment (like that shown in FIG. 7) the device 14 is positioned below the conformable material 18 . In yet another embodiment, as shown in FIG. 12, the device 14 is positioned at an end 563 of the conformable material 14 . Thereby the Air goes into the side apertures 24 a and is distributed throughout the conformable material 18 and apertures 24 , to effect the patient's 22 temperature.
Turning to FIG. 13, another embodiment of the present invention relates to the positioning of the hypothermia and/or hyperthermia device 14 . The device 14 can also be positioned above the conformable material 18 . The device 14 adjusts the temperature of the air within the pad 10 , and that air cools or heats or maintains the temperature of the patient 22 . The air also circulates through the pad 10 within the apertures 24 (and maybe 24 a ).
Turning to FIGS. 10 and 11, the Air of FIG. 7 circulates under the cover 16 , and escapes from, preferably predetermined, a gap 345 in the cover. Extending from gap 345 is a tube 347 , flexible or not, that directs the Air under a conventional blanket 348 , as shown in FIG. 10, or into an aperture 349 of a convective blanket 350 , like the THERMACARE® blanket by Gaymar Industries, Inc., as shown in FIG. 11 .
Alternatively, the pad cover 16 has a material that transfers the temperature to the patient but influences the Air to a predetermined gap(s) 345 in the pad 10 . The predetermined gap(s) 345 can be located anywhere within the pad, i.e. at the bottom of the pad, a side of the pad as shown in FIGS. 10 and 11, if necessary, under the patient 22 , or under the blanket 348 directly.
Turning to the method of the invention the preferred embodiment of the present invention is as an operating table pad and/or any other structure or object used in an operating.room or hospital-like mattress system, such as bed systems or seat cushions. An operating technician inserts at least one pad 10 , having a hypothermia and/or hyperthermia device 14 , and a conformable material 18 , under a predetermined area of a patient 22 . The technician then adjusts the device 14 to a predetermined temperature, in some instances the device 14 can only obtain one temperature. In either case, the device 14 adjusts the pad 10 to the predetermined temperature. At any time before or after the device 14 is initially adjusted to the predetermined temperature, the patient 22 lies on the pad 10 and the contacting side 23 of the patient 22 will be or is exposed to the predetermined temperature.
Although a particular preferred embodiment of the invention has been illustrated and described 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 invention defined by the claims.
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A first conformable material having a three-dimensional shape and a first hypothermia and/or hyperthermia device, used as a pad for sleeping, lying down, or sitting, to maintain a desired temperature to the contacting surface of a body to the pad.
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BACKGROUND OF THE INVENTION
[0001] This invention relates to screening machines of the type used to separate or classify mixtures of solid particles of different sizes. The invention also relates to screening machines of the type used for liquid/solid separations, i.e., for separating solid particles of specific sizes from a liquid in which they are carried. More particularly, the invention relates to an improved screen panel for use within the screening machine.
[0002] In screening machines of the type described, a screen (which may be woven, an aperture plate or another design) is mounted in what is often called a “screen frame” or “screen deck” which includes a supporting peripheral frame around the perimeter of the screen. Some screens are tensioned when they are installed in the screening machine and other screens are pre-tensioned in a frame prior to being installed in the machine. Typically associated with the screen deck are other material handling elements which are moved with the screen and form walls or partitions above or below the screen for containing the liquid and/or particulate materials adjacent to the screen and directing them to appropriate outlets. These elements may comprise a top cover and a pan beneath the screen deck. In the case of screening machines with multiple screens or deck units, spacer pans or frames are provided between the multiple screens.
[0003] The screens are often removed from the screening machines for cleaning, replacement, readjustment or installation of a screen of a different mesh size or the like. The screen is releasably mounted to a carrier, table or box to which vibratory motion is imparted, typically by one or more eccentric motors or other means of excitation. The carrier, table or box is referred to herein as a “vibratory carrier”. The vibratory carrier may be moved in oscillatory, vibratory, gyratory, gyratory reciprocating, fully gyratory, rotary or another type of motion or combinations thereof, all of which are herein collectively referred to as “vibratory” motion or variations of that term.
[0004] In large commercial screening machines, the weight of the various components including the screen assembly carried by the vibratory carrier, and the weight of the material being processed on the screen assembly may total several hundred pounds or more. Screening machines which tension the screen, as opposed to those utilizing pre-tensioned screens, include the added weight associated with the screen tensioning mechanism and related components. This presents a very substantial inertial mass which resists the changes of motion applied thereto by the vibratory drive acting through the vibratory carrier. As a result of these inertial forces, a relative motion may exist between the vibratory carrier and the screen assembly. Typically, the screen assembly and vibratory carrier are each constructed of metal which could result in significant noise, wear and damage due to the relative motion or rubbing action there between. The resulting impact forces between the screen assembly and vibratory carrier significantly increase the stresses on the components and reduce their useful life.
[0005] Reducing the metal-to-metal contact minimizes the wear on the various metal components and the noise associated with the operation of the screening machine. Currently, certain screen assembly designs may not be sealed or secured relative to the remainder of the screening machine, particularly in larger screening machines. This results in the above-described metal-to-metal contact between the screen assembly and the remainder of the screening machine and prevents the screening of very fine material, such as sand or the like. The screens in larger screening machines are typically inserted and/or removed from the machine in a generally horizontal, longitudinal direction typically through an opening or slot at the head or foot end of the machine. This method of installation and removal of the screen is detrimental to known sealing arrangements because a seal which would engage the screen assembly could be torn or damaged during the installation/removal of the screen. In other screening machines, the screen is inserted vertically, typically from the top of the machine. Access to the screens from the top of the machine or the longitudinal ends is often very inconvenient and difficult.
SUMMARY OF THE INVENTION
[0006] The above-described and other problems with prior art screening machines and associated screen panels have been resolved by this invention. Screening machines according to one embodiment of this invention utilize one or more pre-tensioned screens mounted in a perimeter frame for separating various granular and particulate material. One aspect of this invention is the profile or contour of opposite ends of the perimeter frame for the screen. The mesh screen is mounted to a rigid perimeter frame. The screen is pre-tensioned in the frame as opposed to screens which are stretched or tensioned during the screening machine set up. The frame is slid into the side of the machine in a direction parallel with two opposing contoured profile ends of the frame. In one embodiment, the profile of the frame along each end includes a downwardly directed bevel relative to the plane of the screen. The profile or contour of these ends align with and mate in the screening machine with a complementary channel such that when the screen is raised into sealing contact in the screening machine, the bevel ends of the screen panel frame align the screen panel in the machine through a comparably dimensioned and configured channel on the screening machine. Likewise, the bevels on the screen panel frame provide a positive sealing surface for contact with the adjacent portions of the channel to prevent product from escaping off of the screen during use.
[0007] Therefore, according to this invention, the screening operation is much more efficient and more easily accomplished while offering significant advantages in screen service life, installation and removal.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] The objectives and features of the invention will become more readily apparent from the following detailed description taken in conjunction with the accompanying drawings in which:
[0009] FIG. 1 is a perspective view of an exemplary screening machine and associated screen panel being installed therein according to one embodiment of this invention;
[0010] FIG. 2 is a perspective view of the screen panel of FIG. 1 ;
[0011] FIG. 3 is a top plan view of the screen panel of FIG. 2 ;
[0012] FIG. 4 is a side elevational view of the screen panel of FIG. 2 ;
[0013] FIG. 5A is a side elevational view of a portion of the screening machine of FIG. 1 and a screen panel inserted therein prior to a screening operation; and
[0014] FIG. 5B is a view similar to FIG. 5A with the screen panel engaged with a screen panel carrier according to one aspect of this invention.
DETAILED DESCRIPTION OF THE INVENTION
[0015] Referring to FIG. 1 , an exemplary embodiment of a screening machine 10 in which this invention may be used is shown. Screening machines of many types are sold commercially by Rotex, Inc. of Cincinnati, Ohio, the assignee of this invention. However, this invention is not limited to any particular type of screening machine design or application and the machine shown and disclosed herein is shown for illustrative purposes.
[0016] The screening machine 10 includes an inlet port 12 near an inlet section 14 proximate a head end 16 of the machine 10 . The screening machine 10 may also include a top cover 18 in any one of a variety of forms. Particulate or other material to be screened is fed into the inlet port 12 from a hopper (not shown) for screening and processing by the machine 10 .
[0017] The screening machine 10 is supported structurally by a base frame 20 including beams 22 connected together by laterally oriented struts 24 on each end of the screening machine 10 . The screening machine 10 includes an electric motor 26 coupled to a drive weight (not shown) to impart an oscillatory, vibratory, gyratory, gyratory reciprocating, fully gyratory, other motion or combinations thereof (herein collectively referred to as “vibratory” motion or variations of that term) to at least the head end 16 .
[0018] Within a screening chamber of the screening machine 10 , one or more screen panels 28 are each mounted in combination to form one or more screen decks 30 to receive the material being screened from the feed chute 12 at the head end 16 of the machine 10 . The screen panels 28 , are mounted on slightly sloping planes (approximately 4°) with the head end thereof being slightly elevated relative to a foot end so that during the screening process the material advances, in part by gravity, over the screen panels 28 toward the foot or discharge end 32 of the machine 10 . Even though the screen panels 28 of the screening machine 10 may be on a slightly sloping plane, to provide a reference for the purposes of clarity herein, these components will be considered to be generally horizontal and the direction perpendicular or orthogonal to the screen panels 28 will generally be referred to as a vertical orientation, direction or attitude. The direction of travel of the material being screened from the head end to the foot end across the screen panels 28 is referred to as the longitudinal direction and the perpendicular orientation extending from side to side on the screen panels is a lateral direction.
[0019] In the embodiment of the screening machine 10 shown in FIG. 1 , upper and lower screen decks 30 each include four screen panels 28 mounted generally coplanar with each other in the associated screen deck 30 . Accordingly, as the material to be screened is deposited from the inlet port 12 onto the upper screen deck 30 , the vibratory motion of the screening machine advances the material longitudinally across the top of the screen panels 28 of the upper screen deck 30 toward the foot end 32 . Appropriately sized and configured material passes through the upper screen deck 30 and falls onto the lower screen deck 30 . The screen panels 28 of the upper screen deck 30 may include a fine mesh screen material 34 adjacent the inlet port 12 through which dust and other fine particulate matter passes for collection and discharge. Certain material also passes through the upper screen deck 30 and is deposited on the lower screen deck 30 . Therefore, the lower screen deck 30 is included to provide an additional separating mechanism for the appropriately sized particles to pass through the second lower screen deck 30 for collection in the lower pan (not shown) and discharge through an outlet or exit section 36 .
[0020] The unacceptably sized particles remain atop the first upper screen deck 30 and fall off the terminal edge thereof into a collection basin for discharge through the outlet section 36 . Material that passes through the upper screen deck 30 and remains atop the lower screen deck 30 falls off the terminal edge thereof and into the collection basin for discharge through a reject port (not shown). The discharge and reject ports are separated by a baffle (not shown) to keep the classified particles separate from one another.
[0021] Referring to FIG. 1 , one or more doors 38 are each pivotally connected by a hinge 40 to a lateral side 42 of the screening machine 10 . When opened, the doors 38 provide access for insertion and removal in the lateral direction of the screen panels 28 . It will be appreciated that although one side 42 of the screening machine 10 is shown in FIG. 1 , additional doors on the opposite side of the screening machine 10 may also be provided. Advantageously, the screen panels 28 are inserted laterally or perpendicularly to the longitudinal direction of travel of the material being screened in the screening machine 10 from the head end 16 to the foot end 32 of the machine 10 .
[0022] As shown generally in FIG. 5A , when the screen panel 28 is inserted into the screening machine 10 , it is supported on a vibratory carrier 44 . In one embodiment, the vibratory carrier 44 may include a ball tray 46 capturing a number of balls or other agitation producing members (not shown) which repeatedly impact the screen panel 28 to dislodge particulate material that might accumulate on the screen material 34 and inhibit occlusion of the screen material 34 as is well known in the art.
[0023] Referring to FIGS. 2-4 , one embodiment of the screen panel 28 according to this invention includes a generally perforated mesh screen material 34 including a number of intersecting longitudinal 48 and lateral 50 threads, wires or strings which are oriented orthogonally to each other to provide appropriately sized and configured openings 52 in the mesh screen material 34 to prevent/permit the passage particulate material there through. The screen panel 28 includes a generally rigid perimeter frame 54 having a leading side edge 56 opposite from a trailing side edge 58 . In one aspect, the screen material 34 of the screen panel 28 of this invention does not require tensioning by the screening machine 10 upon installation into the screen deck 30 . Many prior screening machines tension the screen mesh material or pull it taught during the installation process. The screen mesh material 34 of the screen panel 28 according to this invention does not require tensioning and in that sense is considered pre-tensioned in that it is mounted in the screen panel frame 54 in a ready-to-use state.
[0024] The panel 28 may be manufactured by a variety of processes, one of which utilizes a bare metal frame which is dipped into an epoxy and allowed to air dry. The epoxy is hard to the touch but has not cured. The frame 54 with dry epoxy is then placed on a table with mesh screen material 34 on top. This stack-up is then bonded together with a heat press for a few minutes. The edges are then cleaned up with a hand grinder, if necessary.
[0025] A further benefit of this aspect of the invention is that the process leaves the panel 28 feeling tensioned although no time or fixture is required to pull (tension) the screen material 34 prior to bonding it to the frame 54 or when installing the screen frame panel into the screening machine 10 . The new panel 28 design incorporates this approach such that open area is maximized but the tension level is comparable to known tension techniques, such as spring clips.
[0026] The leading side edge 56 of the screen panel frame 54 is typically inserted laterally into the screening machine 10 while a user or operator grasps the trailing side edge 58 for manipulation. In particular, a downwardly turned elongate handle 60 is formed on the trailing side edge 58 of the screen panel 28 . In one embodiment, the handle 60 is oriented approximately 90° relative to the plane of the screen panel 28 and provides a convenient and easy access for the user or technician to grasp or manipulate the screen panel 28 . Additionally, the handle 60 or adjacent surfaces of the screen panel frame 54 provide a convenient location for identifying indicia and labels indicating various service parameters, design characteristics and other aspects of the screen panel 28 .
[0027] One or more tabs 62 each located proximate a head end 64 or a tail end 66 of the screen frame 54 are located along the trailing side edge 58 of the frame. The tabs 62 are each oriented approximately 90° relative to the plane of the screen panel 28 and along with the handle 60 provide a convenient location for the user or technician to grasp and manipulate the screen panel frame. Likewise, upon insertion of the screen panel 28 into the screening machine 10 , the tabs 62 and handle 60 provide a detent when juxtaposed against the vibratory carrier 44 for proper orientation and location of the screen panel 28 in the screening machine 10 .
[0028] Another aspect of the screen panel 28 and associated frame 54 according to this invention are beveled edges or lips 68 along the longitudinal head end 64 and/or foot end 66 of the screen panel frame 54 . Each bevel 68 is oriented approximately 45° relative to the upper surface or plane of the screen panel 28 and extends substantially the entire width of the frame 54 . While the bevel 68 are shown along both the longitudinal head and foot ends 64 , 66 of the screen panel frame 54 , one of ordinary skill in the art will readily appreciate that the bevel edge 68 may be provided at either or both of the head and foot ends 64 , 66 within the scope of this invention.
[0029] Referring to FIGS. 5A and 5B , the configuration of the screen panel frame 54 relative to the remainder of the screening machine 10 will now be described. The downwardly turned bevel edges 68 along the head and foot ends 64 , 66 of the screen panel frames 54 are supported by a similarly inclined face 70 of the vibratory carrier 44 as shown in FIG. 5A . The carrier 44 also includes a compressible seal member 72 juxtaposed to the terminal edge 74 of the bevel edge 68 and mounted in the carrier 44 . Likewise, the lower surface of the screen panel frame 54 is supported along a similarly configured profile of the carrier 44 as shown in FIG. 5A .
[0030] The screening machine 10 includes a bracket 76 in which a rotational cam 78 is seated to support the carrier 44 . The rotation of the cam 78 is accomplished by an actuator 80 accessible to the operator or technician when the door 38 of the screening machine 10 is open. One known mechanism suitable for use with this invention to raise/lower the carrier 44 and screen panel 28 is disclosed in Rotex' U.S. Pat. No. 6,070,736 which is incorporated by reference herein. The screening machine 10 also includes a downwardly depending channel 82 initially spaced from the bevel lip 68 of the screen frame 54 as shown in FIG. 5A .
[0031] Upon rotation in the direction of arrow A of the actuator 80 , the cam 78 is rotated thereby raising the carrier 44 and screen panel 28 supported thereon upwardly to sealing engagement with an upper portion 84 of the screen deck 30 as shown in FIG. 5B . As the carrier 44 supporting the screen panel 28 is raised, a face 86 of the channel 82 is juxtaposed against the bevel lip 68 of the screen panel 28 and the seal 72 is compressed against the channel 82 . As a result, the portion of the screen deck 84 and upper surface of the screen panel frame 54 are sealed to prevent and inhibit the discharge of material being screened. Due to the design and configuration of the screen panel frame 54 and associated screen deck 30 , the seal 72 and associated components are neither damaged nor compromised during the lateral installation and removal of the screen panel 28 thereby extending the service life of the associated components while maintaining effective sealing and associated screening operations. The orientation of the seal 72 is generally parallel with the lateral direction in which the screen panel is inserted and removed from the machine 10 .
[0032] The bevel edges 68 on two opposite ends in conjunction with the lift system described in U.S. Pat. No. 6,070,736 permits insertion and proper location, alignment, sealing, and securing of the screen panel 28 to the screening machine 10 while maintaining a smooth transition (no bumps or wear points). This invention offers a screen panel 28 that is pre-tensioned, ready to use, lightweight, standardized in size to lower cost, simple design, mass producible, easy to handle, nestable for storage and shipping. The bevel lip 68 also acts as a seal holder for reusable seal strips 72 .
[0033] Referring to FIGS. 1-3 , the screen panel 28 of this invention includes a number of smaller cells 88 defined around the interior of the perimeter frame 54 by plurality of transverse and longitudinally extending ribs 90 . Because the screen material 34 is flat and pressed, smaller cells 88 result in greater tension in the screen mesh material 34 since it has very little length and is held on both ends and it cannot deflect for a given load. The orientation of the ribs 90 may be skewed or not aligned with the orientation of the openings 52 defined by the threads 48 , 50 of the screen material 34 . Alternatively, the ribs 90 and threads 48 , 50 of the screen material may be aligned with each other in the lateral and longitudinal direction. In one embodiment of the screen panel 28 , the wire mesh screen material 34 is not bonded directly to the ribs 90 , only the perimeter frame 54 . Silicone may be used either as an adhesive to bond the screen material 34 to the frame 54 and/or as a buffer between the screen material 34 and another suitable adhesive known in the industry. It is believed that the silicone retards fatigue of the screen material 34 in use. As such, the service life of the screen panel 28 is extended and the economic benefit of this invention is maximized. It is expected that this general design provides improved throughput, service live and screening accuracy.
[0034] From the above disclosure of the general principles of the present invention and the preceding detailed description of at least one preferred embodiment, those skilled in the art will readily comprehend the various modifications to which this invention is susceptible. Therefore, I desire to be limited only by the scope of the following claims and equivalents thereof.
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A screening machine of the type used to separate or classify mixtures of solid particles of different sizes includes a fixed base and a perforate screen mounted for movement relative to the base during a screening operation. The screens are pre-tensioned and mounted in a perimeter frame for separating various granular and particulate material. The frame is slid into the side of the machine in a direction parallel with two opposing bevel lips at the ends of the frame which mate in the screening machine with a complementary channel such that when the screen is raised into sealing contact in the screening machine, the bevel ends of the screen panel frame align the screen panel in the machine. The bevels on the screen panel frame provide a positive sealing surface for contact with the adjacent portions of the channel to prevent product from escaping off of the screen during use.
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INTRODUCTION
[0001] The Toll-like receptor/Interleukin-1 receptor (TLR) superfamily plays a central role in inflammation and the host response to bacterial infection. Members of the TLR family are characterised by a cytosolic domain termed the Toll-IL-1R (TIR) domain and an extracellular region consisting of a series of leucine rich repeats. Occupation of toll-like receptors by various microbial components leads to the expression of a large number of proinflammatory proteins such as inducible cyclooxygenase, adhesion molecules and chemokines. Ten human TLRs have been identified to date. TLR4, the first TLR to be discovered, is essential for the response to bacterial lipopolysaccharide (LPS) (1,2). TLR2 couples with TLRs 1 and 6 to recognise diacyl- and triacyl-lipopeptides respectively. TLR5 recognises and responds to bacterial flagellin (3) and TLR9 is required for recognition of unmethylated CpG motifs which are present in bacterial DNA (4). TLRs 11, 12 and 13 have recently been described in mice but they have no human orthologs (5, 6). Stimulation of TLRs with the appropriate ligands leads to activation of the transcription factor NF-κB and also the mitogen-activated protein kinases (MAPKs), p38, c-jun N terminal kinase (JNK) and p42/p44.
[0002] The activation of NF-κB is dependent on MyD88, a cytoplasmic TIR domain-containing adapter protein (7, 8, 9). MyD88 acts as an adapter protein for the entire TLR family with the exception of TLR3 which recruits the adapter protein TRIP (10). In addition to activating NF-κB, TRIF is also required for the induction of genes dependent on the transcription factor Interferon Regulatory Factor 3 (IRF3) (11). This pathway is referred to as the MyD88-independent pathway and has been shown to be important for evading pathogens of viral origin (12). Another TIR adapter protein, MyD88 Adapter-like (Mal, also known as TIRAP) is involved in the MyD88 dependent pathway (13, 14) and is required specifically for TLR2 and TLR4 mediated signalling (15, 16).
[0003] During infection, occupation of TLRs by various ligands leads to the production of inflammatory mediators such as cytokines and chemokines and the activation of immune effector cells. This co-ordinated response is designed to clear invading pathogens, however, in many instances bacterial products activate an uncontrolled network of host derived mediators which can lead to multi-organ failure, cardiovascular collapse and eventually death. This condition, referred to as sepsis, is the major cause of deaths in intensive care units of hospitals and continues to increase worldwide. Antagonists for TLR proteins might therefore be useful tools to counteract the harmful effects of over-active immune responses. Interruption of TLR4 signaling is being closely examined as a means of counteracting the toxic effects of LPS. Current therapies include neutralizing antibodies to TLR4 and its co-receptor CD14 and also synthetic lipid A analogues which compete with LPS for binding to the receptor (17, 18).
[0004] As well as sepsis, therapies are also being aimed at other TLRs as a means of combating viral infections. For example, the TLR7 agonist, imiquimod, has been used successfully in the treatment of genital herpes caused by the human papilloma virus (19). In the case of autoimmune diseases, TLR agonists have been considered as a means of shifting adaptive T h 2 responses to T h 1 immune responses which would subsequently prevent the development of allergy. A more long-term goal will involve the development of therapeutics aimed at downstream components of the TLR signalling pathway. It is therefore crucial that all aspects of TLR signalling are fully understood.
[0005] The identification of further members of the TLR family or aspects of the TLR signalling pathway have valuable pharmaceutical potential.
STATEMENT OF INVENTION
[0006] According to the invention there is provided an isolated polypeptide comprising an amino acid sequence of SEQ ID No. 1 or a variant or fragment thereof.
[0007] The invention also provides an isolated polypeptide comprising amino acid sequence SEQ ID No. 2 or a variant or fragment thereof.
[0008] In one embodiment of the invention the variant comprises an amino acid sequence that is at least 70% identical to the amino acid sequence of SEQ ID No. 1 or 2. In another embodiment of the invention the variant Comprises an amino acid sequence that is at least 75%, at least 80%, at least 85%, at least 90%, at least 95%, at least 96%, at least 97%, at least 98%, at least 99%, at least 99.5% identical to the amino acid sequence of SEQ ID No. 1 or 2.
[0009] In one embodiment of the invention the variant comprises a deletion or insertion modification. The variant may also comprise a post translation modification.
[0010] In one embodiment of the invention the fragment is a peptide comprising at least 12 contiguous amino acids of SEQ ID No. 1 or 2.
[0011] In one embodiment of the invention the polypeptide as hereinbefore described exhibits Toll-like receptor activity. The Toll-like receptor activity may be TLR14 activity.
[0012] In one embodiment of the invention the polypeptide exhibits immunomodulatory activity.
[0013] The invention also provides a polynucleotide encoding a polypeptide as hereinbefore described.
[0014] The invention further provides an isolated polynucleotide comprising a nucleic acid sequence SEQ ID No. 3 or variant or fragment thereof or a sequence complementary thereto.
[0015] The invention also provides an isolated polynucleotide comprising a nucleic acid sequence SEQ ID No. 4 or variant or fragment thereof or a sequence complementary thereto.
[0016] In one embodiment of the invention the polynucleotide comprises a nucleic acid sequence that is at least 70% identical to the nucleic acid sequence of SEQ ID NO. 3 or 4.
[0017] In another embodiment of the invention the fragment comprises at least 17 contiguous nucleic acids of SEQ ID No. 3 or 4.
[0018] In one embodiment of the invention the polynucleotide exhibits at least 80% identity top natural cDNA encoding said segment.
[0019] In one embodiment of the invention the polynucleotide encodes a Toll-like receptor or peptide or fusion protein thereof.
[0020] The invention also provides a recombinant nucleic acid comprising a nucleic acid sequence of SEQ ID No. 3 SEQ ID No. 4 or variant or fragment thereof or a sequence complementary thereto.
[0021] The invention further provides a purified protein or peptide comprising an amino acid sequence of SEQ ID No. 1 or 2 or a variant or fragment thereof. Preferably a fragment of the protein or peptide comprises at least 12 contiguous amino acids of SEQ ID No. 1 or 2.
[0022] In one embodiment of the invention the protein or peptide is of mammalian origin. The protein may be of human origin.
[0023] In one embodiment of the invention the protein or peptide has a molecular weight of at least 100 kDa. The protein or peptide may be in glycosylated form.
[0024] One embodiment of the invention provides a recombinant protein or peptide comprising an amino acid sequence of SEQ ID No. 1 or 2.
[0025] The protein or peptide of the invention may exhibit Toll-like receptor functionality/activity.
[0026] The invention also provides a protein comprising an amino acid sequence selected from SEQ ID No. 1 or 2 or a variant or fragment thereof. The protein may be a Toll-like receptor protein,especially TLR14.
[0027] The invention also provides an antigenic fragment of a protein or peptide of the invention.
[0028] The invention also provides a recombinant vector comprising a polynucleotide as hereinbefore described. The invention also provides a host cell comprising the recombinant vector. The invention further provides a gene therapy agent comprising the recombinant vector as an active ingredient.
[0029] One aspect of the invention provides an adjuvant comprising a polypeptide as hereinbefore described.
[0030] The invention also provides a fusion compound or chimeric molecule comprising any one or more of
a protein comprising an amino acid sequence of SEQ ID No. 1 or 2 or a fragment or variant thereof; and a detection or purification tag.
[0033] In one embodiment of the invention the detection or purification tag is selected from any one ore more of a FLAG sequence, His6 sequence, Ig sequence and a heterologous polypeptide of another receptor protein.
[0034] The invention also provides a ligand/receptor complex comprising a recombinant or synthetically produced protein comprising an amino acid sequence of SEQ ID No. 1 or 2 and a TLR ligand. Preferably the TLR ligand is a CpG nucleic acid.
[0035] The invention also provides an immunogen comprising an antigenic determinant of a protein as hereinbefore described.
[0036] The invention further provides a monoclonal or polyclonal antibody or fragment thereof that specifically binds to an epitope of a polypeptide or a protein or peptide as hereinbefore described. The antibody may be prepared in an immobilised form. The antibody may be immobilised by conjugation or attachment to a bead, a magnetic bead, a slide, or a container. The antibody may be immobilised to cyanogen bromide-activated sepharose or absorbed to polyolefin surfaces with or without glutaraldehyde cross-linking.
[0037] The invention also provides a method for identifying compounds which modulate Toll-like receptor activity comprising the steps of:
contacting a polypeptide comprising an amino acid sequence of SEQ ID No. 1 or 2 or variant or fragment thereof with a test sample; monitoring for markers of Toll-like receptor activity; and identifying the compounds which modulate Toll-like receptor activity.
[0041] In one embodiment of the invention the markers of Toll-like receptor activity comprise any one or more of:
(i) NFkappaB activation (ii) NFkappaB protein or polynucleotide encoding the same (iii) IRF3 protein or polynucleotide encoding the same (iv) p38 protein or polynucleotide encoding the same (v) IKKs protein or polynucleotide encoding the same (vi) RANTES protein or polynucleotide encoding the same (vii) TLR4 protein or polynucleotide encoding the same or (viii) any pro-inflammatory or inhibitory cytokine.
[0050] In one embodiment the method comprises the step of determining the difference in the amount relative to the test sample of at least 2 of each of (i) to (viii).
[0051] In another embodiment the method comprises the step of determining the difference in the amount relative to the test sample of at least 3 of each of (i) to (viii).
[0052] In one case the amount relative to the test sample of protein is determined. Alternatively the amount relative to the test sample of mRNA is determined using nucleic acid microarrays. The Toll-like receptor activity may be TLR14 activity.
[0053] In one embodiment of the invention a compound which activates or inhibits TLR activity is identified by determining the amount, expression, activity or phosphorylation relative to the test sample of a least one or more of:
(i) NFkappaB activation (ii) NFkappaB protein or polynucleotide encoding the same (iii) IRF3 protein or polynucleotide encoding the same (iv) p38 protein or polynucleotide encoding the same (v) IKKs protein or polynucleotide encoding the same (vi) RANTES protein or polynucleotide encoding the same (vii) TLR4 protein or polynucleotide encoding the same or (viii) any pro-inflammatory or inhibitory cytokine.
[0062] In another embodiment a compound capable of modulating TLR activity is identified by a method as hereinbefore described.
[0063] The invention also provides a pharmaceutical composition comprising a compound of the invention and a pharmaceutically acceptable carrier.
[0064] The invention also provides a pharmaceutical composition comprising:
a reagent or compound that modulates the activity of a TLR14 polypeptide comprising an amino acid sequence of SEQ ID No. 1 or 2 or a polynucleotide comprising a nucleic acid of SEQ ID No. 3 or 4; and a pharmaceutically acceptable carrier.
[0067] In one embodiment on the invention the reagent is a TLR14 agonist or antagonist.
[0068] Preferably the carrier compound is an aqueous compound selected from any one or more of water, saline and buffer. The composition may be in a form for oral, rectal, nasal, topical or parenteral administration.
[0069] In one embodiment of the invention the compound or composition as is used in the preparation of a medicament for the treatment of any one or more of allergic disease, autoimmune disease, inflammatory disease, cardiovascular disease, CNS disease, neoplastic disease and infectious disease, and/or immune-mediated disorder.
[0070] In one embodiment of the invention the disorder is selected from any one or more of sepsis or acute inflammation induced by infection, trauma or injury, chronic inflammatory disease, graft rejection or graft versus host disease, Crohn's disease, inflammatory bowel disease, multiple sclerosis, type 1 diabetes or rheumatoid arthritis, asthma or atopic disease and allergic encephalomylitis.
[0071] Other immune-mediated disorders include any one or more of diabetes mellitus, arthritis (including rheumatoid arthritis, juvenile rheumatoid arthritis, osteoarthritis, psoriatic arthritis), atherosclerosis, myasthenia gravis, systemic lupus erythematosis, autoimmune thyroiditis, dermatitis (including atopic dermatitis and eczematous dermatitis), Sjogren's Syndrome, including keratoconjunctivitis sicca secondary to Sjogren's Syndrome, alopecia areata, allergic responses due to arthropod bite reactions, aphthous ulcer, iritis, conjunctivitis, keratoconjunctivitis, ulcerative colitis, asthma, allergic asthma, cutaneous lupus erythematosus, scieroderma, vaginitis, proctitis, drug eruptions, leprosy reversal reactions, erythema nodosum leprosum, autoimmune uveitis, allergic encephalomyelitis, acute necrotizing hemorrhagic encephalopathy, idiopathic bilateral progressive sensorineural hearing loss, aplastic anemia, pure red cell anemia, idiopathic thrombocytopenia, polychondritis, Wegener's granulomatosis, chronic active hepatitis, Stevens-Johnson syndrome, idiopathic sprue, lichen planus, Graves ophthalmopathy, sarcoidosis, primary biliary cirrhosis, uveitis posterior, interstitial lung fibrosis, Alzheimers disease or coeliac disease.
[0072] The invention further provides an agonist or antagonist compound to a TLR14 polypeptide having an amino acid sequence of SEQ ID No. 1 or 2 or a variant
[0073] The invention also provides a method of modulating the physiology or development of a cell or tissue culture cells comprising contacting the cell with an agonist or antagonist of a mammalian TLR14.
[0074] The invention further provides a method of screening compounds capable of inhibiting or promoting NF-κB activation comprising the steps of:
providing a cell with a gene encoding a protein as hereinbefore described and a component that provides a detectable signal associated with activation of NF-κB; culturing a transformed cell under conditions providing the expression of the gene in the transformed cell; contacting the transformed cell with one or more compounds for screening; measuring the detectable signal; and isolating or identifying the activator compound or inhibitor compound by measuring the detectable signal.
[0080] In one embodiment the method includes the step of
optimising the isolated or identified compound as a pharmaceutical compound.
[0082] The invention also provides a kit for screening a compound capable of modulating Toll like receptor activity comprising:
a cell comprising a gene encoding a protein of the invention and a component that provides a detectable signal upon activation of NFκB; and reagents for measuring the detectable signal.
[0085] In one embodiment of the invention the gene encodes a Toll-like receptor TLR14.
[0086] The invention also provides use of a polypeptide comprising a fragment or variant of the amino acid sequence of SEQ ID No. 1 or 2 which is capable of inhibiting the activity of TLR14 having the amino acid sequence of SEQ ID No. 1 or 2 in the manufacture of a medicament for the treatment of an immune or inflammatory disorder.
[0087] The invention also provides use of a polypeptide, polynucleotide or compound as hereinbefore described, in the manufacture of an adjuvant or vaccine formulation.
[0088] The present invention is directed to a novel mammalian receptor, Toll-like receptor 14 (TLR14) and its biological activities. It includes nucleic acids coding for the polypeptide and methods for its production and use. The nucleic acids of the invention are characterized in part by their homology to cloned complimentary DNA (cDNA) sequences enclosed herein.
[0089] In certain embodiments, the invention comprises a composition of matter selected from the group of: a substantially pure or recombinant TLR14 protein or peptide exhibiting identity over at least 12 amino acids to SEQ ID No. 1 or 2, a natural sequence of TLR14 of SEQ ID No. 1 or 2, a fusion protein comprising TLR14 sequence composition of matter: novel TLR (TLR14). In specific embodiments the composition of matter is TLR14 which comprises a mature sequence of SEQ ID No. 1 or 2, or lacks a post-translational modification, or the composition of matter may be a protein or peptide which is from a warm blooded animal selected from a mammal including a primate, such as a human, comprising at least one polypeptide of SEQ ID No. 1 or 2; is glycosylated, has a molecular weight of at least 100 kDa with natural glycosylation, is a synthetic polypeptide; is conjugated to another chemical moiety; is a 5-fold of less substitution from natural sequence or is a deletion or insertion variant from a natural sequence. In specific embodiments, the TLR, antigenic fragment of TLR, antibody to TLR, antibody fragment to TLR, antibody to a TLR ligand also includes an immobilised form. Immobilisation may be by conjugation or attachment to a bead, a magnetic bead, to a slide, or to a container. Immobilisation may be to cyanogen bromide-activated sepharose by methods well-known in the art, or absorbed to polyolefin surfaces with or without glutaraldehyde cross-linking.
[0090] Other embodiments include a composition comprising a sterile TLR14 protein or peptide, or the TLR14 protein or peptide and a carrier wherein the carrier is an aqueous compound including water, saline, and/or buffer, and/or formulated for oral, rectal, nasal, topical or parenteral administration.
[0091] In certain fusion protein embodiments, the invention provides a fusion protein comprising: mature protein sequence of SEQ ID No. 1 or 2, a detection or purification tag including a FLAG or His6 or Ig sequence; or sequence of another receptor protein.
[0092] Various kit embodiments include a kit comprising TLR14 protein or polypeptide, and: a compartment comprising the protein or polypeptide; and/or instructions for use or disposal of reagents in the kit.
[0093] Binding compound embodiments include those comprising an antigen binding site from an antibody, which specifically binds to TLR14 protein, wherein the protein is a primate protein; the binding compound is an Fv, Fab or Fab2 fragment; the binding compound is conjugated to another chemical moiety; or the antibody: is raised against a peptide sequence of a mature polypeptide to SEQ ID No. 1 or 2; is raised against a mature TLR14; is raised to a purified human TLR14; is immunoselected; is a polyclonal antibody; binds to a denatured TLR14; exhibits a Kd to antigen of at least 30 μM; is attached to a solid substrate, including a bead or plastic membrane; is in a sterile composition or is detectably labelled, including a radioactive or fluorescent label. A binding composition kit often comprises a binding compound and a compartment comprising said binding compound; and/or instructions for use or disposal of reagents in the kit. Often the kit is capable of making a qualitative or quantitative analysis.
[0094] Methods are provided for example of making an antibody comprising immunizing an immune system with an immunogenic amount of a primate TLR14, thereby causing said antibody to be produced, or producing an antigen/antibody complex comprising contacting such an antibody with a mammalian TLR14 protein or peptide thereby allowing the said complex to form.
[0095] Immunisation methods commonly practised in the art may be used and are well described in the literature.
[0096] Other compositions include a composition comprising: a sterile binding compound, or the binding compound and a carrier, wherein the carrier is an aqueous including water, saline and/or buffer, and/or formulated for oral, rectal, nasal, topical or parenteral administration.
[0097] Nucleic acid embodiments include an isolated or recombinant nucleic acid encoding a TLR14 or peptide or fusion protein, wherein the TLR is from a mammal; or the nucleic acid encodes an antigenic peptide sequence of SEQ ID No. 3 or 4; encodes a plurality of antigenic peptide sequences of SEQ ID No. 3 or 4; comprises at least 17 contiguous nucleotides from SEQ ID No. 3 or 4, exhibits at least 80% identity to natural cDNA encoding said segment; is an expression vector; further comprises an origin of replication; is from a natural source; comprises a detectable label such as a radioactive label, a fluorescent label, or an immunogenic label; comprises synthetic nucleotide sequence; is less than 6 kB, preferably less than 3 kB; is from a mammal, including a primate; comprises a natural full-length coding sequence; is a hybridisation probe for a gene encoding said TLR; or is PCR primer, PCR product, or mutagenesis primer. A cell, tissue or organ comprising such a recombinant nucleic acid is also provided. Preferably the cell is a prokaryotic cell; eukaryotic cell; bacterial cell; yeast cell; insect cell; mouse cell; mammalian cell; primate cell or human cell. Kits are provided comprising such nucleic acids and a compartment comprising said nucleic acid; a compartment further comprising a primate TLR14 protein or polypeptide; and/or instruction for use or disposal of reagents of the kit. Often the kit is capable of making a qualitative or quantitative analysis.
[0098] Also provided are methods for producing a ligand/receptor complex, comprising contacting a substantially pure TLR14 including a recombinant or synthetically produced protein with candidate TLR ligand, thereby allowing said complex to form.
[0099] A TLR ligand refers to a molecule that specifically binds to a TLR polypeptide, in this case aTLR14 polypeptide. In most cases the TLR ligand will also induce TLR signalling when contacted with the TLR under suitable conditions.
[0100] The invention also provides a method of modulating physiology or development of a cell or tissue culture cells comprising contacting the cell with an agonist or antagonist of a mammalian TLR14.
[0101] The present invention relates to methods of identifying and evaluating reagents that modulate the activity of TLR14 using at least one of the following as a marker: (i) NFkappaB activation (ii) NFkappaB protein or polynucleotide encoding the same (iii) IRF3 protein or polynucleotide encoding the same (iv) p38 protein or polynucleotide encoding the same (v) IKKs protein or polynucleotide encoding the same (vi) RANTES protein or polynucleotide encoding the same (vii) TLR4 protein or polynucleotide encoding the same or (viii) any pro-inflammatory or inhibitory cytokine.
[0102] The present invention also relates to the use of a reagent that alters the expression, amount, activity or phosphorylation, in a cell or tissue of (i) NFkappaB activation (ii) NFkappaB protein or polynucleotide encoding the same (iii) IRF3 protein or polynucleotide encoding the same (iv) p38 protein or polynucleotide encoding the same (v) IKKs protein or polynucleotide encoding the same (vi) RANTES protein or polynucleotide encoding the same (vii) TLR4 protein or polynucleotide encoding the same or (viii) any pro-inflammatory or inhibitory cytokine.
[0103] The present invention is based on the discovery of the novel TLR14 protein, and that the inhibition or activation of TLR14 can be detected by determining the amount, expression activity or phosphorylation of signal molecules which can lead to the activation of (i) NFkappaB activation (ii) NFkappaB protein or polynucleotide encoding the same (iii) IRF3 protein or polynucleotide encoding the same (iv) p38 protein or polynucleotide encoding the same (v) IKKs protein or polynucleotide encoding the same (vi) RANTES protein or polynucleotide encoding the same (vii) TLR4 protein or polynucleotide encoding the same or (viii) any pro-inflammatory or inhibitory cytokine.
[0104] One embodiment of the invention provides a method for monitoring the effect of TLR14 activation or inhibition by determining the difference in a level relative to a test sample of (i) NFkappaB activation (ii) NFkappaB protein or polynucleotide encoding the same (iii) IRF3 protein or polynucleotide encoding the same (iv) p38 protein or polynucleotide encoding the same (v) IKKs protein or polynucleotide encoding the same (vi) RANTES protein or polynucleotide encoding the same (vii) TLR4 protein or polynucleotide encoding the same or (viii) any pro-inflammatory or inhibitory cytokine.
[0105] “Level” used herein includes but not limited to, the amount of a protein, expression amount of mRNA, a gene activity, a protein activity, and the amount of phosphorylation.
[0106] Test samples may include but are not limited to peptide nucleic acids (PNAs), antibodies, polypeptides, carbohydrates, lipids, hormones and small molecules. Test compounds may also include variants of a reference immunostimulatory nuclei acid. These may be obtained from natural nucleic acid sources genomic nuclear or mitochondrial DNA or cDNA) or are synthetic (produced by oligonucleotide synthesis for example).
[0107] Thus in one aspect, the invention relates to methods for identifying and evaluating reagents that activate or inhibit TLR14 activity comprising, determining the difference in the amount, expression, activity or phosphorylation relative to a test sample of at least one of the following: (i) NFkappaB activation (ii) NFkappaB protein or polynucleotide encoding the same (iii) IRF3 protein or polynucleotide encoding the same (iv) p38 protein or polynucleotide encoding the same (v) IKKs protein or polynucleotide encoding the same (vi) RANTES protein or polynucleotide encoding the same (vii) TLR4 protein or polynucleotide encoding the same or (viii) any pro-inflammatory or inhibitory cytokine.
[0108] In another embodiment, such methods comprises determining the difference in the amount relative to a test sample of at least 2, at least 3, of each of (i) to (viii) as defined supra.
[0109] In one embodiment of the invention the difference in the amount relative to a test sample of mRNA is determined and can, for example, be determined by the use of nucleic acid microarrays.
[0110] In one embodiment of the invention the difference in the amount relative to a test sample of protein is determined.
[0111] Another aspect of the invention relates to a method for identifying or evaluating reagents that modulate the activity of TLR14, said method comprises: (i) NFkappaB activation (ii) NFkappaB protein or polynucleotide encoding the same (iii) IRF3 protein or polynucleotide encoding the same (iv) p38 protein or polynucleotide encoding the same (v) IKKs protein or polynucleotide encoding the same (vi) RANTES protein or polynucleotide encoding the same (vii) TLR4 protein or polynucleotide encoding the same or (viii) any pro-inflammatory or inhibitory cytokine. In another embodiment, such methods comprises determining the difference in the amount relative to a test sample of at least 2, at least 3, of each of (i) to (viii) as defined supra.
[0112] In a preferred embodiment of a method for identifying or evaluating reagents that modulate the activity of TLR14, said method comprises: : (i) NFkappaB activation (ii) NFkappaB protein or polynucleotide encoding the same (iii) IRF3 protein or polynucleotide encoding the same (iv) p38 protein or polynucleotide encoding the same (v) IKKs protein or polynucleotide encoding the same (vi) RANTES protein or polynucleotide encoding the same (vii) TLR4 protein or polynucleotide encoding the same or (viii) any pro-inflammatory or inhibitory cytokine. In another embodiment, such methods comprises determining the difference in the amount relative to a test sample of at least 2, at least 3, of each of (i) to (viii) as defined supra.
[0113] Sequence Homology
[0114] A particularly preferred nucleotide sequences of the invention is the human sequence set forth in SEQ ID NO:l or SEQ ID NO:2. The sequence of the amino acids encoded by the DNA of SEQ ID NO:3 is shown in SEQ ID NO:1. The sequence of the amino acids encoded by the DNA of SEQ ID NO:4 is shown in SEQ ID NO:2.
[0115] Due to the known degeneracy of the genetic code, wherein more than one codon can encode the same amino acid, a DNA sequence can vary from that shown in SEQ ID NO:3, and still encode a polypeptide having the amino acid sequence of SEQ ID NO:1. Such variant DNA sequences can result from silent mutations (e.g., occurring during PCR amplification), or can be the product of deliberate mutagenesis of a native sequence.
[0116] The invention thus provides isolated DNA sequences encoding polypeptides of the invention, selected from: (a) DNA comprising the nucleotide sequence of SEQ ID NO:1 (b) DNA encoding the polypeptide of SEQ ID NO:3 (c) DNA capable of hybridization to a DNA of (a) or (b) under conditions of moderate stringency and which encodes polypeptides of the invention; (d) DNA capable of hybridization to a DNA of (a) or (b) under conditions of high stringency and which encodes polypeptides of the invention, and (e) DNA which is degenerate as a result of the genetic code to a DNA defined in (a), (b), (c), or (d) and which encode polypeptides of the invention. Of course, polypeptides encoded by such DNA sequences are encompassed by the invention.
[0117] The invention thus provides equivalent isolated DNA sequences encoding biologically active human interferon alpha 14 polypeptides selected from: (a) DNA derived from the coding region of a native mammalian interferon alpha 14 allele c gene; (b) DNA of SEQ ID NO:3, (c) DNA capable of hybridization to a DNA of (a) or (b) under conditions of moderate stringency and which encodes biologically active interferon alpha 14 polypeptides; and (d) DNA that is degenerate as a result of the genetic code to a DNA defined in (a), (b) or (c), and which encodes biologically active interferon alpha 14 polypeptides.
[0118] As used herein, conditions of moderate stringency can be readily determined by those having ordinary skill in the art based on, for example, the length of the DNA. The basic conditions are set forth by Sambrook et al. Molecular Cloning: A Laboratory Manual, 2 ed. Vol. 1, pp. 1.101-104, Cold Spring Harbor Laboratory Press, (1989). Conditions of high stringency can also be readily determined by the skilled artisan based on, for example, the length of the DNA.
[0119] Also included as an embodiment of the invention is DNA encoding polypeptide fragments and polypeptides comprising inactivated N-glycosylation site(s), inactivated protease processing site(s), or conservative amino acid substitution(s).
[0120] In another embodiment, the nucleic acid molecules of the invention also comprise nucleotide sequences that are at least 80% identical to a native sequence. Also contemplated are embodiments in which a nucleic acid molecule comprises a sequence that is at least 90% identical, at least 95% identical, at least 98% identical, at least 99% identical, or at least 99.9% identical to a native sequence.
[0121] The percent identity may be determined by visual inspection and mathematical calculation. Alternatively, the percent identity of two nucleic acid sequences can be determined by comparing sequence information using the GAP computer program, version 6.0 described by Devereux et al. (Nucl. Acids Res. 12:387, 1984) and available from the University of Wisconsin Genetics Computer Group (UWGCG). The preferred default parameters for the GAP program include: (1) a unary comparison matrix (containing a value of 1 for identities and 0 for non-identities) for nucleotides, and the weighted comparison matrix of Gribskov and Burgess, Nucl. Acids Res. 14:6745, 1986, as described by Schwartz and Dayhoff, eds., Atlas of Protein Sequence and Structure, National Biomedical Research Foundation, pp. 353-358, 1979; (2) a penalty of 3.0 for each gap and an additional 0.10 penalty for each symbol in each gap; and (3) no penalty for end gaps. Other programs used by one skilled in the art of sequence comparison may also be used.
[0122] The invention also provides isolated nucleic acids useful in the production of polypeptides. Such polypeptides may be prepared by any of a number of conventional techniques. A DNA sequence encoding an interferon alpha 14 polypeptide, or desired fragment thereof, may be subcloned into an expression vector for production of the polypeptide or fragment. The DNA sequence advantageously is fused to a sequence encoding a suitable leader or signal peptide. Alternatively, the desired fragment may be chemically synthesized using known techniques. DNA fragments also may be produced by restriction endonuclease digestion of a full length cloned DNA sequence, and isolated by electrophoresis on agarose gels. If necessary, oligonucleotides that reconstruct the 5′ or 3′ terminus to a desired point may be ligated to a DNA fragment generated by restriction enzyme digestion. Such oligonucleotides may additionally contain a restriction endonuclease cleavage site upstream of the desired coding sequence, and position an initiation codon (ATG) at the N-terminus of the coding sequence.
[0123] The well-known polymerase chain reaction (PCR) procedure also may be employed to isolate and amplify a DNA sequence encoding a desired protein fragment. Oligonucleotides that define the desired termini of the DNA fragment are employed as 5′ and 3′ primers. The oligonucleotides may additionally contain recognition sites for restriction endonucleases, to facilitate insertion of the amplified DNA fragment into an expression vector. PCR techniques are described in Saiki et al., Science 239:487 (1988); Recombinant DNA Methodology, Wu et al., eds., Academic Press, Inc., San Diego (1989), pp. 189-196; and PCR Protocols: A Guide to Methods and Applications, innis et al., eds., Academic Press, Inc. (1990).
[0124] The invention encompasses polypeptides and fragments thereof in various forms, including those that are naturally occurring or produced through various techniques such as procedures involving recombinant DNA technology. For example, DNAs encoding interferon alpha 14 polypeptides can be derived from SEQ ID NO:3 by in vitro mutagenesis, which includes site-directed mutagenesis, random mutagenesis, and in vitro nucleic acid synthesis. Such forms include, but are not limited to, derivatives, variants, and oligomers, as well as fusion proteins or fragments thereof.
[0125] The polypeptides of the invention include full length proteins encoded by the nucleic acid sequence of SEQ ID NO:1. A particularly preferred polypeptide comprises the amino acid sequence of SEQ ID NO:3.
[0126] The polypeptides of the invention may be membrane bound or they may be secreted and thus soluble. Soluble polypeptides are capable of being secreted from the cells in which they are expressed. In general, soluble polypeptides may be identified (and distinguished from non-soluble membrane-bound counterparts) by separating intact cells which express the desired polypeptide from the culture medium, e.g., by centrifugation, and assaying the medium (supernatant) for the presence of the desired polypeptide. The presence of polypeptide in the medium indicates that the polypeptide was secreted from the cells and thus is a soluble form of the protein.
[0127] Also provided herein are polypeptide fragments of varying lengths. Naturally occurring variants as well as derived variants of the polypeptides and fragments are also provided herein.
[0128] The invention further relates to a pharmaceutical composition. The composition comprises: (a) a reagent that modulates the activity of a TLR14 polypeptide or polynucleotide and (b) a pharmaceutically acceptable carrier. The reagent may be a TLR14 agonist or antagonist. The composition may be used to treat the diseases such as an allergic disease, autoimmune disease, inflammatory disease, cardiovascular disease, Central Nervous System disease, neoplastic disease and infectious disease.
[0129] One skilled in the art will know that the choice of pharmaceutical carrier includes physiologically suitable compounds and the choice of compound depends on the route of administration and the intended administration regime.
[0130] Treatment/Therapy
[0131] The term ‘treatment’ is used herein to refer to any regimen that can benefit a human or non-human animal. The treatment may be in respect of an existing condition or may be prophylactic (preventative treatment). Treatment may include curative, alleviation or prophylactic effects.
[0132] More specifically, reference herein to “therapeutic” and “prophylactic” treatment is to be considered in its broadest context. The term “therapeutic” does not necessarily imply that a subject is treated until total recovery. Similarly, “prophylactic” does not necessarily mean that the subject will not eventually contract a disease condition.
[0133] Accordingly, therapeutic and prophylactic treatment includes amelioration of the symptoms of a particular condition or preventing or otherwise reducing the risk of developing a particular condition. The term “prophylactic” may be considered as reducing the severity or the onset of a particular condition. “Therapeutic” may also reduce the severity of an existing condition.
[0134] The present invention describes methods which involve unless otherwise indicated, commonly used techniques of cell biology, cell culture, molecular biology, transgenic biology, microbiology, recombinant DNA techniques and immunology, all of which art well described in the field.
[0135] The present invention further relates to an endogenous ligand(s) to TLR14 identified in and purified from cell and tissue extracts prepared from mammalian cells.
[0136] The present invention further relates to the modulation of TLR4 signalling, where TLR14 promotes or inhibits TLR4 signalling.
[0137] The peptides according to the present invention may be used in screening for molecules which affect or modulate activity or function of the peptides. The interaction of such molecules with the peptides may be useful in a therapeutic and prophylactic context.
[0138] It is well known that pharmaceutical research leading to the identification of a new drug may involve the screening of a very large number of candidate substances, both before and even after a lead compound has been found. Such means for screening for substances potentially useful in treating or preventing cancer. Substances identified as modulators of the polypeptide represent an advance in the therapy in these areas as they provide basis for design and investigation of therapeutics for in vivo use.
[0139] In various further aspects, the present invention relates to screening and assay methods and to substances identified thereby.
[0140] Thus, a further aspect of the present invention provides the use of a peptide (including a fragment or derivative thereof) of the invention in screening or searching for and/or obtaining or identifying a substance such as a peptide or chemical compound which interacts with or binds with the peptide of the invention and/or interferes with its biological function or activity or that of another substance. For instance, a method according to one aspect of the present invention includes providing a peptide of the invention and bringing it into contact with a substance, which contact may result in binding between the peptide and the substance. Binding may be determined by any number of techniques, both qualitative and quantitative which would be known to the person skilled in the art.
[0141] A substance identified as a modulator of peptide function may be a peptide or non-peptide in nature. Non-peptide “small molecules” are often preferred for many in-vivo pharmaceutical uses. Accordingly, a mimetic or mimic of the substance may be designed for pharmaceutical uses. The designing of mimetics to a known pharmaceutically active compound is a known approach to the development of pharmaceuticals based on a “lead” compound. This might be desirable where the active compound is difficult or expensive to synthesise or where it is unsuitable for a particular method of administration, e.g. peptides are not well suited as active agents for oral compositions as they tend to be quickly degraded by proteases in the alimentary canal. Mimetic design, synthesis and testing may be used to avoid randomly screening large number of molecules for a target property.
[0142] There are several steps commonly taken in the design of a mimetic from a compound having a given target property. Firstly, the particular parts of the compound that are critical and/or important in determining the target property are determined. In the case of a peptide, this can be done by systematically varying the amino acid residues in the peptide, e.g. by substituting each residue in turn. These parts or residues constituting the active region of the compound are known as its “pharmacophore”.
[0143] Once the pharmacophore has been determined, its structure is modelled according to its physical properties, e.g. stereochemistry, bonding, size and/or charge, using data from a range of sources, e.g. spectroscopic techniques, X-ray diffraction data and NMR. Computational analysis, similarity mapping (which models the charge and/or volume of a pharmacophore, rather than the bonding between atoms) and other techniques can also be used in this modelling process.
[0144] In a variant of this approach, the three-dimensional structure of the ligand and its binding partner are modelled. This can be especially useful where the ligand and/or binding partner change conformation on binding, allowing the model to take account of the design of the mimetic.
[0145] A template molecule is then selected onto which chemical groups which mimic the pharmacophore can be grafted. The template molecule and the chemical groups grafted on to it can conveniently be selected so that the mimetic is easy to synthesise, is likely to be pharmacologically acceptable, and does not degrade in-vivo, while retaining the biological activity of the lead compound. The mimetic or mimetics found by this approach can then be screened to see whether they have the target property, or to what extent they exhibit it. Further optimisation or modification can then be carried out to arrive at one or more final mimetics for in-vivo or clinical testing.
[0146] A further aspect of the present invention therefore provides an assay for assessing binding activity between at least one peptide of the invention and a putative binding molecule which includes the steps of: bringing at least one peptide into contact with a putative binding molecule or other test substance, and determining interaction or binding between the at least one peptide and the binding molecule or test surface, wherein binding between the at least one peptide and the binding molecule is indicative of the utility of the at least one peptide.
[0147] A substance which interacts with the peptide of the present invention may be isolated and/or purified, manufactured and/or used to modulate its activity.
[0148] It is not necessary to use the entire peptide of the invention for assays of the invention which test for binding between two molecules. Fragments may be generated and used in any suitable way known to the person skilled in the art.
[0149] Further, the precise format of the assay of the invention may be varied by those skilled in the art using routine skill and knowledge.
BRIEF DESCRIPTION OF THE DRAWINGS
[0150] The invention will be more clearly understood from the following description thereof given by way of example only with reference to the accompanying drawings in which:
[0151] FIG. 1A is a schematic representation of the chromosomal location of human TLR14. TLR14 is located on chromosome 7 at 7p15 as indicated by the line. It is 4.7 kb in length and is flanked by the genes CREB5 and CPVL. The direction of transcription is indicated by the arrows, TLR14 is transcribed in the anti-parallel direction. This information was obtained using the human genome map viewer tool available from the NCBI website at www.ncbi.nlm.nih.gov;
[0152] FIG. 1B shows the nucleotide sequences for human TLR14 (SEQ ID No. 1);
[0153] FIG. 1C shows the nucleotide sequences for murine TLR14 (SEQ ID No. 2);;
[0154] FIG. 1D shows the predicted protein sequence of human (SEQ ID No. 3); and murine (SEQ ID No. 4);TLR14. The putative ORF of the human TLR14 gene encodes an 811 amino acid protein while the murine protein is 809 amino acids in length. The predicted N-terminal signal sequence and transmembrane domains are underlined;
[0155] FIG. 1E shows the alignment of TLR4 and TLR14 ectodomains. Alignment of the putative TLR with human TLR4 reveals a high degree of sequence similarity between the two receptors. At least six leucine rich repeats can be identified and are highlighted by boxes;
[0156] FIG. 2A is an mRNA expression profile of human TLR14 expressed in several tissues. Expression profiles for the human and murine form of the novel TLR are available from the HUGE protein database. RT-PCR reactions were performed with primers targeting the 3′untranslated region of the mRNA encoding the protein. Expression was detected in all tissues tested with highest levels occurring in the kidney; brain and ovary;
[0157] FIG. 2B is a protein expression profile of TLR14 in human tissue samples. High expression levels were detected in the brain and lung.
[0158] FIG. 3 shows the alignment of the cytoplasmic region of TLR14 with other members of the TLR family. Alignment of the cytoplasmic region of TLR with other TLR family members reveals that the putative receptor shares regions of similarity that are characteristic of TLRs. Two regions in particular are homologous (see Box 1 and 2) and are considered the signature sequence of all TIR domain containing proteins. Box 2 of TLR14 is identical to that of TLR3;
[0159] FIG. 4 is a schematic representation of the putative promoter region of human TLR14. The putative promoter region of TLR14 was identified using Promoter Inspector and Mat inspector. All the transcription factors above have a matrix score* of greater than 0.8
[0160] *The matrix score measures how closely the sequences within the promoter correspond to the conserved nucleotides within the transcription factor matrix. A significant match is >0.8;
[0161] FIG. 5 shows the expression of TLR14 is induced by LPS in U373s and primary murine embryonic fibroblasts and also in mice treated with LPS. (A) U373s and MEFs were treated with 1 μg/ml LPS for the indicated times. mRNA was isolated and RT-PCR was carried out as described in the text. (B). Mice were injected with interperitoneally with LPS and left for 3 hours before being sacrificed. RT-PCR was carried out on control untreated and LPS treated mice.
[0162] FIG. 6 shows expression of TLR14 protein in cells following treatment with TLR ligands. (A) The human glioma cell line, A172, was treated for various times with Pam 3 Cys (1 μg/ml) and probed for expression of TLR14. (B) Human HEK-293 cells stably transfected with TLR4 were treated with LPS (1 μg/ml) for various times and probed for expression of TLR14. (C) Protein extracts were prepared from the brains of control untreated mice and mice that had been injected with LPS. The extracts were probed for expression of TLR14.
[0163] FIG. 7 are graphs showing TLR14 activity induces of NF-κB- and ISRE-reporter gene expression in HEK293 and U373 astrocytoma cells. TLR14 activity drives NF-κB- and ISRE-luciferase activity in HEK293 and U373 astrocytoma cells. HEK293 cells were transfected with the NF-κB reporter construct along with 1, 5 and 10 ng of TLR14 (A). HEK293s (B) and U373s (C) were transfected with an ISRE reporter construct and increasing doses (1, 10 and 100 ng) of TLR14. After 24 h the cells were harvested and relative luciferase activity was determined; and
[0164] FIG. 8 is a graph showing TLR14 drives Rantes production in U373 astrocytoma cells. RANTES production was measured by Enzyme-Linked lmmunoabsorbant Assay in U373 cells that had been transfected for 24 h with increasing doses of TLR14. Data are expressed as fold induction over cells transfected with empty vector.
[0165] FIG. 9 shows interactions between TLR14 and the TIR-domain contain proteins TLR2, TLR4 and MyD88.(A) TLR14 was co-tranfected into HEK-293 cells together with Flag-tagged TLR4, TLR2 or mutant forms of the receptors. The complexes were immunprecipitated with anti-flag beads and probed with an anti-TLR14 antibody. (B) TLR14 was co-tranfected into HEK-293 cells together with Myc-tagged MyD88. The complex was immunprecipitated with an anti-myc antibody coupled to protein-A sepharose beads and probed with an anti-TLR14 antibody.
[0166] FIG. 10 . shows an interaction between TLR2 and endogenous TLR14. Flag-tagged TLR2 was immunoprecipitated from HEK-293 cells and western blots were probed with an anti-TLR14 antibody to detect presence of the endogenous protein in complex with TLR2.
[0167] FIG. 11 shows that TLR14 is present in the cytosol and is also found at high levels in serum. (A) Cells were stimulated with LPS before being separated into cytosolic and membrane fraction. The fractions were probed for the presence of TLR14. (B) Cell culture medium containing 10% fetal calf serum was subject to western blotting and probed for the presence of TLR14.
[0168] FIG. 12 shows the secretion of TLR14 into U373 culture medium following stimulation of the cells with LPS (1 μg/ml) for the indicated time points. The secreted protein appears to be the full length form of TLR14 with maximum secretion occurring at 6 hours.
DETAILED DESCRIPTION
[0169] We have identified a novel gene that shows remarkable homology with members of the Toll-like receptor/Interleukin-1 receptor (TLR) family. In cell-based assays, this novel receptor activates the transcription factors NF-κB and IRF3 and drives the production of the anti-viral cytokine, RANTES. The protein interacts with the TLR2, TLR4 and the universal TLR adapter, MyD88. We have named the receptor TLR14.
[0170] Expression of this putative receptor is enhanced by microbial products, for example LPS, suggesting that it may function as an immuno-modulator. In support of this, the transcription factors NF-κB and IRF3 were activated when cells were transfected with a vector expressing TLR14. As both NF-κB and IRF3 are central in the elimination of bacterial and viral pathogens, inhibiting or activating TLR14 is a promising new approach for the treatment of inflammatory diseases. In addition, we have found high levels of TLR14 in serum. A soluble form of TLR2 comprising mainly of the ectodomain of this receptor is also found at high levels in serum and in breast milk. This form of TLR2 is protective in that it dampens over active immune responses to TLR2 ligands. The full length TLR14 polypeptide or the ectodomain itself may have similar biological properties and could therefore be considered a potential biotherapeutic.
[0171] A microarray approach was used to identify genes that are regulated by LPS and components of the TLR4 signalling pathway. As mentioned above, the adapter molecule Mal is required to transmit signals from TLR2 and TLR4 following receptor stimulation. We used a gene-targeting vector to disrupt the gene encoding Mal in embryonic stem cells. These cells were then treated with LPS and differences in gene expression between knockout and wild-type cells were measured. In this way the gene that shows remarkable homology with members of the Toll-like receptor/Interleukin-1 receptor (TLR) family was identified.
[0172] The examples presented are illustrative only and various changes and modifications within the scope of the present invention will be apparent to those skilled in the art.
[0173] Materials & Methods
[0174] Cell Culture.
[0175] HEK 293 and U373 cells were cultured in Dulbecco's Modified Eagles Medium (DMEM) with 10% fetal bovine serum (FBS), supplemented with 100 units/ml penicillin, 100 mg/ml streptomycin, and 2 mM L-glutamine.
[0176] Expression Plasmids.
[0177] The chimeric TLR receptor CD4-TLR4, was a gift from R. Medzhitov (Yale University, New Haven, Conn.). The vector containing the TLR14 cDNA (KIAA0644) was supplied by the Kazusa DNA Research Institute and used as target for subsequent PCR cloning. The primers used included restriction sites for HindIII and EcoRV and were as follows: 5′-GCAAGCTTATGGAGGCTGCCCGCGCCTTG (sense) (SEQ ID No. 5); and 5′-GCGATATCGGCCTAAGCGTAGTCTGGGACGTCGTATGGGTAGTCGGCAAATC GC (antisense) (SEQ ID No. 6);. The antisense primer includes a sequence encoding a 9 amino acid hemagglutinin epitope tag in order to detect expression of the translated protein product in transfected cells. The resulting EcoR1-HindIII fragment was ligated into the multiple cloning site of the mammalian expression vector pCDNA 3.1 (Invitrogen).
[0178] Generation of Mal Deficient Embryonic Stem Cells and Microarray Analysis.
[0179] Embryonic stem cells lacking the gene encoding Mal were generated by homologous recombination. Briefly, murine embryonic stem cells were electroporated with a targeting vector, in which a 700 by exon encoding most of the coding sequence of the Mal gene was replaced with a neomycin resistance cassette. Targeted cells were identified by southern blotting before being subjected to a second round of targeting in order to generate clones homozygous for the Mal deletion. Mutant and wild-type cells were stimulated with LPS for various times and RNA was extracted for microarray analysis.
[0180] Promoter Analysis.
[0181] The complete nucleotide sequence of the human Riken clone KIAA0644 and flanking regions was obtained from the National Center for Biotechnology Information (NCBI) website at www.ncbi.nlm.nih.gov. Identification of transcribed nucleotide sequences and repeat sequences in the genomic sequence was performed using the NIX application (http://menu.hgmp.mrc.ac.uk) and the program Repeat-masker (http://searchlauncher.bcm.tmc.edu) (20). Transcription factor binding site predictions were performed using MatInspector Release Professional (www.genomatix.de/cgi-bin/matinspector/matinspector.pI) (21).
[0182] mRNA Isolation from Cultured Cells.
[0183] mRNA was extracted from cells following treatment for various times with LPS (1 μg/ml). Briefly, treated cells were pelleted and lysed in l ml of TRI reagent (Sigma). Chloroform (0.2 ml) was added to the sample and the mixture was centrifuged at 12,000 g for 15 minutes. The RNA containing aqueous phase was removed and the total RNA was precipitated from the mixture with the addition of an equal volume of isopropanol. Following centrifugation at 12,000 g for 10 minutes, the RNA containing pellet was washed with 500 μl of 75% ethanol. Any traces of ethanol were then removed and the pellet was left to dry at room temperature for 10 minutes. The pellet was resuspended in 30 μl of RNAse free water and stored at −80° C.
[0184] Reverse Transcriptase Polymerase Chain Reaction (RT-PCR).
[0185] RT-PCR was carried out using the Promega ImpromptII RT-PCR kit. The reverse transcription reaction was carried out in two steps, a PCR reaction was then carried out on the synthesised cDNA.
[0186] Step 1: 1 μl of Random Primers were added to 4 μl of RNA in a thin walled 500 μl PCR micro centrifuge tube. The tube was placed in a thermal cycler at 70° C. for 5min and 4° C. for 5 min.
[0187] Step 2: A second set of components were added; 1 μl deoxynucleotide mix (dNTPs mix) (500 μM each dNTP), 5.5 μl of PCR reagent water, 4.0 μl of 10× buffer, 3.0 μl of magnesium chloride, 1 μl RNase inhibitor (1 units/μl), 1 μl of RT (1 units/μl). This brought the total volume of the PCR tube to 20 μl. The tube was placed in a thermal cycler for the following times and temperatures, 25° C. for 5 min, 42° C. for 60 min, 70° C. for 15 min.
[0188] The following was added to a thin walled 500 μl PCR microcentrifuge tube on ice: 5 μl of 10× buffer, 1 μl dNTPs (200 μM each dNTP), 1 μl PCR primers (0.4 μof each), 2-5 μl Template DNA (cDNA), 1 μl Taq DNA polymerase mix (0.05 units/μl) and a sufficient volume of PCR reagent water to make a total volume in the PCR tube of 50 μl. The amplification temperatures were as follows, denaturation/RT inactivation (step 1) 94° C. for 2 min, denaturation (step 2) 94° C. for 15 sec, annealing (step 3) 55° C. for 30 sec, extension 68° C. for 1 min (step 2, 3 and 4 were repeated 35 times), final extension (step 5) 68° C. for 5 min. The PCR products were then electrophoresed on a 1% agarose gel and visualised on a UV transluminator.
[0189] Detection of Protein Expression.
[0190] A peptide antibody directed at the C-terminus of the putative protein was synthesised by Eurogentec, Liege Science Park, Belgium. The peptide used for immunization is composed of the following amino acids—CGSLRREDRLLQRFAD (SEQ ID No. 7);. Cell lines were treated for various times with TLR ligands as indicated. Stimulations were stopped with the addition of cold PBS and cells were lysed in SDS-PAGE sample buffer. For western blotting, the TLR14 antibody was diluted 1:1000 in tris buffered saline containing 0.5% tween 20.
[0191] Luciferase Reporter Gene Assays.
[0192] HEK 293 cells or U373 cells were seeded into 96-well plates (2×10 4 cells per well) and transfected the next day with expression vector and reporter plasmids. Genejuice™ (Novagen) was used for transient transfections, according to the manufacturer's instructions. For experiments involving NF-κB or IRF3, 80 ng of the NF-κB- or ISRE-luciferase reporter gene (Stratagene) were transfected into cells along with 40 ng of the Renilla luciferase internal control plasmid (Promega). After 24 h cells were harvested in passive lysis buffer (Promega) and reporter gene activity was measured in a luminometer. In cases where cells were stimulated, LPS (Sigma) was added to the cells at a final concentration of 1 μg/ml 6 h prior to harvesting. Data are expressed as mean fold induction±s.d. relative to control levels, for a representative experiment from a minimum of three separate experiments, each performed in triplicate.
[0193] Enzyme-Linked Immunoabsorbant Assay.
[0194] U373 cells were transfected with increasing doses (1, 10 and 100 ng) of the TLR14 expression plasmid. The cells were incubated at 37° C. for 24 h. A 96 well microtitre plate was coated with the capture antibody (mouse anti-human RANTES) at a final concentration of 40 ng/ml. After 24 hours the plates were washed with PBS containing 0.05% Tween 20. The plates were then blocked for 1 h at room temperature in PBS containing 1% BSA and 5% sucrose. Cell supernantant (100 μl) was added to each well and the plates were incubated for 2 h at room temperature. Detection antibody (biotinylated goat anti-human RANTES) was then added to the wells at a final concentration of 10 ng/ml. The plates were again incubated for 2 h at room temperature. After washing, 100 μl of streptavidin-HRP was added to each well, the plates were covered and incubated for 20 minutes at room temperature. Finally, 100 μl of substrate solution (R&D Systems, Catalog #DY999) was added to the wells followed by 50 μl of stop solution (2N H 2 SO 4 ). The optical density of each well was measured in a microplate reader set to 450 nm.
[0195] Co-Immunoprecipitation Assays.
[0196] HEK293 cells were seeded on 10 cm plates at 1×10 5 cells/ml. The following day, cells were transfected with 3 μg of flag-tagged TLR2, TLR4 or Myc-tagged MyD88. After 24 hrs the cells were lysed in Hepes buffer containing 1% NP40. The cell lysates were then incubated with M2 anti-flag agarose beads (Sigma). After three hours the beads were washed x3 with Hepes buffer and resuspended with 20 μl of SDS-PAGE sample buffer. The protein samples were run on 10% SDS-PAGE gels and transferred to nitrocellulose for western blotting. The resulting blots were probed with anti-TLR14 and anti-flag antibodies.
[0197] Localisation Studies.
[0198] Cells were seeded in 10 cm dishes at 1×105 cells/ml 24 hours prior to stimulation with LPS. Membrane and cytosolic fractions were prepared by ultracentifugation and subjected to SDS-PAGE and western blotting in order to determine the localisation of TLR14. Medium (DMEM) containing 10% FCS was blotted for the presence of TLR14 following SDS-PAGE.
[0199] Characterization of the Gene Encoding TLR14.
[0200] Preliminary microarray analysis identified six genes that exhibit lower expression levels in Mal knockout cells. Five of the genes identified have been characterised to some extent while the remaining gene is novel and characterised herein. The sequence of this gene is available on the HUGE (Human Unidentified Gene-Encoded Large Proteins) protein database as part of the Human cDNA project at the Kazusa DNA Research Institute (www.Kazusa.or.jp). We have named this novel gene TLR14 for reasons outlined below.
[0201] We have mapped the gene to human chromosome 7 using the Map Viewer tool available from NCBI ( FIG. 1A ). The gene is 4.7 kb in length and is flanked by CREB5 and CPVL carboxypeptidase. The nucleotide sequences for human and murine TLR14 are shown in FIGS. 1B and 1C , respectively. The predicted protein is 811 amino acids in length ( FIG. 1D ) and contains an N-terminal signal sequence, a feature common to all membrane localised proteins. The N-terminus of the putative protein also contains at least 6 leucine rich repeats and is highly homologous to the extracellular region of several TLRs (TLR4 is given as an example in FIG. 1E ).
[0202] Expression profiles reveal a high abundance of the gene product in brain, kidney and ovary as shown in FIG. 2A (information obtained from Kazusa DNA Research Institute). We have generated a polyclonal antibody to the C-terminus of TLR14. The peptide used for immunization comprises the amino acids CGSLRREDDRLLQRFAD (SEQ ID No. 7);. The antibody detected a protein at approximately 81 kDa in human brain and lung tissue ( FIG. 2B ).
[0203] As described above, members of the TLR family all contain a cytosolic TIR domain. This domain spans about 200 amino acids, with varying degrees of sequence similarity among family members. Three particular boxes can be identified which are highly conserved among family members. Box1 is considered the signature sequence of the family whereas boxes 2 and 3 contain amino acids critical for signalling. The crystal structure of the TIR domains of TLR1 and TLR2 has revealed a core structural element centered around box 2 (22). This region, termed the BB loop, forms an exposed surface patch and contains a critical proline or arginine residue. These amino acids are located at the tip of the loop and are thought to form a point of contact with downstream signalling components. Close inspection of TLR14 reveals that it also contains a highly conserved box 2 and an identifiable box 1 and 3 ( FIG. 3 ) suggesting that this novel protein belongs to the TLR superfamily.
[0204] Expression of TLR14 is Induced Following Treatment of Cells with TLR2 and TLR4 Ligands.
[0205] As described above, TLR14 expression was abolished in cells lacking Mal following exposure to LPS. This indicates that the gene in question is regulated by LPS and possibly other TLR ligands. In order to address this issue further, we identified the promoter region of TLR14 and possible transcription factor binding sites using the NIX application (http://menu.hgmp.mrc.ac.uk) and MatInspector Release Professional (www.genomatix.de/cgi-bin/matinspector/matinspector.pI). It is likely that the functional TLR14 promoter is contained within the 4 kb region proximal to exon 1. Further analysis of this region revealed putative binding sites for several transcription factors, such as NF-κB, IRF7 and Ets-1 ( FIG. 4 ). The induction of TLR14 mRNA expression was analysed by RT-PCR following treatment of cells with inflammatory stimuli. As shown in FIG. 5A , TLR14 mRNA expression is induced in brain astrocytoma cells (U373s) and primary murine embryonic fibroblasts (MEFs) with time following exposure to LPS. A striking increase was also detected in the levels of TLR14 mRNA prepared from the brains of mice treated with LPS ( FIG. 5B ). Induction of expression was also detected at the protein level in the humal glioma cell line, A172, following treatment with the TLR2 ligand Pam 3 Cys, as shown in FIG. 6A . A similar effect was seen in HEK-293 cells stably transfected with TLR4 following treatment with LPS ( FIG. 6B ). In addition, an increase in TLR14 protein expression was seen in the brains of mice injected with LPS as shown in FIG. 6C .
[0206] TLR14 Activates the Transcription Factors NF-κB and IRF3.
[0207] As described above, NF-κB is activated by most members of the TLR superfamily while IRF3 activation is restricted to TLR3 and TLR4. In order to address whether TLR14 can also activate these factors and therefore modulate immune responses, we cloned the cDNA encoding the protein into the mammalian expression vector pcDNA 3.1 and performed functional assays using luciferase reporter constructs containing elements of DNA to which NF-κB and IRF3 bind. The protein contains a tag encoding hemaglutinin (HA) and expression was detected in various cell lines using an anti-HA antibody (data not shown). When the TLR14 expression plasmid was transfected into cells along with the κB and ISRE reporter constructs, luciferase activity was enhanced ( FIG. 7 ) suggesting that TLR14, like TLR4, activates both NF-κB and IRF3. Preliminary ELISAs have also shown an increase in RANTES production (an IRF3 inducible cytokine) in cells transfected with TLR14 ( FIG. 8 ).
[0208] TLR14 Interacts with Other Members of the TLR Family.
[0209] A common feature of TIR domain containing proteins is their ability to homo- or heterodimerize with other TIR domain containing proteins. We performed co-immunoprecipitation experiments with TLR14 and the TIR domain containing receptors TLR2 and TLR4 in order to determine if TLR14 could interact with either or both receptors. We found that TLR14 interacts strongly with overexpressed TLR2 and TLR4 as shown in FIG. 9A . Mutation of the conserved proline residue to a histidine in the TIR domain of TLRs is known to abolish TIR-TIR interactions (22). Accordingly, the interaction between TLR14 and either TLR2 or TLR4 was significant reduced with mutant (P/H) forms of the receptors were co-expressed with TLR14. TLR14 was also found to interact with the universal TIR-domain containing adapter MyD88 as shown in FIG. 9B . This supports the notion that TLR14 is a TIR domain containing protein. Finally, we were able to detect an interaction between TLR2 and endogenous TLR14 as shown in FIG. 10 . In order to test this, we transfected HEK293 cells with flag-tagged TLR2. Cells were then lysed and incubated with anti-flag beads in order to immunprecipitate TLR2 and any interacting proteins. Following western blotting, we were able to detect a band corresponding to TLR14 using the anti-TLR14 antibody.
[0210] TLR14 is Found at high Levels in Serum and may be Produced as a Soluble Protein.
[0211] We prepared cellular fractions in order to determine whether TLR14 is localised to the plasma membrane. Surprisingly, TLR14 was found in the cytosolic fraction of cells ( FIG. 11A ). In addition, high levels of the protein were found in fetal calf serum ( FIG. 11B ) suggesting that the protein may be a soluble secreted protein. Mass spectroscopic analysis revealed that the band present in FCS was the bovine homolog of human TLR14 (data not shown). Preliminary experiments have also shown that the protein is secreted from U373 cells following stimulation with LPS. The protein does not appear to be cleaved as the molecular weight corresponds to that of the full length protein. Maximum secretion occurs at 6 hours.
[0212] The invention is not limited to the embodiments hereinbefore described which may be varied in detail.
REFERENCES
[0213] 1. Poltorak, A. et al. Science 282, 2085-2088 (1998).
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[0216] 4. Hemmi, H. et al. Nature 408, 740-745 (2000).
[0217] 5. Zhang, D. et al. Science 303, 1522-1526 (2004).
[0218] 6. Tabeta, K. et al. PNAS 101, 3516-3521 (2004)
[0219] 7. Hemmi, H. et al. Nature Immunol. 3, 196-200 (2002).
[0220] 8. Adachi, O. et al. Immunity 9, 143-150 (1998).
[0221] 9. Takeuchi, O. et al, J. Immunol. 164, 554-557 (2000).
[0222] 10. Yamamoto, M. et al. J. Immunol. 169, 6668-72 (2002).
[0223] 11. Kaisho, T. et al. J. Immunol. 166, 5688-5694 (2001).
[0224] 12. Servant, M. J. et al. J. Biochem. Pharmacol. 64, 985-992 (2002).
[0225] 13. Fizgerald, K. A. et al. Nature 413, 78-83 (2001).
[0226] 14. Homg, T. et al. Nature Immunol. 2, 835-841 (2001).
[0227] 15 . Yamamoto, M. et al. Nature 420, 324-329 (2002).
[0228] 16. Horng, T. et al. Nature 420, 329-33 (2002).
[0229] 17. Axtelle, T. & Pribble, J. J. Endotoxin Res. 7, 310-314 (2001).
[0230] 18. Lynn, M. et al. J Infect Dis. 187, 631-639 (2003).
[0231] 19. Berman, B. Int. J. Dermatol. 29, 7-11 (2002).
[0232] 20. Smith, R. et al. Genome Res. 6, 454-462 (1996).
[0233] 21. Quandt, K. et al. Nucleic Acids Res. 23, 4878-4884 (1995).
[0234] 22. Xu, Y. et al. Nature 408, 111-5 (2000).
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An isolated polypeptide comprises an amino acid sequence of SEQ ID No. 1 or 2 or a variant or fragment thereof. The variant may comprise an amino acid sequence that is at least 70% or 95% identical to the amino acid sequence of SEQ ID No. 1 or 2. A fragment thereof may be a peptide comprising at least 12 contiguous amino acids of SEQ ID No. 1 or 2. The polypeptide exhibits toll-like receptor activity. The TLR has been named TLR1 4. TLR receptors recognise a range of ligands and activate a series of signalling pathways that lead to the induction of immune and inflammatory genes.
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BACKGROUND OF THE INVENTION
1. The Field of the Invention
This invention relates to mainmasts of sailboat vessels and more particularly to that class utilizing telescoping mast elements. 2. Description of the Prior Art
The prior art abounds with telescoping masts. U.S. Pat. No. 3,263,382 issued on Aug. 2, 1966 to M. C. Tourtellotte teaches a telescoping vertically directed cantilevered flag pole having the telescoping elements thereof fitted with threaded set screws adapted for engagement within openings in adjacent telescoping elements so as to maintain the pole in an erected or elongated state.
U.S. Pat. No. 859,233 issued on July 9, 1907 to G. M. Lane discloses a plurality of tubular telescoping elements utilizing a pair of outwardly directed arms and a spring biasing the arms so as to engage holes in opposed positions in the wall of an adjacent layer telescoping element.
The aforementioned patents suffer the common deficiency of requiring the user to operate the locking mechanisms thereof into an unlocking position in order to collapse the mast. Thus the user would have to climb the mast so as to effectively be close enough to the locking mechanisms in order to collapse the mast by the loosening or disengagement thereof. Furthermore, the aforementioned patents do not provide for slideably fastening a mainsail along the length of the mast when extended.
SUMMARY OF THE INVENTION
A primary object of the present invention is to provide a mast which may be collapsed into its shortest position without requiring manual manipulation at the sight of those elements utilized to maintain the mast in an extended position.
Another object of the present invention is to provide a collapsible mast which may be hingeably and removably affixed to a deck of a sailboat.
Still another object of the present invention is to provide a collapsible mainmast which adequately and effectively provides lateral and vertical support to a mainsail leading edge at a plurality of points there-along.
Yet another object of the present invention is to provide a collapsible mainmast whose mainsail supporting means is always maintained abaft the mainmast.
Heretofore, collapsible tubular masts, of the telescoping variety, employed diverse clamping or locking mechanisms to maintain the mast in an extended position requiring physical manipulative efforts at various points along the length of the mast to enable it to be collapsed. Furthermore, such extending devices were heavy and cumbersome and were more directed towards a one time use, such as in erecting a flag pole. Sailing vessels require a light flexible mast structure, which in order to be effective, must be adapted to support a mainsail along a line disposed abaft the mainmast. Of further advantage, is a mainmast which may be stored along the deck of the boat, in a collapsed position, and hingeably affixed thereto so as to enable the vessel's crew to "foot" an extended mast in the erecting or lowering process.
These objects, as well as other objects of the present invention, will become more readily apparent after reading the following description of the accompanying drawings.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a side elevation view of a portion of a sailing vessel having an erected mainmast and mainsail affixed thereto.
FIG. 2 is a cross-sectional front elevation view of a pair of telescoping elements and a locking apparatus.
FIG. 3 is a front elevation cross-sectional view of the mainmast depicted in FIG. 1, showing the mainmast hingeably secured to the deck portions of the vessel.
FIG. 4 is a cross-sectional plan view taken along line 4--4 viewed in the direction of arrows 4--4 as shown in FIG. 3 illustrating the mainmast apparatus.
FIG. 5 is a partial side elevation view of an alternate embodiment illustrating a mainsail securing line.
FIG. 6 is a cross-sectional view taken along line 6--6 viewed in the direction of arrows 6--6 as shown in FIG. 5 illustrating the elliptical cross-section of the mast and mainsail height controlling line.
DESCRIPTION OF THE PREFERRED EMBODIMENT
The structure and method of fabrication of the present invention is applicable to a plurality of diverse diameter hollow tubes. Each of the tubes is adapted to telescope within an adjacent larger diameter tube and, when extended, to be utilized as a mainmast of a sailing vessel. The uppermost region of each of the tubes, save the smallest, is adapted with a ball or sphere, spring biased inwardly, serving as a disengageable detent, for engagement within an opening disposed adjacent the lowermost end of each tube, save the largest. An anti-rotation protrusion is fastened to the exterior surface of each tube engaging a longitudinal notch in the interior surface of an adjacent tube, so as to maintain the tubular elements of the mast in a fixed rotational alignment regardless of the length of the mast. A slot extends along the length of each mast element and is aligned longitudinally with the slot element of adjacent tubular members, forming thereby, an extended slot running substantially the length of the mast when in an extended position. The innermost walls of each slot are widened adjacent the innermost surface of each tubular element so as to facilitate the engagement of the cap portion of a T-shaped sliding element therewithin, having the leg portion of the T-shaped element extending radially outwardly from the longitudinal axis of the mast. The innermost point of the cap of the T-shaped element is confined within the wall of the tubular element in which it resides, thereby enabling a smaller adjacent tubular element to telescope therewithin without restriction by a portion of the cap of the T-shaped sliding element. The outermost end of the T-shaped sliding elements engage the foremost leading edge of the mainsail so as to provide lateral support thereto against the forces of the wind.
The bottom of the mainmast is secured to one plate of a large barrel-type hinge. The other plate of the hinge is fixedly secured to the deck of the vessel. A removable pin, passing through a block, fixedly secured to the deck, and a pair of holes in the lowermost portions of the lowermost end of the lowermost section, maintains the mainmast in a vertical erected state. Removing the pin allows the mainmast to be pivoted about the longitudinal axis of the hinge pin, thereby permitting the mast to be pivoted in parallel relationship with the deck of the vessel. Upon the removal of the hinge pin, the entire mast and the upper plate of the barrel-hinge affixed thereto may be removed from engagement with the vessel deck.
An alternate means of fastening the mainsail to the mainmast includes an opening, disposed in the vertical direction, in each free end of each T-shaped sliding element, adapted to permit a mainsail supporting line to pass therethrough. Tabs, affixed to the leading edge of the sail, securely grasp the line, which when raised or lowered, causes the said to be raised or struck a height roughly equivalent to the free extended portions of the extended elements of the mainmast. This embodiment may be utilized for tubular elements having circular as well as elliptical cross-sections. The line passes over a pulley affixed to the mast top and then descends downwardly towards the deck. To collapse the mast, in the upright position, the crew simply exerts a downward force on both lowermost ends of the line sufficient to overcome the detenting forces exerted by the spheres and the openings in which they reside.
Now referring to the Figures, and more particularly to the embodiment illustrated in FIG. 1 showing the deck 10 of a sailing vessel supporting mast 12 vertically thereabove. Mainsail 14 is supported by mast 12 utilizing sliding elements 16 therefor. Dotted lines 18 illustrates the mast 12 as it is being pivoted in the direction of arrow 20. Mast tubular elements 22, 24, 26, and 28 comprise mast 12 as shown in the fully extended position.
FIG. 2 illustrates a portion of mast element 26, residing in a portion of mast element 24. Detenting sphere 28 is urged in the direction of arrow 30 by spring 32, shown within spring housing 34. Sphere 28 resided in circular opening 36 formed within the walls of mast element 26. Thus, mast element 26 is restrained in moving in the direction of arrows 38 due to the locking forces exerted on opening 36 by sphere 28. Sufficiently strong opposed forces, exerted on mast elements 26 and 24 causes sphere 28 to overcome the bias forces exerted by spring 32 enabling the disengagement from circular opening 36 so as to permit the relative displacement of mast element 26 from mast element 24 in the directions of arrows 38. Slot 40 is shown piercing the walls of mast element 26, running in a direction parallel to the longitudinal axis of mast element 26.
FIG. 3 illustrates deck 10 supporting lowermost tubular element 22 upon the upper plate of barrel hinge 42. Line 44 extends upwardly from cleat 46, passing through pulley 48 secured to the top 50 of mast 12. Sliders 16 extend outwardly from the walls of tubular elements 22, 24, 26, and 28 supporting mainsail 14. Circular opening 36a, 36, and 36b are shown within the walls of tubular elements 24, 26, and 28 respectively. Spheres, not shown, reside within the walls of adjacent tubular elements 22, 24, and 26 respectively, maintaining the mast in the upright position shown. Pin 52 passes through openings 54 and 56 within lowermost tubular element 22, maintaining the mast in the upright position due to the support provided by block 58 secured to deck 10. When pin 52 is removed from openings 54 and 56, mast 12 may be pivoted on barrel hinge 42 to a position parallel to deck 10.
FIG. 4 shows circular plate 60 secured to deck 10 utilizing bolts 62 therefor. Barrel hinge 42 is affixed to lowermost tubular element 22. Barrel hinge pin 64, when removed, by pulling in the direction of arrow 66, enables the mast elements 22, 24, 26, and 28 and the uppermost plate 68, of the barrel hinge, to be disengaged from securement with deck 10, provided pin 52 has been removed from block 58 and from openings 54 and 56 in tubular element 22. Semi-circular projections 70 extend outwardly from tubular element 28 and engage mating semi-circular notches in tubular element 26. In like fashion, semi-circular protrusions extend radially outwardly from tubular elements 26 and 24, engaging semi-circular notches in tubular elements 24 and 22 thereby aligning T-shaped longitudinal slots 72, 74, 40 and 76, located in tubular elements 22, 24, 26, and 28 respectively. Sliders 16, shown in FIG. 1, engage T-shaped longitudinal slots 72, 74, 40 and 76, by having their cap portion of their T-shaped cross-section engaged within the widest portions of the T-shaped notches and by having their leg portions extend radially outwardly from the tubular elements in which they reside.
FIG. 5 illustrates a tubular element 78 in which slot 80 extends along the longitudinal length thereof. Caps 82, of sliders 16a, reside in the widened portion 80a of the slot 80. Legs 80B emerge from slot 80 and permit line 44a to pass through openings 82 therein. Mainsail tab 84 is secured to mainsail 14a at one end and grasps line 44a, securely, at another end thereof. When line 44a is caused to move in the directions of arrows 86 and 88, sail 14a is forced to move in similar directions.
FIG. 6 illustrates tubular element 78a shown having an elliptical cross-section. T-shaped slider 16a is shown captured within T-shaped slot 80b disposed within the walls of elliptical tubular element 78a. Line 44a is illustrated passing through opening 82 and is captured by tab 84 secured to mainsail 14a.
One of the advantages of the present invention is a mast which may be collapsed into its shortest position without requiring manual manipulation at the sight of those elements utilized to maintain the mast in an extended position.
Another advantage of the present invention is a collapsible mast which may be hingeably and removably affixed to a deck of a sailboat.
Still another advantage of the present invention is a collapsible mainmast which adequately and effectively provides lateral and vertical support to a mainsail leading edge at a plurality of points there-along.
Yet another advantage of the present invention is a collapsible mainmast whose mainsail supporting means is always maintained abaft the mainmast.
Thus, there is disclosed in the above description and in the drawings, an embodiment of the invention which fully and effectively accomplishes the objects thereof. However, it will become apparent to those skilled in the art, how to make variations and modifications to the instant invention. Therefore, this invention is to be limited, not by the specific disclosure herein, but only by the appending claims.
The embodiment of the invention in which an exclusive privilege or property is claimed are defined as follows:
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This disclosure pertains to a telescoping mast hingeably and removably affixed at the base portion thereof to the deck of a sailboat. A series of inwardly spring biased spheres engage recesses in adjacent telescoping elements of the mast thereby releasably maintaining the mast in an extended position. Each telescoping section of the mast is provided with a longitudinal slot, used to engage a plurality of outwardly radially extending mainsail securing tabs. Circular or elliptical mast cross-sections may be employed, utilizing a flexible line running over the mast top to raise and lower the mainsail.
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FIELD OF THE INVENTION
This invention relates to construction forms and methods and more particularly it relates to column forms and support systems therefor.
BACKGROUND OF THE INVENTION
In the construction of buildings or other structures, it has long been known to use temporarily erected forms to receive concrete. For example, to fashion a column, a form is erected, perhaps about reenforcing steel bars (rebar) or a solid steel column. Hereinafter, rebar and solid steel members or columns will be collectively referred to as steel. Concrete is poured into the form around the steel and allowed to harden. When the concrete has sufficiently hardened to be self-supporting the form is disassembled, leaving behind the desired concrete column encasing the steel.
A problem encountered with conventional forms is that of locating the forms so as to be properly positioned about the steel and to maintain that position during the pouring of the concrete. Failure to initially obtain or to maintain the correct orientation of the form relative to the steel can result in improper or otherwise unacceptable encasement of the steel within the concrete. For example, the resultant column may be aesthetically unappealing due to undulations in the concrete encasement, the steel may be exposed leading to unappealing rust marks on the concrete column or, from a structural support standpoint, the steel reinforcing bars may be improperly encased and integrated into the column to give the desired supporting characteristics.
To obtain and maintain the proper relationship of the form to the steel, laborious alignment of the form to the steel during assembly of the form is required. Numerous external supporting means must also be used to maintain the form about the steel against the pressure of the concrete when it is poured into the form. As can be appreciated, these prior art techniques have been time consuming, fraught with pitfalls and, particularly from a labor standpoint, expensive.
SUMMARY OF THE INVENTION
There is, therefore, provided in the practice of the present invention, a column form support system which is easily and automatically aligned with the steel to be encased, which maintains the proper, spaced relationship between the steel and the form during the pouring and hardening of the concrete and which dispenses with the need for external supports. With this system, it is believed that substantial savings of labor and material in the construction of columns can be obtained.
Toward this end, the form system includes supports affixed to the steel and extending outwardly therefrom. Form panels are interconnected to each other about the steel to define a form for receiving the concrete. At least one of the supports is arranged to bear against each panel to support and align the form about the steel. When the concrete is poured into the form, the supports are integrated into the concrete to form part of the column itself. When the concrete is hardened the form panels can be disassembled, leaving behind the desired structurally and aesthetically pleasing column.
Each of the supports preferably includes a first member adapted to be affixed to the steel as by welding or the like and a second member which is movably disposed along the first member for adjustment to bear against the form panel. By adjusting the positions of the second members to bear against the panels, the proper orientation of such form panels can be quickly and easily obtained.
Further, by virtue of the supports in effect bracing the form panels against the steel, external supports to maintain alignment of the panels are not required.
More particularly, each support includes the first member such as a stud affixed to the steel and an adapter connected to the first member having an external, threadlike surface. The second member is threaded over the adapter for easy adjustment therealong. The second member may be embodied as a plastic cone the frustrum of which is directed toward the steel and the larger base of which is adapted to bear against the panel. When the concrete is hardened and the forms are disassembled, the conical second member may be unthreaded and removed from the encased adapter and stud for repeated use. The bore left by the removal of the second member may be later filled in with concrete, thereby giving the column the desired appearance.
The method for forming a column according to the present invention consists of affixing outwardly extending supports to the steel and erecting a form about the steel, the form bearing against and supported by the supports to maintain its relationship to the steel. Concrete is poured into the form and allowed to harden. Thereafter, the form is disassembled leaving behind the finished column.
BRIEF DESCRIPTION OF THE DRAWINGS
These and other features and advantages of the present invention will be appreciated as the same becomes better understood with reference to the specification, claims and drawings wherein:
FIG. 1 is a perspective view of a steel column and concrete form according to the prior art;
FIG. 2 is a perspective view of a steel column and form according to the present invention;
FIG. 3 is a top view of the steel column and form of FIG. 2; and
FIG. 4 is an assembly view showing the components and the assembly of the supports which maintain the form about the steel column.
DETAILED DESCRIPTION
Turning to FIG. 1, a form 10 according to the prior art is shown encasing a steel H-column 12. In construction of buildings and the like it may be necessary from a fire protection, aesthetic or structural point of view to encase the H-column 12 in concrete 14. For example, in parking garages encasing the H-column 12 in concrete 14 protects the column from damage by vehicles and provides an aesthetically pleasing and fire protecting casing around the column. It is to be understood that while the following description is directed toward encasement of a steel H-column, the prior art form 10 and the form according to the present invention described hereinafter can also be used for pouring concrete in and about a skeleton of steel reinforcing bars, commonly referred to as rebar, to fashion a load-supporting column or the like.
To encase the H-column 12, the form 10 includes a plurality of upright wooden panels 16 interconnected as by nails 18 to define the desired upstanding shape for the form 10. During assembly of the panels 16 it is important that they remain aligned and spaced from the H-column 12 so that, upon the subsequent pouring of concrete into the form 10, the H-column 12 is properly encased. Subsequent to or during the assembly of the form 10, a plurality of braces 20 are provided, at least one of which bears against each of the panels 16. The braces 20 are connected at one end as by nails 18 to a panel 16, the other ends of the braces 20 being supported against a floor, ceiling, beam or other suitable structure. These braces 20 support the upstanding form 10 to prevent it from shifting relative to the H-column 12 during further assembly of the form and during the pouring of the concrete. The braces 20 must be fashioned and supported so as to maintain the proper alignment of the form 10 about the H-column 12. As can be appreciated, the interconnecting of the panel 16 and the attachment of the braces 20 so as to maintain the aforesaid proper alignment is time consuming and therefore, from a labor standpoint, expensive. Further, from a materials standpoint, the bracing contributes to the expense of using the prior art technique.
After or during assembly and bracing of the form, suitable collars (not shown) are provided about the panels 16 to prevent bursting of the form 10 under the head pressure of the concrete 14 when it is poured into the form 10.
Turning to FIGS. 2 and 3, a form 10' according to the present invention is shown for encasing an H-column 12 in concrete. Again, it is to be understood that the form 10' and method for joining a column as hereinafter set forth can also be used with a rebar skeleton. As shown, the H-column 12 has a web 22 which extends between two flanges 24, all of which extend the length of the column. Typically, the H-column 12 is supported between a floor and an upper beam or ceiling.
To support and maintain the form 10' about the H-column there is provided at each of the web and flanges at least one support 26 extending outwardly therefrom to bear against the interior surface of the form 10'. Each of the supports 26 at the flanges 24 as shown in FIGS. 2-4 includes a first member embodied as a stud 28. The stud 28 has a flux 30 at one end and outer threads 32. Each stud 28 is metallic and is preferably of the type to be used with an appliance, generally known as a Nelson Stud Gun (not shown) which is manufactured by Nelson Stud Welding Co., a United Carr Division of TRW Inc. Stud Gun, Ser. No. 700279. Also Control Box Ser. No. 8910 by TRW Inc. and is known by those skilled in the art. When the stud 28 is positioned in the gun and is abutted against a metallic object such as the H-column 12, the gun is energized to send current through the stud to melt the flux 30 and weld the stud 28 to the H-column 12. Thereafter the stud 28 is released from the gun, leaving the stud bonded to the H-column.
Disposed about the end of each stud 28 opposite the flange 24 is an adapter 34 fashioned to be threaded over the stud 28. The adapter 34 may be constructed by coiling No. 9 gauge wire in such a manner as to have a suitable internal diameter to be threaded over the stud 28. By virtue of its coiled shape, the adapter 34 presents an outer threaded surface 35.
The stud 28 and adapter 34 therefore provide a fixed structure to withstand compressive forces which may be generated during forming or during pouring. It can be appreciated that in conjunction with the stud and adapter, means are required to adjust the length of the overall support 26 so that each such support, regardless of variances in the length of the stud or adapter or the position of the adapter on the stud, suitably bears against the form 10' to properly position and maintain the form against movement. For this purpose the support 26 includes a second member, preferably embodied as a cone 36 threaded over the adapter 34. As best shown in FIG. 4, the cone 36 is frustroconical, having a frustrum 38 which is directed toward the flange 24 and a larger diameter base 40 to bear against the form 10' as shown in FIGS. 2 and 3. To thread over the adapter 34, the cone 36 has a threaded bore 42 extending from the frustrum 38 axially into the cone 36. The threaded bore 42 terminates at a larger diameter smooth bore 44 which extends therefrom axially through the remainder of the cone to exit at the base 40. The threaded bore 42 extends approximately one-half the axial length of the cone 36 which is sufficient to mount the cone 56 to the adapter 34. Via the adapter 34, the position of the cone 36 can be adjusted, thereby adjusting the overall length of the support 26 so that the base 40 can suitably bear against, support and align the form 10' about the H-column 12. Further, the cone 36 can be unthreaded from the adapter 34 for removal upon completion of the column.
As shown in FIGS. 2 and 3, supports 26 as set forth above are provided at each of the flanges 24, the supports 26 extending outwardly to bear against the form 10'. At the web 22, however, it can be appreciated that the support 26 must be fashioned to extend a greater distance than those at the flanges 24. Accordingly, these modified supports, hereinafter referred to as supports 26', include adapters 34' having a length greater than that of adapters 34. Each of the supports 26' includes a stud 28 welded to the web 22 in the manner described above. The adapter 34' is threaded over the outer threads 32 of the stud 28 also in the manner described above, and may be embodied in its entirety as a long wire coil like that described above with reference to FIG. 4. Alternatively, the adapter 34' may be as shown in FIGS. 2 and 3 including a first coil portion 46 of coil wire similar to that shown in FIG. 4 and threaded over the stud 28. Extending from the first coil portion 46, the adapter 34' includes a pair of rods 48 welded or otherwise suitably bonded to the first coil portion 46 and extending outwardly from the web 22 to mount between their respective ends a second coil portion 50. The second coil portion 50 extends outwardly from the rods 48 to mount the cone 36 in the manner described above. Accordingly, in effect, the rods 48 act as extensions to extend the overall length of the adapter 34'.
The supports 26 and 26' are disposed at intervals along the length of the H-column 12. Preferably, the supports are grouped to support the upper and lower ends of the form 10' and are grouped at locations therebetween as determined for the proper support and alignment of the form. Once the supports 26 and 26' have been secured to the H-column 12, the cones 36 are adjusted to align with their counterparts in other groupings of supports along the length of the H-column 12. In other words, the cones 36 of the supports 26 at the H-column flanges 24 are adjusted such that their bases 40 are arranged to be co-planar with those supports positioned above and/or below those particular supports 26.
The form 10' may be of the type as previously described or may be of the type as set forth in U.S Pat. Nos. 3,705,220 and 3,857,540, the disclosures of which are hereby incorporated by reference. These types of forms include panels 16 joined by attaching angles 52 providing for a form which can quickly and easily be erected.
As can be appreciated by virtue of the supports 26, the form during assembly, and more particularly its panels 16, are arranged to abut and bear against the cones of corresponding supports 26 or 26'. In this manner the panels 16 are properly aligned and spaced from the H-column 12 to assure proper encasement of the column in concrete. By virtue of the supports 26 and 26', the form 10' is easily supported during assembly, and is automatically aligned and supported relative to the H-column 12. Should the form 10' be urged during assembly or during the pouring of concrete into the form to be displaced relative to the H-column 12, the supports 26 and 26' prevent such displacement. Therefore, external supports for forms heretofore necessary to prevent such displacement can be dispensed with. This, in turn, translates into a cost savings, for casting such encasing concrete columns.
After the form 10' has been assembled about the H-column 12 and the supports 26 and 26', exterior collars are applied about the form to prevent the form 10 from bursting under the head pressure of the concrete. These collars (not shown), by virtue of the supports 26 and 26', need not be exteriorly supported and need only be secured about the form 10'. Once the supports 26, 26' have been positioned and the form 10, 10' has been erected, concrete is poured into the form about the H-column and is allowed to harden. During pouring and hardening of the concrete, the form 10, 10' cannot shift or move, in that the supports 26, 26' bear against the inside of the form 10, 10'. After the concrete is sufficiently hard to be self-supporting, the collars are removed and the form 10, 10' is disassembled, leaving behind the desired concrete, steel encasing column.
To finish the concrete column the cones 36 are unthreaded from their adapters 34, 34'. The frustroconical shape of the cone prevents it from becoming encased in the concrete with its counterparts, the stud and adapter. Removal of the cones leaves frustroconical bores in the column which can be filled with cement or grout, giving the column an aesthetically pleasing appearance.
While I have shown and described certain embodiments of the present invention, it is to be understood that it is subject to many modifications without departing from the spirit and scope of the appended claims. For example, the cone could be threaded directly to the studs.
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A column form support system and method are set forth encasing steel in concrete. Included are support members which are affixed to the steel and extend outwardly therefrom. A concrete form is exerted about the steel, the support members being adjustable to bear against, and support and align the form relative to the steel. Concrete is poured into the form to encase the steel, the support members maintaining the proper alignment of the form. After the concrete has hardened, the form is disassembled.
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